Professional Documents
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SVM 122-A
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Oct. 1996
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TM
IDEALARC DC-400
For use with machine code numbers 9847, 9848 and 9850
SERVICE MANUAL
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View Safety Info
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
i i
SAFETY
WARNING
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Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do
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1.e. In some cases it may be necessary to remove safety 2.d.1. Route the electrode and work cables together - Secure
guards to perform required maintenance. Remove them with tape when possible.
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.2. Never coil the electrode lead around your body.
Always use the greatest care when working near moving
parts. 2.d.3. Do not place your body between the electrode and
___________________________________________________ work cables. If the electrode cable is on your right
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1.f. Do not put your hands near the engine fan. Do not attempt to side, the work cable should also be on your right side.
override the governor or idler by pushing on the throttle con-
trol rods while the engine is running. 2.d.4. Connect the work cable to the workpiece as close as
___________________________________________________ possible to the area being welded.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance 2.d.5. Do not work next to welding power source.
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
ii ii
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3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
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• Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
3.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
iii iii
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6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can • A safe distance from arc welding or cutting operations and
cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
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6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
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6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
6.h. Also see item 1.c.
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
iv iv
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PRÉCAUTIONS DE SÛRETÉ 7. Quand on ne soude pas, poser la pince à une endroit isolé
de la masse. Un court-circuit accidental peut provoquer un
Pour votre propre protection lire et observer toutes les instructions échauffement et un risque d’incendie.
et les précautions de sûreté specifiques qui parraissent dans ce
8. S’assurer que la masse est connectée le plus prés possible
manuel aussi bien que les précautions de sûreté générales suiv-
de la zone de travail qu’il est pratique de la faire. Si on place
antes:
la masse sur la charpente de la construction ou d’autres
Sûreté Pour Soudage A L’Arc endroits éloignés de la zone de travail, on augmente le
risque de voir passer le courant de soudage par les chaines
1. Protegez-vous contre la secousse électrique: de levage, câbles de grue, ou atres circuits. Cela peut
provoquer des risques d’incendie ou d’echauffement des
a. Les circuits à l’électrode et à la piéce sont sous tension
chaines et des câbles jusqu’à ce qu’ils se rompent.
quand la machine à souder est en marche. Eviter tou-
jours tout contact entre les parties sous tension et la 9. Assurer une ventilation suffisante dans la zone de soudage.
peau nue ou les vétements mouillés. Porter des gants Ceci est particuliérement important pour le soudage de tôles
secs et sans trous pour isoler les mains. galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumées toxiques.
b. Faire trés attention de bien s’isoler de la masse quand
on soude dans des endroits humides, ou sur un planch- 10. Ne pas souder en présence de vapeurs de chlore provenant
er metallique ou des grilles metalliques, principalement d’opéerations de dégraissage, nettoyage ou pistolage. La
dans les positions assis ou couché pour lesquelles une chaleur ou les rayons de l’arc peuvent réagir avec les
grande partie du corps peut être en contact avec la vapeurs du solvant pour produire du phosgéne (gas forte-
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
v v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page Accueil
Page
Safety.................................................................................................................................................i-iv
Installation .............................................................................................................................Section A
Installation Section Table of Contents ........................................................................................A-1
Technical Specifications .............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Select Suitable Location (Stacking, Tilting, Lifting) ....................................................................A-3
Input Connections.......................................................................................................................A-4
Reconnect Procedure .................................................................................................................A-6
Output Connections....................................................................................................................A-7
Operation...............................................................................................................................Section B
Safety Instructions ......................................................................................................................B-2
General Description ....................................................................................................................B-3
Controls and Settings .................................................................................................................B-4
Welding Operation ......................................................................................................................B-6
Overload Protection....................................................................................................................B-9
Auxiliary Power ...........................................................................................................................B-9
Accessories...........................................................................................................................Section C
Maintenance .........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance ............................................................................................D-2
General Component Locations...................................................................................................D-3
Parts Manual.................................................................................................................................P-234
IDEALARC DC-400
LINCOLN ®
ELECTRIC
Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
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Installation
Stacking................................................................................................................................A-3
Input Connections.......................................................................................................................A-4
Ground Connection ..............................................................................................................A-4
Input Supply Connections....................................................................................................A-4
Input Wire and Fuse Size ...............................................................................................A-5
Reconnect Procedure .................................................................................................................A-6
Output Connections....................................................................................................................A-7
Wire Feeder Connections.....................................................................................................A-8
Connections for Stick, TIG, Air/carbon Arc Operations.......................................................A-8
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
A-2 A-2
INSTALLATION
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RATED OUTPUT
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OUTPUT
PHYSICAL DIMENSIONS
IDEALARC DC-400
LINCOLN ®
ELECTRIC
A-3 A-3
INSTALLATION
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WARNING
SAFETY PRECAUTIONS FALLING EQUIPMENT can cause
injury.
WARNING
• Do not lift this machine using the
ELECTRIC SHOCK can kill. lift bail if it is equipped with a heavy
• Do not touch electrically live accessory such as a trailer or a gas
parts or electrodes with your cylinder.
skin or wet clothing. • Lift only with equipment of adequate lifting capacity.
• Insulate yourself from the work • Be sure the machine is stable when lifting.
and ground.
• Do not stack more than three high.
• Always wear dry insulating gloves.
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STACKING
Idealarc DC-400s may be stacked three high. The
bottom machine must be on a stable, hard, level sur-
face capable of supporting the weight of up to three
machines (1419 pounds/645 kilograms). Be sure that
the two pins in the roof of the bottom machine fit into
the holes in the base of the machine above. The lift
bail is positioned so that it fits without interference
under the base of the second machine.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
A-4 A-4
INSTALLATION
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INPUT CONNECTIONS
Be sure the voltage, phase, and frequency of the Input supply line entry is through a hole in the case
input power is as specified on the rating plate, lo- rear top panel. A removable door covers the input
cated on the case front control panel. See Figure connection box, which contains the input contactor
A.1. (CR1) and reconnect panel assembly for multiple volt-
age machines. Input power is connected to the three
line terminals on the input contactor. See Figure A.2.
1. RATING PLATE
GROUND CONNECTION
WARNING
The frame of the welder must be grounded. An earth
grounding lead must be connected to the grounding ELECTRIC SHOCK can kill.
terminal, marked on the input box floor with the sym-
bol ( ). • Have a qualified electrician
install and service this equip-
ment.
INPUT SUPPLY CONNECTIONS • Turn the input power off at the
Be sure the voltage, phase, and frequency of the input fuse box before working on this
power is as specified on the rating plate. equipment.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
A-5 A-5
INSTALLATION
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Have a qualified electrician connect the input power INPUT WIRE AND FUSE SIZE
leads to the L1, L2, and L3 terminals of the input con-
tactor. Follow all national and local electrical codes. Fuse the input circuit with the super lag fuses recom-
Use a three-phase line. Refer to the connection dia- mended on the Technical Specifications page or use
gram located on the inside cover of the access panel delay type circuit breakers. Choose an input and
cover. Also see Figure A.3. grounding wire size according to local or national
codes; also see the Technical Specifications page.
Using fuses or circuit breakers smaller than recom-
mended may result in “nuisance” shut-offs from
welder inrush currents, even if you are not welding at
high currents.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
A-6 A-6
INSTALLATION
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FIGURE A.4 - INPUT CONNECTION DIAGRAM FOR 208, 208/230 and 230/460 VOLTS AC, 50/60 HZ
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{
2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
L3 W CR1
LEAST 600 VOLT INSULATION.
LINES
L2 V
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H3 TRANSFORMER LEADS
INPUT CONTACTOR
TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.
L1 U
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC
GND H1 CODES.
H3 H2
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
PILOT DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE
TRANSF. USE. SECURE THE REMAINING HEX NUTS IN PLACE.
{
L3 W CR1 2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LINES LEAST 600 VOLT INSULATION.
L2 V
INPUT CONTACTOR 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H2 TRANSFORMER LEADS
L1 U TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
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PILOT
TRANSF.
3-17-95E
THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A. M15009
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
A-7 A-7
INSTALLATION
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{
W CR1
6 CONNECTION FOR 575 VOLTS, 60 HZ.
L3 18
15 RECONNECT
LINES 5 1. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H4 PILOT
L2 V 17
14
PANEL TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
INPUT CONTACTOR
4
16 2. INSULATE UNUSED H2, H3 LEAD TERMINALS SEPERATELY TO PROVIDE
L1 U 13
AT LEAST 600V INSULATION.
H1 H2 1 2 3 7 8 9
3. CONNECT TERMINAL MARKED TO SYSTEM GROUND PER NATIONAL ELECTRIC CODES.
GND H4 H3 4. CONNECT TRANSFORMER LEADS 16, 17, 18, 4 & 13, 5 & 14, 6 & 15 TO RECONNECT PANEL.
PILOT 5. TAPE SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 1, 2, 3, 7, 8, 9.
TRANSF.
TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS.
{
W CR1
6 CONNECTION FOR 460 VOLTS, 60 HZ.
L3 3
9 RECONNECT
LINES 5 1. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H3 PILOT
L2 V 2
8
PANEL TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
INPUT CONTACTOR
4
1 2. INSULATE UNUSED H2, H4 LEAD TERMINALS SEPERATELY TO PROVIDE
L1 U 7
AT LEAST 600V INSULATION.
H1 H2 16 17 18 13 14 15
3. CONNECT TERMINAL MARKED TO SYSTEM GROUND PER NATIONAL ELECTRIC CODES.
GND H3 H4 4. CONNECT TRANSFORMER LEADS 1, 2, 3, 4 & 7, 5 & 8, 6 & 9 TO RECONNECT PANEL.
PILOT 5. TAPE SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 13, 14, 15, 16, 17, 18.
TRANSF.
TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS.
{
W CR1 CONNECTION FOR 230 VOLTS, 60 HZ.
L3 9
3 RECONNECT
LINES 8
6 1. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H2 PILOT
L2 V
2
5 PANEL TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
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INPUT
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CONTACTOR 4
7
2. INSULATE UNUSED H3, H4 LEAD TERMINALS SEPERATELY TO PROVIDE
L1 U 1
AT LEAST 600V INSULATION.
H1 H3 16 17 18 13 14 15
3. CONNECT TERMINAL MARKED TO SYSTEM GROUND PER NATIONAL ELECTRIC CODES.
GND H2 H4 4. CONNECT TRANSFORMER LEADS 1 & 7, 2 & 8, 3 & 9, 4 & 5 & 6, TO RECONNECT PANEL.
PILOT 5. TAPE SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 13, 14, 15, 16, 17, 18.
TRANSF.
TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS.
OUTPUT CONNECTIONS
The output (welding) cables are connected to the output relief for the cables is provided by routing them through
terminals marked “+” and “-”. See Table A.1 for recom- the rectangular holes in the base before connecting
mended cable sizes for the combined lengths of elec- them to the output terminals. Lift the output terminal
trode and work cables. They are located at the lower cover to access the output terminals. Lower the cover
right and lower left corners of the front panel. Strain after making the connections. See Figure A.6.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
A-8 A-8
INSTALLATION
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See the Accessories section of this manual for spe- The work and electrode cables for stick, TIG, or
cific instructions on connecting the following semi- air/carbon arc cutting are connected as described ear-
automatic and automatic wire feeders to the Idealarc lier, under the heading Output Connections. A TIG
DC-400: torch is connected to the electrode (+) terminal of the
welder. Select cable size according to Table A.1.
• LN-9 operation.
• LN-25 However, the Idealarc DC-400 can be used for both
wire feeder operation and stick, TIG, air/carbon arc
• LN-742
operation if a K804-1 Multiprocess Switch is used.
See the Accessories section of this manual for spe-
cific instructions on connecting and using the
CONNECTIONS FOR STICK, TIG, OR Multiprocess Switch.
AIR/CARBON ARC CUTTING OPERA-
TIONS
WARNING
The output terminals are energized at all times when
the Idealarc DC-400 is used for stick, TIG, or air/car-
bon arc cutting.
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96OCT
IDEALARC DC-400
LINCOLN ®
ELECTRIC
Section B-1 Section B-1
- OPERATION SECTION -
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Operation...............................................................................................................................Section B
Safety Instructions ......................................................................................................................B-2
General Description ....................................................................................................................B-3
Recommended Processes ...................................................................................................B-3
Operational Features and Controls ......................................................................................B-3
Design Features and Advantages ........................................................................................B-3
Welding Capability................................................................................................................B-3
Limitations ............................................................................................................................B-3
Controls and Settings ................................................................................................................B-4
Welding Operation ......................................................................................................................B-6
Operating Steps ...................................................................................................................B-6
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Local Control..................................................................................................................B-6
Remote Control ..............................................................................................................B-6
Welding Procedure Recommendations .........................................................................B-6
Semiautomatic and Automatic Wire Feeding with an Idealarc DC-400 ..............................B-6
NA-3 Automatic Wire Feeder .........................................................................................B-7
Good Arc Striking Guidelines for the NA-3.............................................................B-7
Arc Striking with the NA-3 Start Board ...................................................................B-7
NA-5 Automatic Wire Feeder .........................................................................................B-8
LN-8 Semiautomatic Wire Feeder..................................................................................B-8
LN-7 and LN-9 Semiautomatic Wire Feeders................................................................B-9
Overload Protection....................................................................................................................B-9
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
B-2 B-2
OPERATION
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OPERATING INSTRUCTIONS
Read and understand this entire section of operating
instructions before operating the machine.
SAFETY INSTRUCTIONS
WARNING
IDEALARC DC-400
LINCOLN ®
ELECTRIC
B-3 B-3
OPERATION
GENERAL DESCRIPTION
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resist corrosion.
OPERATIONAL FEATURES AND
CONTROLS
WELDING CAPABILITY
The following operational controls are standard on the
Idealarc DC-400: The Idealarc DC-400 has the following duty cycle
ratings. If the duty cycle is exceeded, a thermal pro-
• Power Source Pilot Light tector will shut off the machine output until it cools to
• ON/OFF Power Toggle Switch normal operating temperature. The amber thermal
protection indicator light will turn on until the machine
• Output Control Potentiometer cools.
• Output Control Switch (with Local or Remote posi-
tions)
Duty Cycle* Amps Volts
• Output Terminals On or Remote Switch 100% 400 36
• Arc Force Selector (for CC stick or TIG processes 60% 450 38
only) 50% 500 40
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• Auxiliary Power Connections for Wire Feeder and *Based on a 10 minute time period. For example, a 60% duty cycle
means 6 minutes on and 4 minutes off.
Other Equipment (115V and 42V)
• Mode Switch
• Arc Control
LIMITATIONS
• Thermal Protection Indicator Light The Idealarc DC-400 has no provisions for paralleling.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
B-4 B-4
OPERATION
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1. POWER SOURCE PILOT LIGHT: This light indi- 5. OUTPUT TERMINALS “ON” OR “REMOTE”
cates that the power source input contactor is SWITCH: When in the “Remote” position, leads
energized (closed). This also means that the main #2 and #4 have to be jumpered externally to ener-
power transformer and all auxiliary control trans- gize the output terminals. When in the “ON” posi-
formers are energized. tion, this switch internally jumpers leads #2 and #4,
which energizes the output terminals.
2. ON/OFF POWER TOGGLE SWITCH: Energizes
or de-engergizes the input contactor which is pow- 6. ARC FORCE SELECTOR: Allows you to select
ered by the 115 volt auxiliary transformer. The the ideal arc force according to the procedure and
switch turns the machine ON or OFF. Position “I” electrode being used for CC stick or TIG welding.
is ON; position “0” is OFF. It controls the amount of current added to the
welding current when the electrode shorts to the
3. OUTPUT CONTROL POTENTIOMETER: Con-
work. At minimum setting, no extra short circuit
trols voltage in CV mode and current in CC mode.
current is added. The arc will be softer and have
4. OUTPUT CONTROL SWITCH (WITH LOCAL OR less spatter but may be more prone to sticking. At
REMOTE POSITIONS): Selects the mode of con- maximum setting, the arc will be more forceful and
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trol. In the “Local” position, control is by the less prone to sticking but will produce more spat-
machine control panel. In the “Remote” position, ter.
control is by either a wire feeder unit or through an
optional remote control device.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
B-5 B-5
OPERATION
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
B-6 B-6
OPERATION
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2. Set the VOLTMETER “+” or “-” switch to the Use the CV FCAW/GMAW mode.
appropriate position.
2. Submerged Arc Welding: Use the CV Submerged
• Set toggle to “´Electrode Negative” position if Arc mode. If performing high speed welding,
the electrode is connected to the negative (-) switch between the CV Submerged Arc and the CV
output terminal. FCAW/GMAW mode and use the mode that pro-
• Set toggle to “Electrode Positive” position if the duces the best welding results.
electrode is connected to the positive (+) output 3. Air/Carbon Arc Cutting / Stick Welding / High
terminal.
Current, Large Puddle Submerged Arc Welding:
3. Set the welding MODE switch to welding process Use the CC mode. When the Idealarc DC-400 is
being used. used for Air/Carbon Arc cutting, the OUTPUT
• CV FCAW/GMAW CONTROL potentiometer should be set to “9” ini-
tially. Based on the size of the carbon being used
• CV Submerged Arc or the process, turn the potentiometer to a lower
• CC Stick/Tig setting as required by the process. You can use
carbon rods up to 5/16” (8 mm) in diameter at cur-
4. Set the OUTPUT CONTROL switch to “Local.”
rents as high as 450 amps with excellent arc con-
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
B-7 B-7
OPERATION
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NA-3 AUTOMATIC WIRE FEEDER NOTE: The open circuit voltage of the Idealarc
DC-400 varies from apporximately 12
1. Set the DC-400 OUTPUT CONTROL switch to
volts to 45 volts in the CV FCAW/GMAW
“Remote.”
or CV Submerged Arc modes. The open
NOTE: Later model NA-3 automatic wire feeders circuit voltage is constant in the CC mode.
are capable of cold starts when the NA-3
3. Run a test weld. Set proper current, voltage, and
Mode switch is in the CV or CC mode posi-
travel speed.
tion. Some earlier models are capable of
cold starting only in the CC mode position. a. For the best starting performance, the NA-3
Cold starting enables you to inch the wire Open Circuit Voltage Control and Voltage
down to the work, automatically stop, and Control setting should be the same. Set the
automatically energize the flux hopper Inch Speed Control for the slowest inch speed
valve. The cold start feature requires the possible.
factory installed diode option. See the
b. To adjust the Open Circuit Voltage Control to
Accessories section.
get the best starting performance, make
2. Set the DC-400 welding MODE switch for the repeated starts observing the NA-3 voltmeter.
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1. Cut the electrode to a sharp point. 2. Set NA-3 start current and start voltage at mid-
range.
2. Set the NA-3 Open Circuit Voltage Control to the
same dial setting as the Arc Voltage Control. If this 3. Set the NA-3 output current and voltage to the
is a new welding procedure, a good starting point is proper settings for the welding procedure to be
to set the Open Circuit Voltage Control to #6. used.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
B-8 B-8
OPERATION
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4. Turn the Start Board Timer to maximum. NA-5 AUTOMATIVE WIRE FEEDER
5. Set Start Board current and voltage control. When using the Idealarc DC-400 with the NA-5 wire
feeder, set the controls on the Idealarc DC-400 as fol-
a. Set the Start Board current control to 1-1/2
lows for the best performance:
dial numbers below that set on the NA-3 cur-
rent control. 1. Turn OFF main AC input power to the Idealarc DC-
400.
b. Set the Start Board voltage control equal with
the NA-3 voltage control setting. 2. Connect the electrode cables to the terminal
polarity to be used.
NOTE: These Start Board current and voltage set-
tings result in a start up current that is 3. Set the VOLTMETER “+” or “-” switch to the same
lower than the NA-3 current setting and polarity as the electrode cable connection.
approximately equal with the NA-3 voltage
4. Set the OUTPUT CONTROL switch to “Remote.”
setting for the desired welding procedure.
5. Set the OUTPUT TERMINALS switch to “Remote.”
6. Establish the correct arc striking procedure with
the NA-3 Start Board timer set at maximum. 6. Set the Idealarc DC-400 welding MODE switch to
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the Open Circuit Voltage Control is set too high. Idealarc DC-400:
This can result in a bad start where the wire tends
1. Set the Idealarc DC-400 welding MODE switch to
to “blast off.”
either CV FCAW/GMAW mode or CV Submerged
If the voltmeter pointer hesitates before coming up Arc mode, depending on the welding process
to the desired voltage, the Open Circuit Voltage being used.
Control is set too low. This can cause the elec-
2. Set the Idealarc DC-400 OUTPUT CONTROL
trode to stub.
switch to “Remote.”
c. Set NA-3 Start Board current and voltage as
3. Set the OUTPUT TERMINALS switch to “Remote.”
close to the welding procedure current and
voltage as possible. 4. Set the ARC CONTROL to midrange, 3.
NOTE: The Start Board current and voltage 5. Set the LN-8 Welding Mode switch to the CV posi-
should be as close as possible to the tion. The LN-8 Welding Mode switch is located on
welding procedure current and voltage, the variable voltage (CC) board.
while still getting satisfactory starts.
6. Refer to the LN-8 Operator’s Manual for instruc-
d. Set the start time to as low a time as possible tions on how to use the LN-8.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
B-9 B-9
OPERATION
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Control Box Assembly or set the Idealarc DC- on the SCR bridge asssembly through an electronic
400 OUTPUT CONTROL switch in the “Local” protection circuit. This circuit senses an overload on
position. the power source and limits the output to 550 amps by
phasing back the SCRs.
b. LN-9: Refer to the LN-9 Operator’s Manual for
instructions on how to use the LN-9. The Idealarc DC-400 also has self-restoring fusing to
prevent damage to the machine in the event of an
c. LN-25: Refer to the LN-25 Operator’s Manual accidental grounding of the remote control leads (#75,
for instructions on how to use the LN-25. #76 or #77).
d. LN-742: Refer to the LN-742 Operator’s
Manual for instructions on how to use the LN-
742. AUXILIARY POWER
The Idealarc DC-400 can provide nominally 115 volt
AC and 42 volt AC auxiliary power for operating wire
feeding equipment and other accessories. This power
is available at the 14-pin amphenol on the control
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
Section C-1 Section C-1
TABLE OF CONTENTS
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- ACCESSORIES -
Accessories...........................................................................................................................Section C
Options/Accessories...................................................................................................................C-2
Factory Installed Option.......................................................................................................C-2
Field Installed Options .........................................................................................................C-2
Cover for 14-Pin Amphenol ...........................................................................................C-2
Multiprocess Switch (K804-1)........................................................................................C-2
Remote Output Adapter Cable (K857)...........................................................................C-4
Remote Control Adapter Cable (K864) ..........................................................................C-4
Amptrol Adapter Cable (K843) .......................................................................................C-4
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
C-2 C-2
ACCESSORIES
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Protects the amphenol from dirt and moisture when Refer to installation instructions (M17137) included
the amphenol is not being used. with Multiprocess Kit for installation.
FIGURE C.1
MULTIPROCESS SWITCH
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
C-3 C-3
ACCESSORIES
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Multiprocess Switch Operation If both stick and semiautomatic welding is done on the
same workpiece, only one work cable is required. To
The operation of the Multiprocess Switch is as follows:
do this, connect a 4/0 (107 mm2) jumper from the work
A semiautomatic or automatic wire feed unit electrode terminal on the semiautomatic side to the terminal to
and work cables are connected to the terminals on the be used for work on the stick side. The work cable
left side of the box. Stick or air carbon arc electrode from the semiautomatic side then serves as the work
and work cables are connected to the terminals on the cable for both semiautomatic and stick welding. See
switch. With the switch in the left position, the wire Figure C.2.
feed terminals are electrode negative. In the center
To change stick polarity, reverse the leads at the (+)
position, the wire feeder terminals are electrode posi-
and (-) terminals on the right side of the Multiprocess
tive. In both the left and center switch position, the
Switch.
right side stick terminals are disconnected. In the right
switch position, the wire feed terminals are discon- NOTE: When a DC-400 equipped with Multiprocess
nected from the DC-400 and the stick terminals con- Switch is mounted on an undercarriage, the
nected. The polarity of the stick terminals is marked undercarriage handle in the resting position
on the end of the box. To change polarity, the elec- can hit the case of the Multiprocess Switch.
trode and work cables must be interchanged. In the This does no harm, but if the user desires, a
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stick position, the stick terminals are energized at all 1/4” or 3/8” bolt and nut may be placed in the
times. hole in the undercarriage tow bar to limit the
travel of the undercarriage handle.
Connections
(For those applications where it is not necessary to
have separate work cables for stick and semiautomat-
ic welding.)
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
C-4 C-4
ACCESSORIES
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REMOTE OUTPUT CONTROL (K857 WITH K864 K843 AMPTROL™ ADAPTER INSTALLATION
ADAPTER PLUG OR K775) INSTRUCTIONS
The K857 has a 6-pin MS-style connector. The K857
requires a K864 adapter cable which connects to the
WARNING
14-pin connector on the machine.
ELECTRIC SHOCK can kill.
An optional “remote output control” is available. This
is the same remote control that is used on the Lincoln • Turn the input supply power OFF
R3R and DC-600 power sources (K775). The K775 before installing plugs or cables or
consists of a control box with 28 ft (8.5m) of four con- when connecting or disconnecting
ductor cable. This connects to terminals 75, 76, and plugs to the welder.
77 on the terminal strip and the case grounding screw
marked with the symbol on the machine. These
terminals are located behind the control panel on the This K843 adapter is used to connect Amptrol (K812,
front. This device will give the same control as the out- K813 or K870), remote control (K775), and Hi-Freq™
put control on the machine. (K799) accessories to the DC-400. The OUTPUT
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
C-5 C-5
ACCESSORIES
K843 AMPTROL ADAPTER INSTALLATION INSTRUCTIONS (Continued)
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Amptrol Only: The Amptrol provides remote current Amptrol and Hi-Freq. Kit: The Amptrol will start the
control through the full range of the power source. Hi-Freq kit to turn on gas and high frequency starting
for DC TIG welding. The Amptrol controls current
through the full range of the power source.
K812, K813 or
K870 Amptrol
K799)
CUT OFF
ARC START
Black and white leads SWITCH and connect black
not used. Tape lead to black and white
and insulate. lead to white.
Amptrol Plus Remote Limit Control: The Amptrol Amptrol and Hi-Freq. Kit Plus Remote Limit
provides remote current control from the minimum of Control: The Amptrol switch will start the Hi-Freq kit to
the power source to a maximum set by the remote turn on gas and high frequency starting for DC TIG
limit control. welding. The Amptrol controls current from the mini-
mum of the power source to a maximum set by the
remote limit control.
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K812, K813 or
K870 Amptrol
K775 Remote
K799 Limit Control
Hi-Freq
Kit K812, K813
or K870
Amptrol
K843 Bolt and nut
Adapter connection.
Insulate
and tape.
K843 Adapter
Arc start cable Bolt and nut
(included connection.
with K799) Insulate
and tape.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
C-6 C-6
ACCESSORIES
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pin amphenol.
A “V” cable to connect a K799 Hi-Freq kit (5-pin con-
nector) with either a K812 Hand Amptrol or a K870
Foot Amptrol (6-pin connector) and the machine. The AUTOMATIC WIRE FEEDERS
cable going to the machine has a 6-pin connector
which requires either a K864 adapter to connect with CONNECTING THE NA-3 TO THE IDEALARC
the 14-pin connector on the machine or a K843 DC-400 (TERMINAL STRIP)
adapter to connect to terminals #75, #76, #77 and the 1. Disconnect main AC input power to the Idealarc
case grounding screw on the machine. DC-400.
UNDERCARRIAGES (K817, K817R, K841) 2. Set Idealarc DC-400 POWER toggle switch to the
For easy moving of the machine, optional undercar- OFF (0) position.
riages are available with either steel (K817) or rubber 3. Connect the wire feeder control cable leads to the
tired (K817R) wheels or a platform undercarriage Idealarc DC-400 terminal strip as shown in Figure
(K841) with mountings for two gas cylinders at the rear C.4.
of the welder.
Connect the wire feeder control cable ground lead
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Installation instructions are included with each kit. to the frame terminal marked .
NOTE: The Idealarc DC-400 must be properly
grounded.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
C-7 C-7
ACCESSORIES
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terminal.
d. Set the VOLTMETER toggle switch to nega-
tive (-).
6. Set the DC-400 OUTPUT CONTROL switch to the
“Remote” position and the OUTPUT TERMINALS
switch in the “Remote” position.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
C-8 C-8
ACCESSORIES
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5. Extend wire feeder control cable lead #21 so it can NOTE: For proper NA-5 operation, the electrode
be connected directly to the work piece. cables must be secured under the clamp bar
on the left side of the NA-5 Control Box.
a. Make a bolted connection using AWG #14 or
larger insulated wire. Tape the bolted connec- 7. Set the DC-400 OUTPUT CONTROL switch to the
tion with insulating tape. “Remote” position and the OUTPUT TERMINALS
switch to the “Remote” position.
b. An S-16586- X remote voltage sensing work
lead is available for this purpose. CONNECTING THE NA-3 OR NA-5 TO THE
IDEALARC DC-400 (14-PIN AMPHENOL)
c. Keep the #21 lead electrically separate from
the work cable circuit and connection. 1. Disconnect main AC input power to the Idealarc
DC-400.
d. Tape the #21 lead to work cable for ease of
use. 2. Set the Idealarc DC-400 POWER switch to the OFF
(0) position.
6. Connect NA-5 wire feeder control jumpers on
Voltage Control Board. See NA-5 Operator’s 3. Connect the electrode cable from the K597-XX
Manual. Input Cable Assembly to the “+” terminal of the
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FIGURE C.6
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
C-9 C-9
ACCESSORIES
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FIGURE C.7
IDEALARC DC-400/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM
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3. Connect the electrode cable from the K584-XX 7. Adjust wire feed speed at the LN-7 and set the
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Input Cable Assembly to the “+” terminal of the welding voltage with the OUTPUT CONTROL.
welder and to the LN-7 wire feeder. Connect the
NOTE: If optional remote control is used, place the
work cable to the “-” terminal of the welder.
OUTPUT CONTROL and the OUTPUT TERMI-
Reverse this hookup for negative polarity.
NALS switch in the “Remote” position.
NOTE: Welding cable must be sized for the current
and duty cycle of the application.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
C-10 C-10
ACCESSORIES
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CONNECTING THE LN-7 TO THE NOTE: If the work cable length is less than 25 feet
IDEALARC DC-400 (TERMINAL STRIP) and the connections to the work piece are
secure, then wire feeder control cable lead
1. Disconnect main AC input power to the Idealarc
#21 can be connected directly to the DC-
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DC-400.
400 terminal strip.
2. Set the Idealarc DC-400 POWER toggle switch to
b. An S-16586- X remote voltage sensing work
the OFF (0) position.
lead is available for this purpose.
3. Connect the wire feeder control cable leads to the
c. Keep the #21 lead electrically separate from
Idealarc DC-400 terminal strip as shown in Figure
the work cable circuit and connection.
C.8.
d. Tape the #21 lead to work cable for ease of
4. Connect the wire feeder control cable ground lead
use.
to the frame terminal marked .
NOTE: The connection diagram shown in Figure
NOTE: The Idealarc DC-400 must be properly
C.8 shows the electrode connected for
grounded.
positive polarity. To change polarity:
5. PERFORM THIS STEP ONLY IF THE LN-7 IS
a. Set the IDEALARC DC-400 POWER toggle
EQUIPPED WITH A METER KIT.
switch to the OFF (0) position.
Extend wire feeder control cable lead #21 so it can
b. Move the electrode cable to the negative (-)
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output terminal.
a. Make a bolted connection using AWG #14 or
c. Move the work cable to the positive (+) output
larger insulated wire. Tape the bolted connec-
terminal.
tion with insulating tape.
d. Set the VOLTMETER toggle switch to nega-
tive (-).
IDEALARC DC-400
LINCOLN ®
ELECTRIC
C-11 C-11
ACCESSORIES
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FIGURE C.9 - LN-8 OR LN-9 WIRE FEEDER CONNECTION TO THE IDEALARC DC-400
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CONNECTING THE LN-8 OR LN-9 TO THE NOTE: Using the extended #21 lead eliminates
IDEALARC DC-400 (TERMINAL STRIP) the need to use the LN-9’s remote work
lead accessory, which has a direct work
1. Disconnect main AC input power to the Idealarc
lead jack.
DC-400.
6. Connect LN-9 wire feeder control jumpers on
2. Set the Idealarc DC-400 POWER toggle switch to
Voltage Control board. See LN-9 Operator’s
the OFF (0) position.
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Manual.
3. Connect the wire feeder control cable leads to the
NOTE: The connection diagram shown in Figure C.9
Idealarc DC-400 terminal strip as shown in Figure
shows the electrode connected for positive
C.9.
polarity. To change polarity:
4. Connect the wire feeder control cable ground lead
a. Set the Idealarc DC-400 POWER toggle
to the frame terminal marked .
switch to the OFF (0) position.
5. Extend wire feeder control cable lead #21 so it can
b. Move the electrode cable to the negative (-)
be connected directly to the work piece.
output terminal.
a. Make a bolted connection using AWG #14 or
c. Move the work cable to the positive (+) output
larger insulated wire. Tape the bolted connec-
terminal.
tion with insulating tape.
d. Set the VOLTMETER toggle switch to negative
b. An S-16586- X remote voltage sensing work
(-).
lead is available for this purpose.
7. Set the OUTPUT CONTROL switch to the
c. Keep the #21 lead electrically separate from
“Remote” position and the OUTPUT TERMINALS
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
C-12 C-12
ACCESSORIES
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CONNECTING THE LN-8 OR LN-9 TO THE NOTE: Welding cable must be sized for the current
IDEALARC DC-400 (14-PIN AMPHENOL) and duty cycle of the application.
1. Disconnect main AC input power to the Idealarc 4. Connect the input cable (K595-XX) between the
DC-400. 14-pin amphenol on the DC-400 and the input
cable plug on the LN-8 or LN-9. See Figure C.10.
2. Set the POWER toggle switch to the OFF (0) posi-
tion. 5. Set the welder VOLTMETER switch to the desired
polarity, either DC (-) or DC (+).
3. Connect the electrode cable from the LN-8 or
LN-9 to the “+” terminal of the welder. Connect 6. Set the MODE switch to a CV (constant voltage)
the work cable to the “-” terminal of the welder. position.
Reverse this hookup for negative polarity. See
7. Adjust wire feed speed at the LN-8 or LN-9 and
Figure C.10.
set the welding voltage with the WIRE FEEDER
VOLTAGE CONTROL.
Place the OUTPUT CONTROL switch in the “Remote”
position and the OUTPUT TERMINALS switch in the
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“Remote” position.
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TO LN8/LN9 INPUT
CABLE PLUG
IDEALARC DC-400
LINCOLN ®
ELECTRIC
C-13 C-13
ACCESSORIES
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
Section D-1 Section D-1
TABLE OF CONTENTS
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-MAINTENANCE-
Maintenance .........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance ............................................................................................D-2
General Component Locations...................................................................................................D-3
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
D-2 D-2
MAINTENANCE
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SAFETY PRECAUTIONS
Perform periodically:
WARNING 1. In extremely dusty conditions, dirt may clog the
cooling air channels, causing the machine to run
ELECTRIC SHOCK can kill.
hot. Blow out the machine at regular intervals with
• Only qualified personnel low pressure air. Clean the following parts. See
should perform this mainte- Figure D.1.
nance.
• Main transformer and choke
• Turn the input power OFF at
• SCR/diode bridge
the disconnect switch or fuse
box before working on this • Control PC board
equipment.
• Starting PC board
• Do not touch electrically hot parts.
• Electrode and work cable connections
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• Fan assembly
ROUTINE AND PERIODIC NOTE: The fan motor has sealed bearings that require
MAINTENANCE no service.
Perform the following preventative maintenance at • Remote control terminal strip TS1.
least once every six months. NOTE: Keeping remote control terminal strip TS1
Perform the following daily: clean is especially important in damp locations.
the machine.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
D-3 D-3
MAINTENANCE
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1. CONTROL PANEL
2. SCR/DIODE BRIDGE
3. MAIN TRANSFORMER
4. CHOKE
5. RECONNECT PANEL (LOCATION)
6. INPUT CONTACTOR (LOCATION)
7. FAN ASSEMBLY
8. CONTROL TRANSFORMER
9. CAPACITORS
10. PC BOARDS (LOCATION)
11. CASE FRONT
12. OUPUT TERMINALS
(LOCATION BENEATH HINGED PANEL)
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5 6
2
4
8
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1 9
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10
12 11
IDEALARC DC-400
LINCOLN ®
ELECTRIC
Section E-1 Section E-1
TABLE OF CONTENTS
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FEEDBACK
CONTROL BOARD NEGATIVE
OUTPUT
G S PART
TERMINAL
A I OF
POWER T G
MODE
SWITCH MAIN E N
SWITCH
A
TRANSFORMER L
S
OUTPUT
CHOKE
R F
E PART E
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OF E
C MODE D
O SWITCH B START
A BOARD
N C
N OUTPUT K
E CAPACITORS
C POSITIVE
T OUTPUT
TERMINAL
SHUNT REED
INPUT SCR / DIODE SWITCH
CONTACTOR HYBRID BRIDGE
T 115VAC
REMOTE E S
TO CONTROL R T
CONTROL M
I R
BOARD I
N
A P
L
FAN
42VAC
14 PIN
AMPHENOL
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
E-2 E-2
THEORY OF OPERATION
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FEEDBACK
CONTROL BOARD NEGATIVE
OUTPUT
G S PART
TERMINAL
A I OF
POWER T G
MODE
SWITCH MAIN E N
SWITCH
A
TRANSFORMER L
S
OUTPUT
CHOKE
R F
E PART E
OF E
C MODE D
O SWITCH B START
A BOARD
N C
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N OUTPUT K
E CAPACITORS
C POSITIVE
T OUTPUT
TERMINAL
SHUNT REED
INPUT SCR / DIODE SWITCH
CONTACTOR HYBRID BRIDGE
T 115VAC
REMOTE E S
TO CONTROL R T
CONTROL M
I R
BOARD I
N
A P
L
FAN
42VAC
14 PIN
AMPHENOL
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GENERAL DESCRIPTION
The DC-400 is a multiprocess welder power source The transformer changes the high voltage, low current
capable of both constant voltage and constant current input power to a lower voltage, higher current output.
operation. Its power system is SCR controlled with The finishes or “neutrals” of the main secondary coils
solid state electronic circuitry. Minimum to maximum are connected together, and the three starts of the
output is obtained with a single potentiometer control. secondary windings are connected to the rectifier
bridge assembly. In addition, the main transformer has
INPUT LINE VOLTAGE, separate and isolated 115VAC and 42VAC auxiliary
CONTACTOR AND MAIN windings. The 115VAC winding supplies power to the
cooling fan and also offers 10 amps of auxiliary power,
TRANSFORMER at the terminal strip and 14 pin amphenol, to operate
The desired three-phase input power is connected to wire feeding equipment. The 42VAC auxiliary power is
the DC-400 through an input contactor, located in the available at the 14 pin amphenol only and is protected
input box at the rear of the machine. Two phases of by a 10 amp circuit breaker. The three 21VAC phase
the input line are also connected to the control trans- angle windings are also housed in the main trans-
former assembly. These windings provide power and
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power to activate the input contactor. “timing” for the control board.
ELECTRIC
E-3 E-3
THEORY OF OPERATION
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FEEDBACK
CONTROL BOARD NEGATIVE
OUTPUT
G S PART
TERMINAL
A I OF
POWER T G
MODE
SWITCH MAIN E N
SWITCH
A
TRANSFORMER L
S
OUTPUT
CHOKE
R F
E PART E
OF E
C MODE D
O SWITCH B START
A BOARD
N
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C
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N OUTPUT K
E CAPACITORS
C POSITIVE
T OUTPUT
TERMINAL
SHUNT REED
INPUT SCR / DIODE SWITCH
CONTACTOR HYBRID BRIDGE
T 115VAC
REMOTE E S
TO CONTROL R T
CONTROL M
I R
BOARD I
N
A P
L
FAN
42VAC
14 PIN
AMPHENOL
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nal strip or the 14 pin amphenol, signals the control the welding circuit. This is accomplished by changing
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board to apply gate firing signals to the SCR/ Diode the amount of “pinch” or arc control windings that are
Bridge, which creates a DC voltage at the output of the active in the output choke. When weld current is
bridge assembly. If the Mode Switch is in the constant established, the reed switch closes and the start board
voltage (FCAW/GMAW) mode, this DC voltage is fil- becomes inactive.
tered by the Output Capacitors.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
E-4 E-4
THEORY OF OPERATION
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with an excessive overload or insufficient cooling. The leads (#75, #76 or #77) are accidentally connected to
machine will not have output, the amber protection the positive output welding lead, the DC-400 output
light will be on, and the fan should continue to oper- will be reduced to a low level, thus preventing damage
ate. When the thermostats reset, the amber protec- to the machine. If an erroneous connection is made
tion light will be off. between the remote control leads and the negative
output welding lead, the control board self-restoring
fuses will blow, preventing damage to the machine.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
E-5 E-5
THEORY OF OPERATION
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SCR OPERATION
A silicon controlled rectifier (SCR) is a three terminal An SCR is fired by a short burst of current into the
device used to control rather large currents to a load. gate. This gate pulse must be more positive than the
An SCR acts very much like a switch. When a gate cathode voltage. Since there is a standard PN junc-
signal is applied to the SCR, it is turned ON and there tion between gate and cathode, the voltage between
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is current flow from anode to cathode. In the ON these terminals must be slightly greater than 0.6V.
state, the SCR acts like a closed switch. When the Once the SCR has fired, it is not necessary to contin-
SCR is turned OFF, there is no current flow from anode ue the flow of gate current. As long as current contin-
to cathode; thus the device acts like an open switch. ues to flow from anode to cathode, the SCR will
As the name suggests, the SCR is a rectifier; so it remain on. When the anode to cathode current drops
passes current only during positive half cycles of the below a minimum value, called holding current, the
AC supply. The positive half cycle is the portion of the SCR will shut off. This normally occurs as the AC sup-
sine wave in which the anode of the SCR is more pos- ply voltage passes through zero into the negative por-
itive than the cathode. tion of the sine wave. If the SCR is turned on early in
the positive half cycle, the conduction time is longer,
When an AC supply voltage is applied to the SCR, the
resulting in greater SCR output. If the gate firing
device spends a certain portion of the AC cycle time in
occurs later in the cycle, the conduction time is less,
the ON state and the remainder of the time in the OFF
resulting in lower SCR output.
state. The amount of time spent in the ON state is
controlled by the gate.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
Section F-1 Section F-1
TABLE OF CONTENTS
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-2 F-2
TROUBLESHOOTING & REPAIR
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WARNING
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
This Troubleshooting Guide is provided to help Step 3. PERFORM COMPONENT TESTS. The
you locate and repair possible machine malfunc- last column, labeled “Recommended Course of
tions. Simply follow the three-step procedure Action” lists the most likely components that may
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possibilities that may contribute to the machine trical wiring diagrams and schematics. Refer to
symptom. Perform these tests/checks in the the Electrical Diagrams Section Table of Contents
order listed. In general, these tests can be con- to locate the appropriate diagram.
ducted without removing the case wrap-around
cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 216-383-2531 or 1-800-833-9353.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-3 F-3
TROUBLESHOOTING & REPAIR
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please use the following procedure: 4. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
board.
1. Determine to the best of your technical ability that NOTE: Allow the machine to heat up so that all elec-
the PC board is the most likely component caus- trical components can reach their operating
ing the failure symptom. temperature.
2. Check for loose connections at the PC board to 5. Remove the replacement PC board and substitute
assure that the PC board is properly connected. it with the original PC board to recreate the original
3. If the problem persists, replace the suspect PC problem.
board using standard practices to avoid static a. If the original problem does not reappear
electrical damage and electrical shock. Read the by substituting the original board, then the
warning inside the static resistant bag and perform PC board was not the problem. Continue
the following procedures: to look for bad connections in the control
PC Board can be damaged by wiring harness, junction blocks, and termi-
static electricity. nal strips.
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• Remove your body’s static charge b. If the original problem is recreated by the
before opening the static-shield- substitution of the original board, then the
ing bag. Wear an anti-static wrist PC board was the problem. Reinstall the
strap. For safety, use a 1 Meg replacement PC board and test the
ATTENTION machine.
Static-Sensitive ohm resistive cord connected to a
Devices grounded part of the equipment 6. Always indicate that this procedure was followed
Handle only at frame. when warranty reports are to be submitted.
Static-Safe
Workstations
• If you don’t have a wrist strap, NOTE: Following this procedure and writing on the
touch an unpainted, grounded, warranty report, “INSTALLED AND SWITCHED
part of the equipment frame. PC BOARDS TO VERIFY PROBLEM,” will help
Reusable Keep touching the frame to pre- avoid denial of legitimate PC board warranty
Container vent static build-up. Be sure not claims.
Do Not Destroy to touch any electrically live parts
at the same time.
• Tools which come in contact with the PC Board must
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-4 F-4
TROUBLESHOOTING & REPAIR
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Machine is dead – no output – no 1. Make sure that the input Power 1. Check the Power switch (S1) for
fan – no pilot light. switch is in the “ON” position. proper operation.
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-5 F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE Observe Safety Guidelines
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-6 F-6
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines TROUBLESHOOTING GUIDE
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switch (S3).
3. Check the 10A circuit breaker in
the 42VAC line.
4. If remote control is not being
used, make certain the Output
Control switch (S2) is in the
OUTPUT CONTROL “LOCAL”
position.
5. Check for loose or faulty weld
cable connections.
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-7 F-7
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE Observe Safety Guidelines
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-8 F-8
TROUBLESHOOTING & REPAIR
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-9 F-9
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE Observe Safety Guidelines
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-10 F-10
TROUBLESHOOTING & REPAIR
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The Arc Control switch (S5) has no 1. Make sure the correct process 1. Check the Arc Control switch
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effect in CV (FCAW/GMAW) mode and gas are being used. (S5) for proper operation.
when welding with the short circuit
2. Check the welding Mode switch
transfer process.
(S4), the microswitches, and the
associated wiring.
3. Check to make sure the output
choke control coil is not “open”
or grounded. See Wiring
Diagram.
4. Check resistor R1. Normal
resistance is 15 ohms.
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-11 F-11
TROUBLESHOOTING & REPAIR
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-12 F-12
TROUBLESHOOTING & REPAIR
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faulty. Replace.
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-13 F-13
TROUBLESHOOTING & REPAIR
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-14 F-14
TROUBLESHOOTING & REPAIR
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board.
3. The control board may be
faulty. Replace.
The welding arc is variable and 1. Check the input voltage at the 1. Check the welding Mode switch
sluggish. DC-400, making sure the cor- (S4), the microswitches, and the
rect voltage and all three associated wiring.
phases are being applied to the
2. Perform the SCR/Diode Rec-
machine.
tifier Bridge Test.
2. Make sure welding process is
3. Perform the Main Transformer
correct for machine settings.
Test.
3. Check welding cables for loose
4. The control board may be faulty.
or faulty connections. Also
Replace.
make sure cables are sized cor-
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-15 F-15
TROUBLESHOOTING & REPAIR
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WARNING
Service and repair should be performed by only Lincoln Electric factory trained person-
nel. Unauthorized repairs performed on this equipment may result in danger to the tech-
nician or machine operator and will invalidate your factory warranty. For your safety and
to avoid electrical shock, please observe all safety notes and precautions detailed
throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353
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(WELD).
DESCRIPTION
This test will help determine if the input contactor is receiving the correct coil voltage and
if the contacts are functioning correctly.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16” Nut driver
Idealarc DC 400 Wiring Diagrams (See the Electrical Diagrams section of this
manual.)
External 120VAC supply
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-16 F-16
TROUBLESHOOTING & REPAIR
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TEST PROCEDURE
1. Disconnect the main input supply power to 5. Apply the correct voltage to the machine
the machine. and turn the power switch (S1) ON.
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2. With the 5/16” nut driver, remove the case 6. Check for 120VAC at the contactor coil
top and the reconnect panel cover. leads.
3. Locate the two leads connected to the input If the 120VAC is NOT present, with the
contactor coil, #233 and X1 #232 (top). See power switch (S1) on, check the power
Figure F.1 for location. switch (S1) and associated circuitry. See the
Wiring Diagram. Also perform the Control
4. Connect an AC voltmeter to the leads.
Transformer (T2) Voltage Test.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-17 F-17
TROUBLESHOOTING & REPAIR
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-18 F-18
TROUBLESHOOTING & REPAIR
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WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
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DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of the control
transformer and induced on the secondary winding of the control transformer.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16” Nut driver
IDEALARC DC-400 Wiring Diagrams (See the Electrical Diagrams section of this
manual.)
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-19 F-19
TROUBLESHOOTING & REPAIR
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TEST PROCEDURE
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1. Disconnect the main input supply power to 5. Locate control transformer leads X1 (top)
the machine. and X2.
2. With the 5/16” nut driver, remove the top, a, Lead X1 is connected to the input con-
case sides, and lower the front control tactor (CR1) coil located on the input
panel. side of the contactor. See Figure F.3.
3. Locate the control transformer (T2) on the b. Lead X2 is spliced into lead #231. See
left side of the input box (facing the back the Wiring Diagram. Lead #231 is
of the machine). See Figure F.3. connected to the power switch (S1).
Remove five machine screws holding
4. Locate the control transformer primary
the control panel to the case front and
leads (H1, H2, H3, etc.). See the Wiring
tilt the panel forward to access the
Diagram.
power switch and Lead #231 connec-
NOTE: Unused leads should be taped. tion. See Figure F.4.
a. Inspect for broken or incorrect con-
nections.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-20 F-20
TROUBLESHOOTING & REPAIR
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RIGHT
SIDE VIEW
6. Test for 115VAC between leads X1 and 8. If 115VAC is not present between leads X1
#231. and #231, check the spliced connection
between #231 and X2. Test for correct
NOTE: If the main AC input supply voltage
main input supply power to the control
varies, the control transformer voltage will
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-21 F-21
TROUBLESHOOTING & REPAIR
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WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this man-
ual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
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DESCRIPTION
This test will determine if the correct voltages are being applied to the primary windings of
the Main Transformer (T1) and induced on the secondary winding, auxiliary windings, and
phase angle windings.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16” Nut driver
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-22 F-22
TROUBLESHOOTING & REPAIR
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TEST PROCEDURE
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1. Set the ON/OFF power switch to OFF. 5. Connect main input supply power to the
machine.
2. Disconnect main input supply power from
the machine. 6. Set the ON/OFF power switch to ON.
3. With the 5/16” nut driver, remote the case a. Make sure the input contactor (CR1)
top and sides and the reconnect panel energizes and the fan runs.
cover.
7. Test with an AC voltmeter for proper main
4. Inspect the input contactor, reconnect input supply voltage to the line side of the
panel, and primary leads to the main trans- input contactor (CR1). See the Wiring
former for loose or faulty connections. See Diagram.
Figure F.5.
a. L1 to L2.
a. Confirm that the reconnect panel is
b. L2 to L3.
connected properly for the three-phase
main input supply power supplied to c. L1 to L3.
the machine. See the reconnect panel
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-23 F-23
TROUBLESHOOTING & REPAIR
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b. If proper voltage is not present in any tact if necessary. See Figure F.6. See the
or all of the three phases, check input Wiring Diagram.
fuses and leads.
a. If one or more of the above voltage
9. Test with an AC voltmeter for proper main tests are incorrect, check for loose or
input supply voltage from the output side of faulty connections.
the input contactor (CR1). See the Wiring
b. If the connections are good, then the
Diagram.
main transformer may be faulty. Re-
a. T1 to T2. place the main transformer.
b. T2 to T3.
c. T1 to T3.
10. Read the meter.
a. If proper voltage is present for all three
phases, the input contactor is working
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properly.
b. If the proper voltage is not present for
any or all of the three phases, the input
contactor may be faulty. Replace the
input contactor.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-24 F-24
TROUBLESHOOTING & REPAIR
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FIGURE F.7 – PHASE ANGLE WINDINGS TEST POINTS AND TERMINAL STRIP LOCATION
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12. Test for 115VAC between leads #31 and 13. Test with an AC voltmeter for 21VAC for
#32 on the terminal strip. Also test for each phase angle winding at plug P1 on
42VAC between pin K (lead #42) and pin I the control board as shown in Figure F.8
(lead 41) in the 14 pin amphenol. and the accompanying table.
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a. Remove the sheet metal screws from NOTE: If the main input supply voltage
the control box cover with the 5/16” varies, the main transformer voltages will
nut driver and flip the cover down. It vary proportionately.
does not have to be completely
a. If the voltage is low, remove plug P1
removed to perform the tests.
and recheck the voltage for 21VAC. If
b. If the above voltage checks are incor- the reading is normal, the control board
rect, check for loose or faulty wiring. may be faulty. Replace the control
Check continuity. board.
c. If the wiring is good, then the main b. If one or more of the voltage tests are
transformer may be faulty. Replace the incorrect, check for loose or faulty
main transformer. wiring.
c. If the wiring is good, then the main
transformer may be faulty. Replace the
main transformer.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-25 F-25
TROUBLESHOOTING & REPAIR
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Plug P1
DC-400 CONTROL
G2588-X
Plug P3
#201
#204 #203 #202
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-26 F-26
TROUBLESHOOTING & REPAIR
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WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
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DESCRIPTION
This test will help determine if an SCR or diode is shorted or “leaky.” See the Machine
Waveform Section in this manual for normal and abnormal output waveforms.
MATERIALS NEEDED
Analog Volt/Ohmmeter (Multimeter)
5/16” Nut driver
Idealarc DC-400 Wiring Diagrams (See the Electrical Diagrams section of this manual.)
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-27 F-27
TROUBLESHOOTING & REPAIR
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Plug P5
Plug P1
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DC-400 CONTROL
G2588-X M15370-X SNUBBER
Plug P3
TEST PROCEDURE
1. Disconnect the main input supply power to 5. Locate and remove molex plug P5 from the
the machine. snubber board. See Figure F.9.
2. With the 5/16” nut driver, remove the case 6. Rotate the mode switch (S4) to the constant
top and sides. current (CC) position.
3. Disconnect the welding cables from the 7. Locate and remove lead #204 from resistor
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-28 F-28
TROUBLESHOOTING & REPAIR
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8. Remove the red insulating paint from the a. Reverse the meter leads and measure
heat sink test points. See Figure F.11. the resistance from cathode (+probe)
to anode (-probe) of diode D1. The
NOTE: Do not disassemble the heat sink.
resistance should be high. See Figure
9. Measure the resistance from the anode to F.11.
the cathode of SCR 1 using an analog
b. If a low resistance is measured in both
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F.11.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-29 F-29
TROUBLESHOOTING & REPAIR
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WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
Return to Section TOC
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DESCRIPTION
This test will help determine if the device can be gated ON and conduct current from anode
to cathode.
MATERIALS NEEDED
An SCR tester as specified in this procedure.
5/16” Nut driver
Idealarc DC-400 Wiring Diagrams (See the Electrical Diagrams section of this manual.)
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-30 F-30
TROUBLESHOOTING & REPAIR
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Plug P5
Plug P1
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DC-400 CONTROL
G2588-X M15370-X SNUBBER
TEST PROCEDURE
1. Disconnect the main input supply power to 5. Locate and remove molex plug P5 from the
the machine. snubber board. See Figure F.13.
2. With the 5/16” nut driver, remove the case 6. Rotate the mode switch (S4) to the constant
top and sides. Remove the screws holding current (CC) position.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-31 F-31
TROUBLESHOOTING & REPAIR
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-32 F-32
TROUBLESHOOTING & REPAIR
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9. Construct the circuit shown in Figure F.16. b. If the voltage is 3-6 volts only when the
One 6-volt lantern battery can be used., Set switch is closed or if there is no voltage
voltmeter scale low, at approximately 0-5 when the switch is closed, the SCR is
volts or 0-10 volts. defective.
10. Test the voltage level of the battery. Short NOTE: Be sure the battery is function-
leads (A) and (C). Close switch SW-1. ing properly. A low battery can affect the
Battery voltage should be 4.5 volts or higher. results of the test. Repeat Battery Test
If lower, replace the battery. Procedure in Step 10 if needed.
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11. Connect the tester to the SCR 1 as shown in 16. Open switch SW-1.
Figure F.16.
17. Reconnect the tester leads. See Figure F.16.
a. Connect tester lead (A) to the anode.
a. Connect tester lead (A) to the cathode.
b. Connect tester lead (C) to the cathode.
b. Connect tester lead (C) to the anode.
c. Connect tester lead (G) to the gate.
c. Disconnect test lead (G) from the gate.
12. Close switch SW-1.
18. Close switch SW-1.
NOTE: Switch SW-2 should be open.
19. Read meter for zero voltage.
13. Read meter for zero voltage.
a. If the voltage is zero, the SCR is func-
a. If the voltage reading is higher than zero, tioning.
the SCR is shorted.
b. If the voltage is higher than zero, the
14. Close or keep closed switch SW-1. SCR is shorted.
15. Close switch SW-2 for 2 seconds. Release 20. Perform the Active Test Procedure outlined
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-33 F-33
TROUBLESHOOTING & REPAIR
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CH1
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0 volts
50 volts 2 ms
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....2 ms/Div.
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Coupling ............................DC
Trigger .........................Internal
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-34 F-34
TROUBLESHOOTING & REPAIR
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CH1
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0 volts
20 volts 2 ms
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....2 ms/Div.
Coupling ............................DC
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Trigger .........................Internal
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-35 F-35
TROUBLESHOOTING & REPAIR
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CH1
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0 volts
20 volts 5 ms
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
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Trigger .........................Internal
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-36 F-36
TROUBLESHOOTING & REPAIR
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CH1
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0 volts
20 volts 5 ms
Coupling ............................DC
Trigger .........................Internal
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-37 F-37
TROUBLESHOOTING & REPAIR
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CH1
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0 volts
20 volts 5 ms
Trigger .........................Internal
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-38 F-38
TROUBLESHOOTING & REPAIR
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CH1
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0 volts
2 volts 5 ms
SCOPE SETTINGS
Volts/Div.......................2V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
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Trigger .........................Internal
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-39 F-39
TROUBLESHOOTING & REPAIR
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CH1
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0 volts
20 volts 5 ms
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
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Coupling ............................DC
Trigger .........................Internal
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-40 F-40
TROUBLESHOOTING & REPAIR
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WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
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DESCRIPTION
The following procedure will aid the technician in inspecting, cleaning, and replacing the input
contactor.
MATERIALS NEEDED
Phillips head screwdriver
5/16” socket wrench
Flat heat screw driver
Low pressure air source
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-41 F-41
TROUBLESHOOTING & REPAIR
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6. Replace the input contactor cover plate. 8. Remove the input contactor.
9. Insert the replacement input contactor and
install it following the procedures in reverse
order.
NOTE: Be sure to reconnect all leads cor-
rectly.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-42 F-42
TROUBLESHOOTING & REPAIR
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WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
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DESCRIPTION
The following procedure will aid the technician in gaining access to the fan blade and fan
motor for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
3/8” Wrench
Allen head type wrench
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-43 F-43
TROUBLESHOOTING & REPAIR
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PROCEDURE
1. Remove the main input supply power to the 5. Remove the four mounting nuts and associ-
machine. ated flat and lock washers that hold the
motor to the mounting bracket. See Figure
2. Using the 5/16” nut driver, remove the case
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F.18.
top and sides.
6. Carefully remove the fan motor.
3. The fan blade can be removed using the
Allen head wrench. 7. To replace the fan motor, mount the motor to
its mounting bracket using the four nut and
NOTE: You may need to loosen the
associated flat and lock washers.
machine case back to gain clearance to
remove the fan. See Figure F.18. 8. Resplice any motor leads cut for removal.
Soldering the wires is recommended.
4. If the fan motor is to be removed, the leads
to the motor must be disconnected. This 9. Reattach the fan blade, if it was removed
will require cutting the wires or “breaking the earlier, using the Allen head wrench to
splice.” tighten it to the motor shaft.
10. Install the case top and sides.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-44 F-44
TROUBLESHOOTING & REPAIR
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WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
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DESCRIPTION
The following procedure will aid the technician in the removal and replacement of the SCR/
diode assembly.
MATERIALS NEEDED
5/16” Nut driver
7/16” Wrench
1/2” Wrench
9/16” Wrench
3/8” Wrench
Slot head screw driver
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-45 F-45
TROUBLESHOOTING & REPAIR
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PROCEDURE
1. Remove the main input supply power to the panel to allow clearance for SCR/diode
machine. assembly removal. Clear any necessary
leads that might hinder removal.
2. With the 5/16” nut driver, remove the case
top and sides. 11. For reassembly, carefully place the SCR/
diode assembly into position on the mount-
3. Remove the glastic stiffeners (one on each
ing bracket and reinstall the washers and
side-left and right). See Figure F.19.
nuts. Tighten the front panel to base if it was
4. Remove the positive capacitor lead and loosened earlier.
shunt from the positive heat sink plate. See
12. Replace and tighten the four nuts and lock-
Figure F.19.
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5. Remove the choke and mode switch lead to the mounting brackets.
from the left side of the negative heat sink
13. Reattach the three heavy aluminum sec-
plate. See Figure F.19.
ondary leads to the SCR finned heat sinks.
6. Remove the gate leads from the control Apply a thin coating of Dow Corning 340
board (plug P3). heat sink compound (Lincoln E1868) to con-
nection points.
7. Remove plug P5 from the snubber board.
Also remove lead #224 from the positive 14. Connect the green ground lead to the front
output lead. Remove lead #225 from the panel, lead #225 to the negative output lead,
negative output lead. Remove the green and lead #224 to the positive output lead.
ground lead from the front panel.
15. Connect plug P5 to the snubber board and
8. Remove the three heavy aluminum sec- plug P3 to the control board.
ondary leads from the SCR finned heat
16. Connect the choke and mode switch lead to
sinks.
the left side of the negative heat sink plate.
9. Remove the four nuts and associated wash- See Figure F.19.
ers that hold the SCR/diode assembly to the
17. Connect the positive capacitor lead and
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mounting brackets.
shunt to the positive heat sink plate. See
10. Carefully lift and remove the SCR/diode heat Figure F.19.
sink assembly from the machine. Note: It
18. Install the glastic stiffeners to the left and
may be necessary to loosen the six sheet right sides. See Figure F.19.
metal screws that hold the front panel to the
base. Carefully lift and pull out the front 19. Install the case top and sides.
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-46 F-46
TROUBLESHOOTING & REPAIR
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WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
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DESCRIPTION
The following procedure will aid the technician in removing the SCRs from the output rectifier
heat sink for maintenance or replacement.
MATERIALS NEEDED
NO.000 Fine Steel Wool
Penetrox A-13 (Lincoln E2529) or Penetrox A
7/16” Open end wrench
Allen head type wrenches
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-47 F-47
TROUBLESHOOTING & REPAIR
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SPECIAL INSTRUCTIONS
NOTE: Before disassembling the existing recti- 5. Clean the area on the heat sink around the
fier, note toward which heat sink the outer metal SCR mounting surface, using a putty knife or
ring of the power SCR is mounted. Also, note similar tool. DO NOT SCRATCH THE SCR
the positioning of the gate lead of the SCR. MOUNTING SURFACE.
Failure to reinstall the new SCR in the same ori-
6. Polish each heat sink’s mounting surface
entation as the original may result in subsequent
using NO. 000 fine steel wool. Wipe surface
damage to the new SCR and other components
clean with a lint-free cloth or paper towel.
of the welder. See Figure F.20.
7. Inspect the mounting surfaces of each new
CAUTION SCR.
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ELECTRIC
F-48 F-48
TROUBLESHOOTING & REPAIR
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SPRING
1. Place a piece of sleeving around each cap screw.
2. Insert cap screws through the leaf spring. Orient
the leaf spring so that its ends are curved upward
toward the cap screw heads. See Figure F.21.
Pressing on the cap screw heads should produce
a “rocking” motion of the spring in its housing. If
the spring does NOT rock, it is installed upside
down. Remove the spring and turn it over. Check
for “rocking” motion. See Figure F.21.
3. Insert cap screws and leaf spring into the plastic
housing.
4. Insert clamp assembly through heat sinks. Install
nuts. Tighten clamp nuts equally on cap screws
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-49 F-49
TROUBLESHOOTING & REPAIR
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-50 F-50
TROUBLESHOOTING & REPAIR
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HOUSING
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-51 F-51
TROUBLESHOOTING & REPAIR
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-52 F-52
TROUBLESHOOTING & REPAIR
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WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
Return to Master TOC
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in mounting stud type diodes to the aluminum
heat sinks on the DC-400.
MATERIALS NEEDED
5/16” Nut driver
1/2” Open end wrench
Lincoln E1868 (Dow Corning 340) Heat Sink Compuond
“Slip” type torque wrench
No. 000 fine steel wool
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-53 F-53
TROUBLESHOOTING & REPAIR
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PROCEDURE
1. Remove the main input supply power to the DIODE STUD FOOT- INCH-
machine. SIZE POUNDS POUNDS
2. With the 5/16” nut driver, remove the case 3/4-16 25-27 300-324
top and sides. 3/8-24 10±.5 125+0/-5
1/4-28 22-25
3. Loosen the appropriate diode nut and
remove the diode that is to be replaced.
4. Clean the area on the heat sink around the
diode mounting surface using a putty knife
or similar tool. DO NOT SCRATCH THE
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-54 F-54
TROUBLESHOOTING & REPAIR
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WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
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DESCRIPTION
The following procedure will aid the technician in removing the main transformer for mainte-
nance or replacement.
MATERIALS NEEDED
5/16” Nut driver
9/16” Socket wrench
9/16” Box end wrench
1/2” Socket wrench
1/2” Box end wrench
3/8” Nut driver or socket wrench
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-55 F-55
TROUBLESHOOTING & REPAIR
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REMOVAL OF LIFT BAIL 10. Remove the sheet metal screw that holds
the capacitor bank assembly to the case
1. Remove the main input supply power to the back. (This should enable the capacitor
machine.
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-56 F-56
TROUBLESHOOTING & REPAIR
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-57 F-57
TROUBLESHOOTING & REPAIR
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REASSEMBLY OF TRANSFORMER
COILS
NOTE: The following procedure describes a
complete replacement of all primary and sec-
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-58 F-58
TROUBLESHOOTING & REPAIR
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MACHINE FRONT
3. Install the bottom primary coils, one on each of the 7. Place insulation (Lincoln Electric part number
three legs of the bottom iron assembly. The coils S20728) on top of each of the three secondary
must be in correct position (left, center, right). coils. The longer side of the insulation should be
Place the coils so that the leads come out at the placed toward the front of the machine, where the
back of the machine. See Figure F.28 for proper secondary start and finish leads come out. See
positioning. Figure F.29.
4. Place insulation (Lincoln Electric part number 8. Install the three top primary coils, noting which is
S20728) on top of each of the three primary coils. right, left, and center. Leads should come out at
The longer side of the insulation should be placed the back of the machine. See Figure F.28 for prop-
toward the front of the machine. See Figure F.29 er positioning. The coils must be in correct position
for the location of this insulation (left, center, right).
5. Place the three secondary coils on top of the insu- 9. Install the top iron (lamination) and choke assem-
lation installed in Step 4. The leads should come bly. With the 9/16” deep well socket wrench,
out at the front of the machine with the short leads reassemble the four thru-bolts that clamp the top
on top. See F.28 for proper positioning. “E” iron to the bottom “E” iron. Lightly tap on the
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-59 F-59
TROUBLESHOOTING & REPAIR
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TOP VIEW
THERMOSTAT
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INSULATION
FRONT VIEW
10. Mount the primary thermostat to the lead 11. If necessary, trim off excess secondary lead
end coil nose. See Figure F.30. Place a stickout and TIG weld the leads together.
small amount of Lincoln Electric E1603 See Figure F.31.
Epoxy between the coil nose and the coil
insulation and between the insulation and
the thermostat. Hold the thermostat in
place with E2381 (.375” wide) tape. If nec-
essary, after assembly protect the thermo-
stat terminals with E2547 terminal boots.
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TIG WELD
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-60 F-60
TROUBLESHOOTING & REPAIR
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-61 F-61
TROUBLESHOOTING & REPAIR
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• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the
machine’s electrical characteristics. OR
IDEALARC DC-400
LINCOLN ®
ELECTRIC
F-62 F-62
TROUBLESHOOTING & REPAIR
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Constant Voltage Output Control at Maximum 525 Amps @ 41.5 Volts (Min)
(FCAW/GMAW)
Constant Voltage Output Control at Maximum 525 Amps @ 41.5 Volts (Min)
(SUB ARC)
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IDEALARC DC-400
LINCOLN ®
ELECTRIC
G-1 TABLE OF CONTENTS G-1
- ELECTRICAL DIAGRAMS SECTION -
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IDEALARC DC400
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES
IDEALARC DC400
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-2
L3 L2 L1
3 X1 11 9 6 PER NATIONAL
9 6 3 11
W 9 5 3 3 18
W W 3 ELECTRICAL
2
2 2 W CODE
V V V 2 8 5
8 8 10 2 10
232 1 5 232 1 4 232 1
17 V
u
U U 1
U
CR1 4 CR1 7 6 12 CR1 1 16 12 7 4
7 CONTACTOR CONTACTOR CR1 FLEX LEAD
CONTACTOR 233
H1 TO PRIMARY CONTACTOR JUMPER
COILS 233 233 H1
233 H1 COILS TO PRIMARY COILS
TO PRIMARY T0 PRIMARY COILS H1
THIS CONNECTION
10AMP INSULATE AS
N.B. H2 H2 115V
TO SUPPLY CIRCUIT 42 SHOWN ON
DOES NOT APPEAR ON 50
LINES INPUT
H3 220/380/440V AND BREAKER H3
52 CONNECTION
230/400V MACHINES 42
X1 L3 L2 L1 H4 X2
DIAGRAM
241 2 231
3
W 10 SECONDARY PRIMARY T2 CONTROL
2 11 12 42A TRANSFORMER
TOP S THERMOSTAT THERMOSTAT
V S 220V 115V 42V
232 1 PRIMARY
U N.C. 41
7 9 S 41
CR1 231
201 203
CONTACTOR AUXILIARY 202 4
COILS 204
233 H1 21V 21V CAPACITOR
21V 41
S S DISCHARGE
CAPACITOR
CR4 RELAY
S DISCHARGE
BOTTOM 4 5 6 T1 MAIN OPTION
8 TRANSFORMER
PRIMARY
1 2 3 N.A.
N.E.
F2
SLOW
16 17 18 BLOW
254 204
P5
1 220 204 C1 +
RECTIFIER
2 221 D1 D2 D3 ASSEMBLY C2 + 31,000MFD
3 222 D4 C3 + 50V EACH
4 REED
223 C4 +
J5 SWITCH
5 225 SCR2 SHUNT C5 +
SCR1 SCR3
+ - CR3
6 224
GREEN
7 227 204
8 204 205 206
R3
204 215 216 7.5 /100W
SNUBBER G3 204
BOARD G2 R2
204
G1 40 /50W
225
P2 225
P1 P3
1 2 4 3 1 209 LEAD NOT PRESENT WITH
201 1
2 214 232 DIODE OPTION
202 2
3 217 PILOT
203 3
J3 LIGHT ELECTRICAL SYMBOLS PER E1537
204 4 4 204 W
J1
225 5 5 206 233 7 1
220 6 8 2
ELECTRICAL DIAGRAMS
6 206 233 6 1
THERMAL 41 7 J2 5 1 9 3
7 2
PROTECTION 7 208 4 1
4 8 6 2 8 3 10 4
S1
LIGHT 8 213 1 5 2 7 3 11 5
2 9 POWER 3 9 4
42 6 3 12 6
9 75 SWITCH 4 2 8 4 10 5
Y 240 10
10 212
231 4 PIN 6 PIN 8 PIN 10 PIN 12 PIN
MODE SWITCH 11 205 J3 J6 J5 J1 J2
FRONT GANG CONTROL BOARD 12 205 CONNECTOR CAVITY
CV-FCAW/GMAW +
VM NUMBERING SEQUENCE
CC CV-SUB ARC 225 - (COMPONENT SIDE OF P.C.
P6 STARTING
ARC CONTROL 31 206 BOARD)
4 BOARD
S4A 205 +
L1 SWITCH AM
32 1
OUTPUT S5 206 -
228 2
CHOKE MIN. IND. (5) J6 METERS
NOTES
CV-FCAW/GMAW
CC S 216 3
1 N.A. CIRCUITRY PRESENT ON
2 215 5
CV-SUB ARC 15 /100W 234 CAPACITOR DISCHARGE
MAX. IND. 218 6
S4B 3 (1) R1 ONLY.
F
216 218 219
N.C.
N.B. TAPE UP SEPARATELY
S4D 224 204 208 209 32A 76 212 210 211 213 77 210 TO PROVIDE AT LEAST
217 224
N.O. ACTUATED 225 600 V INSULATION.
234
CV-FCAW/GMAW R5 75 211
204 219 10A
N.C.
ONLY
218 10K /2W CIRCUIT R4 N.C. 220V WINDING, PLUG
21 N.D.
N.O.
ARC FORCE CONTROL BREAKER
S4C S6 10K /2W AND CIRCUIT BREAKER
214 VOLTMETER S2
ACTUATED OUTPUT ARE PRESENT ONLY ON
204 SWITCH OUTPUT CONTROL
42
228 IN CC ONLY CONTROL 50/60 HERTZ WELDER.
32 SWITCH
C6 .0047MFD/1400V 32 31
41
2 N.D. 31 AND 32 ARE NOT
OPTIONAL
GREEN 4 N.A. PRESENT ON EUROPEAN
21 MULTI-PROCESS
77 SWITCH 224 MODELS.
75
STUD 76
21 4 2 31 32 75 76 77 N.E. CIRCUITRY PRESENT ON
GROUNDING 4 S3 WORK +
OUTPUT DIODE OPTION ONLY.
2
225 TERMINALS
TS2 TS1
SWITCH ELECTRODE -
N.A.
4 2
12-9-94F
L9106
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
G-2
IDEALARC DC400
ENHANCED DIAGRAM
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-3
Wiring Diagram (Code 9850)
230/460/575V.
H3 (SHOWN CONNECTED FOR 230 V.)
N.B. H4 TO SUPPLY
LINES
H2 RECONNECT PANEL
L3 L2 L1 13
X1 3
9 14
W 15
TO GROUND PER NATIONAL 8 4 5 N.B.
V 2 16
ELECTRICAL CODE 6
17
FAN MOTOR U 7
18
CR1 1
233 CONTACTOR
TO PRIMARY
10 AMP
CIRCUIT COILS
BREAKER 232 CONNECT OR H1
31 INSULATE AS X1
SHOWN ON
42 T2
AUXILIARY INPUT H2
42 115V CONTROL
COILS CONNECTION
10 TRANSFORMER
S 42A 32A DIAGRAM H3
12
115V 42V 241 H4 X2
2
231
7 8 9 S SECONDARY PRIMARY
231
201 THERMOSTATS
203 4
TOP 202 41
PRIMARY 13 14 15 CAPACITOR
21V 21V 21V 41
S 41
S DISCHARGE
204 CR4 RELAY
S
4 5 6 CAPACITOR
BOTTOM
DISCHARGE
PRIMARY
OPTION
1 2 3 N.A.
10A 0.5 /50W
R8
F2
SLOW
16 17 18 N.C. BLOW
T1 MAIN
0.5 /50W
R7
TRANSFORMER
X1 SEC X2 SEC X3 SEC DIODE
OPTION
254 204
P5
1 220 204 C1 +
RECTIFIER
2 221 D1 D2 D3 ASSEMBLY C2 + 31,000 MFD
3 222 D4 C3 + 50V EACH
4 REED
223 C4 +
J5 SWITCH
5 225 SCR2 SHUNT C5 +
SCR1 SCR3
+ - CR3
6 224
GREEN
7 227 204
8 204 205 206
R3
204 215 216
204 7.5 /100W
SNUBBER G3
BOARD G2 204 R2
G1
40 /50W
225
225
P1 P3 P2
1 2 4 3 LEAD NOT PRESENT WITH
201 1 1 209
232 DIODE OPTION
202 2 2 214
PILOT
203 3
3 217 LIGHT ELECTRICAL SYMBOLS PER
204 4 J3 W
4 204 E1537
225 5 7 1
233
220 6 J1 5 206 6 1 8 2
233
41 7 5 1 7 2 9 3
6 206
J2 4 1 6 2 8 3 10 4
4 8 208
7 S1 5 2
3 1 7 3 9 4 11 5
42
2 9 8 213 POWER 4 2 6 3 8 4 10 5 12 6
ELECTRICAL DIAGRAMS
SWITCH
Y 240 10 9 75
4 PIN 6 PIN 8 PIN 10 PIN 12 PIN
THERMAL 10 212 231 J3 J6 J5 J1 J2
PROTECTION 11 205
LIGHT CONNECTOR CAVITY
CONTROL BOARD 12 205 + NUMBERING SEQUENCE
VM
MODE SWITCH
225 - (COMPONENT SIDE OF P.C.
FRONT GANG 206 BOARD)
CV-FCAW/GMAW 205 +
AM
CC CV-SUB ARC P6 STARTING 206 - NOTES
ARC CONTROL 31 4 BOARD N.A. CIRCUITRY PRESENT ON
S4A METERS
L1 SWITCH
32 1 CAPACITOR DISCHARGE
OUTPUT S5
228 2 ONLY.
CHOKE MIN. IND. (5) J6
CV-FCAW/GMAW
CC S 216 3
N.B. TAPE UP SEPARATELY
1 215 5
CV-SUB ARC 2 15 /100W TO PROVIDE AT LEAST
234
MAX. IND. 218 6
S4B (1)
600 V INSULATION.
3 R1
F
216 218 219
N.C. CIRCUITRY PRESENT ON
N.C.
204 208 209 210 DIODE OPTION.
217 S4D 224 32A 76 212 210 211 213 77 224
N.O. ACTUATED
225 75 211
234 CV-FCAW/GMAW R5 10A R4
204 219 ONLY
N.C. CIRCUIT
218 10K /2W 10K /2W
S4C 21 BREAKER
N.O.
ARC FORCE CONTROL OUTPUT
ACTUATED S6
214 IN CC ONLY VOLTMETER S2 CONTROL
204 SWITCH 32 OUTPUT CONTROL
42
228 SWITCH
C6 .0047MFD/1400V 32 31
41
2
N.A.
GREEN 4 21
77 WORK +
GROUNDING 75 OPTIONAL 224
STUD 21 4 2 31 32 75 76 77 76 MULTI-PROCESS
4 S3
SWITCH
2 OUTPUT
ELECTRODE -
225 TERMINALS
TS2 TS1
SWITCH 4 2
N.A.
TO TERM. TO NEG. TO POS.
STRIP TERM. TERM.
12-9-94F
L9107
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
G-3
IDEALARC DC400
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
IDEALARC DC400
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
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
C20
C57 Q8 C36 C56 D50
C23 R139 R83
D40
D63
R95
R98
R99
R122
R88
R137 R59
D41 R58 R82 A
R89
R134
R135
X2 M E C19
R106 C35 C15
C61 C60
R111 X3 D55
D51
R85
R61
R100
R125
R124
D61
D47
F R60 R65
D43 R110
R66 D52
D53
R62 C31
C58 C24 D64 R57
R96 R55 R38
R300 D36 D31
C51
D57 R56 G
Return to Master TOC
C30 Q5
Return to Section TOC
D37 X6
D42 R107 D48 R148 R149
R97 D56
D44 D58 C33 D46
R70 C32
D45 R44 R127 R37
R301 R128
R132
R303
R109
Q1
R304 R80
R71
R51 R138
R35
R36
C45
DZ6
R101
R102
R50
D28 DZ7 D59
R53 R49 D27 D60 C25
D54
R69 R123
R103
Q3 Q4
R48 R90 DZ8
R54 C26
R129
R104
R76 R47 R91
R52 R94 R105
D30 C34
D26
R68 D82
X4
R108
R77
C68 X1 R46 D49
R67 R121 R315 Q6
R72 C16 R63
C67 R119 R143
R305 R64
R130 R120 R142
C17 R131 R145
R74 C22
C18 D79
R75 D24 D29
R156 D22
C D23 R144 D R150
DZ10
R73
R42
R41
R40
R45
C59
D33
D32
D35
D34
D25
DZ4
R126
K C39 X5
R141
D74
C14
B
R302
R147 R118
R93
R146
R115
R140
C38
C37
R117
R79 R78 X7
DZ9
C41
Q2 N
DZ5
R116
R81
C44
D62 R316
D10
D11
D12
R27 R28 R317
R26 R153
R112 R318
C40 R319
R320
OCI1 R321
C7
C8
C9
R20
R29
R30
R25
QU1
R307
R308
R24
R31
QU2 QU3 C43 R322
R323
R324
SCR1
SCR2 SCR3 R114 R325
D78
D76
R326
D7
D8
D9
C4
R152
DZ12
D14
D15
R23
R21
R18
R22
R19
R8
D4
R306
R14
R17
R11
D5
C5 R327
D67
C6
R328 R151
D13
R4 R15 R16
H R154 R155
I J R113
Return to Master TOC
C1
D1
D16
Return to Section TOC
R32
C10
D2
D3
R1
R309
D18
D65
D66
DZ2
DZ3
R7
R2
R5
R3
C3
R33
R86
R12
R34
R87
D17
R9
D6
C2
R310
R10
R13
D73
D72
D71
D80
D81
D77
D75
C11
C12
R311
DZ1
DZ13
R314
R313
R312
D69
D70
D68
D21
D20
D19
DZ14
R6
J2 J3
DC400 CONTROL
J1
G2588-1
ITEM
Return to Master TOC
Return to Section TOC
REQ'D.
PART No.
IDEALARC DC-400
NO.
SHT.
G
CONTROL P.C. BOARD ASSEMBLY
IDENTIFICATION
2588-1
Return to Master TOC
Return to Section TOC
C1 S13490-72 1 50/50
D1, D2 T12199-2 2 1N4007
D3, D4, D5, D6, D7 T12199-1 5 1N4004
R1, R2 T14648-9 2 5W/2500 OHM RESISTOR
R3, R5 2 1K 1/4W
R4 S19400-1501 1 1.5K 1/4W
R6 T14649-4 1 100 10W
SCR1 S15161-19 1 4A, 400V SCR
S19400-1001
SCR2 T14805-1 1 SCR HEAT SINK AS'BLY
Return to Section TOC
Return to Master TOC
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
IDEALARC DC400
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
G-6 ELECTRICAL DIAGRAMS G-6
Snubber PC Board (M15370) Layout
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
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. IDEALARC DC400
G-7 ELECTRICAL DIAGRAMS G-7
Control PC Board (G2588) Schematic
Return to Section TOC
Return to Master TOC
2586 G
+15V
D79
1N4004
R140
R126
D21 33.2K
R121
4 4 4 4 7
R123
R85
D60 D22
R144
100 1.00M 10K
C32 10K C31
R142
475K 1N4004 1N4004 C30 X1 X2 X3 X4 X6
1.8 POWER UP .022
R128
Q1 D82 .022
20V OUTPUT CLAMP 50V
1N4004 50V LM224 LM224 LM224 LM224 AD620
2N4857
9
C34 R156
C33 .022 8 11 11 11 11 4
D59 221K X4 R146
4 50V C39
10
50V DZ6 1N4004 47 2.67K
15V 35V
1W 10K
R143
R145
+15V
10K D23
D57
1N4004
1N4004
82.5K
C67 C68 C57 C59 C60 C61
R132
102K C58
D61
R100
R99
D42 9 1N4004
475K
1N4004 D74 D -10V
8 6
13.7K 13.7K X2 R98 1N4004
J1 10 7
6 10K
220 R96 R300 X2
5 CAPACITOR 2.7 1W +15V
D40 Q5
C51 RECTIFIER BRIDGE OVER-VOLTAGE X5 RF
1N4004 2N4123 R154
D41
.0047 1.50K VOLTAGE BUFFER PROTECTION IN OUT
R97
1400V 1N4004
R122
61.9K D68 D69 D70
N D
10K C40 GND
DZ9
+15V 1N4005 1N4005 1N4005 C41
R147
RF 500 17V Q2
22.1K 4.7
-10V 26.7K 50V 5W
R44
R95
35V 15A
1.50K D58
R301
203 60V
D56
1N4004 G
100K 1N4004 S
Return to Section TOC
R59
Return to Master TOC
-7.5V 202
RF DZ5
12 201
R57 D71 D72 D73
-10V R118
14
100K C15 X3 1N4005 1N4005 1N4005
D55 31.6K H 15V
1.8 13 D63
CURRENT + 1W
1N4004 20V 1
E SWITCH 2N4857 1N4004 R155 D10
2K
R134 Q8 X7 8
1N4004
R117
2.7
R58
2.21K C35 15.0K 1W TL431 REF J3
250 CW
.68 150 201 R112 1 G1
10W - 6
R148
221K C36
R135
50V 50V 68 D65 D13 D16
100K
R137
4.7 C43 SCR1
5W 1N4004 1N4004 1N4004
35V R116 27
D1 4A 1.00K
-10V
R20
1/2W 267
R23
400V
R1
10K 1N4004
+15V R88 A
475
R10
C23 33.2K
4
.33
C24
50V 5W 562 562
200V
R309
R32
10V
R306
6.81K R62 DZ10 267 200
R14
R61
475K R125
100K 50K
26.7K
DZ1
R11
C10
R26
6 2.67K
G R56
15V
R4
CW .022
7 2 D7
10K X3 R124 1W 50V
QU1
5 1 1N4004
J2 R60 D64 68.1K X2
12 K CC CURRENT 3 R89 M
3.01K 1N4004 D47 C1
LIMITER 1N4004 D4
J2 CV CURRENT 3 475K 4.7
11 R36 35V 1N4004
205 LIMITER
3
C56
1 C4 C7 100K
X3
C38 475 .15 .022
R29
CURRENT AMP 10 4.75K
R17
R7
1 0.1 2
.047 R37 RG1
CC CONTROL AMP 2.67K 100V 50V
8 50V
100V 6 X3 C.V. CONTROL D48
C45 475 X6 R55
9 1N4004 J3
8 RF 3 204
R38 RG2
REF +15V 22.1K +15V
2 5
J2 24.9
R66 I
206 5 R35 +15V
1.00M D46 D11
475 267K
J2
R104
1N4004 1N4004
6 L 10K J3
+15V R113
R64
15.0K 202 2 G2
R139
Q6 D37
C37 D51 D66 D14 D17
2N4857 1N4004 68
.047 1N4004 1N4004 1N4004
R102 1N4004 5W 27
100V 4A 1.00K
1/2W D2
R21
33.2K R65 R83 SCR2
R2
C26 1N4004 400V 267
R24
.22 1.00M 33.2K 10K 20V D36 10K D49
100K 15.0K 475
R103
R90
R86
100V D52
R91
R105
R82
30V 4.75K 1N4004 1N4004
C20 1.00K
R63
DZ8 D31 D54
1N4004 1N4004
R307
267 200
R15
-10V
100K 50K
R101 13
R12
DZ2
Return to Section TOC
R27
X4 2.67K C11
Return to Master TOC
R5
14 .022
R310
.047 CW
R33
22.1K 1W QU2 D8
100V 50V
12
+15V 1N4004
100K
D53 R315
START PRESET
R94
15.0K C2
1N4004
4.7 D5
1N4004
R110
R81 35V
J2 C5 C8
5.62K R106 +15V 10 100K
D45 212
.15 .022
R30
D43 4.75K
R18
R8
475K +t
1N4004 1N4004 C19 2.67K 100V 50V
56
J1 .022 C22
5 12
225 R108 R303 R107 50V 1.8
14 20V
13.7K 13.7K 26.7K X2 +15V
C14 D44 10K
13
R93
CC LOW VOLTAGE RF
R109
.0047 R74
R68
J2 6 D34
R111
RF 47.5K 7 1N4004
-10V 208 1N4004 R78
R304
1.50K 7 J2 J3
CW 392K X1 R75 8 213 203 R114 4 G3
CC MAX R73 5 MAX. +t D67 D15 D18
R72 100 68
R67
OUTPUT
OUTPUT D35 C18 56 1N4004 SCR3 1N4004 1N4004
13.7K 5W 27
10K 267K .022
R302
R22
1/2W 267
50V
R25
R3
Q3 1N4004 400V
R115
2N4857 1.82K 475
R87
C
RF
-10V
J2
R42 4 204 10K
R308
10K 200
100K ARC FORCE 10K 267
J1 CV MAX
R16
CONTROL D28 R69 OUTPUT
R71
4 9
R41 1N4004 OUTPUT 750
R305
R13
100K X1 DZ3
R28
DZ4 1 209 2.67K C12
D24 15V 562
.022
R6
10 D25 562
15V CW
R311
R34
1N4004 10K 1W D9
1N4004 50V
QU3
R70
1W
10K 1N4004
ARC FORCE AMP DZ7
R138
5.1V 750
+15V 1.50K
R54
R77
-10V 4.7 D6
+15V
475K 1N4004
J2 22.1K +15V 35V
R131
D26 C6 C9 100K
R130
214 2 R45 C3
.15 4.75K .022
R19
-10V -7.5V
R31
1N4004
R9
100 10K
R52 2.67K 100V 50V
R48
13
R53
D30 1 J2
1N4004 -7.5V X1 9 75
14
FIRING CIRCUIT
J1 X1 2 +t
8 267
4 12 D32 56
R76
2 10K
DZ14
50V
D27
2N4857 -10V .022 B
+15V 50V
24V 1.5K 15W +15V
1N4004
5W 3-11-94
Return to Section TOC
Return to Master TOC
R322
R324
R325
R327
R328
R326
R323
6.2V
R317
R318
R319
R321
R316
1W N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE POWER SUPPLY SOURCE POINT
100K
R50
2.21K
D77 D76 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
R151
COMMON CONNECTION
160 3 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
R153
1N4004 1N4004
10W 1 NUMBER. FRAME CONNECTION
X4 SUPPLY
2 FILE: G2586-1BD EARTH GROUND CONNECTION
MODE INVERTER
J1
7
41
D78
IDEALARC DC400
1N4004 C44
4.7
CONTROL BOARD SCHEMATIC
35V
SHT.
NO. G 2586
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. IDEALARC DC400
G-8 ELECTRICAL DIAGRAMS G-8
Starting PC Board (M14520) Schematic
Return to Section TOC
Return to Master TOC
S 19686
228
GENERAL INFORMATION 2
R6
100
2
1
31 J6
Return to Section TOC
Return to Master TOC
4
D3 D4 D5
SBS1 SCR1
D2
5W 7.5-9.0V 4A
1N4007 1.50K
2500 400V 38J
MT2 MT1 130V
R1 R4 TP1
1.00K
32 J6
1
1.00K D7 D6
R3
R5
50V
160J 50
320V C1
TP2
Return to Section TOC
Return to Master TOC
R2
5W 1N4007
2500 D1
J6 J6 J6
5 3 6
218
215 216
Return to Section TOC
Return to Master TOC
11-17-95G
IDEALARC DC400
START SCHEMATIC
S 19686
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. IDEALARC DC400
G-9 ELECTRICAL DIAGRAMS G-9
Snubber PC Board (M15370) Schematic
Return to Section TOC
Return to Master TOC
S 19687
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS,1/4 WATT (UNLESS OTHERWISE SPECIFIED)
DIODES = 1 AMP/400 VOLT (UNLESS OTHERWISE SPECIFIED)
OP AMPS = LM124 (UNLESS OTHERWISE SPECIFIED)
= COMMON CONNECTION
2 8 3 4 1 5 7 6
J5 J5 J5 J5 J5 J5 J5 J5
Return to Section TOC
Return to Master TOC
1 C1 1 C2 C3 1
R2
R3
2W 2W 2W 80J 600V 160J
10 10 10 150V .05 320V
TP6 C5 TP5
Return to Section TOC
Return to Master TOC
TP1 TP2
130V 130V
38J 38J
TP3
130V
38J
Return to Section TOC
Return to Master TOC
3-8-91G
MISC. USE
SNUBBER SCHEMATIC
S 19687
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. IDEALARC DC400