Lincoln Electric SVM 122-A User Manual

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SVM 122-A
IDEALARC DC-400
For use with machine code numbers 9847, 9848 and 9850
Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . . and thoughtful operation on your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ­ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,
most importantly, think before you act and be careful.
TM
Oct. 1996
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World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
SERVICE MANUAL
LINCOLN
ELECTRIC
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
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause can­cer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
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 W elding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. AFree 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.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle con­trol rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
ii ii
SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet 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 accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES can be dangerous.
5.a.Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
vapors
to
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5.e. Also see item 1.b.
IDEALARC DC-400
LINCOLN
ELECTRIC
®
iii iii
SAFETY
WELDING SPARKS can cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil 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 welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode if damaged.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
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
SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lir e et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv­antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter tou­jours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand
on soude dans des endroits humides, ou sur un planch­er metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état defonctionnement.
d. Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous ten-
sion des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enroule le câble-électrode autour de n’importe quelle partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnementde l’arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma­bles.
4. Des gouttes de laiter en fusion sont émises de l’arc de soudage. Se protéger avec es vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir ttout risque d’incendie dû étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de la faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou atres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumées toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant d’opéerations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas forte­ment roxique) ou autres produits irritants.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFOR­MATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dis­positif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, l’installation et l’entretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispostifis de sûreté à leur place.
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
v v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
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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
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair.................................................................................................Section F
How To Use Troubleshooting Guide...........................................................................................F-2
Troubleshooting Guide................................................................................................................F-4
Test Procedures ........................................................................................................................F-15
Oscilloscope Waveforms ..........................................................................................................F-33
Replacement Procedures..........................................................................................................F-40
Retest After Repair....................................................................................................................F-61
Electrical Diagrams..............................................................................................................Section G
Parts Manual.................................................................................................................................P-234
IDEALARC DC-400
LINCOLN
ELECTRIC
®
Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation
Technical Specifications Idealarc DC-400..................................................................................A-2
Input and Output Specifications ..........................................................................................A-2
Cable and Fuse Sizes...........................................................................................................A-2
Physical Dimensions ............................................................................................................A-2
Safety Precautions ......................................................................................................................A-3
Select Suitable Location.............................................................................................................A-3
Lifting .................................................................................................................................A-3
Tilting .................................................................................................................................A-3
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
TECHNICAL SPECIFICATIONS - IDEALARC DC-400
INPUT - THREE PHASE ONLY
Standard Voltage Input Current @ Rated Output
208V 87A 230V 78A 460V 39A 575V 32A
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amps
100% 400 36
60% 450 38 50% 500 40
OUTPUT
Current Maximum Open
Mode Range Circuit Voltage Auxiliary Power
Constant Current 60 to 500 Amps 57 VDC 115 VAC, 10 Amps Constant Voltage 60 to 500 Amps 45.5 VDC 42 VAC, 10 Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES
Input Wire Size Ground Wire Size
Input Voltage / Fuse Input Ampere Type 75°C Type 75°C
Frequency (Super Lag) Rating on Copper Wire in Copper Ground
or Breaker Size Nameplate Conduit AWG Wire in Conduit
Volts/Hz (IEC) Sizes AWG (IEC) Sizes
208/60 125 87 4 (21 mm2) 6 (13 mm2) 230/60 125 78 4 (21 mm2) 6 (13 mm2)
460/60 60 39 8 (8.4 mm2) 10 (5.3 mm2) 220/50/60 125 81 4 (21 mm2) 6 (13 mm2) 230/50/60 125 77 4 (21 mm2) 6 (13 mm2) 380/50/60 70 47 8 (8.4 mm2) 8 (8.4 mm2) 400/50/60 70 44 8 (8.4 mm2) 8 (8.4 mm2) 440/50/60 60 41 8 (8.4 mm2) 10 (5.3 mm2)
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PHYSICAL DIMENSIONS
Height Width Depth Weight
30.75 in. 22.25 in. 32 in. 473 lbs.
(781 mm) (565 mm) (813 mm) (215 kg)
IDEALARC DC-400
LINCOLN
ELECTRIC
®
A-3 A-3
INSTALLATION
Read this entire installation section before you start installation.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
Only qualified personnel should install, use, or ser­vice this equipment.
SELECT SUITABLE LOCATION
Place the Idealarc DC-400 where clean, cooling air can flow freely in through the front louvers and out through the rear louvers. Keep dust, dirt, and other foreign materials that can be drawn into the machine to a min­imum. Failure to observe these precautions can lead to excessive operating temperatures and nuisance shut-downs.
LIFTING
WARNING
FALLING EQUIPMENT can cause injury.
• Do not lift this machine using the lift bail if it is equipped with a heavy accessory such as a trailer or a gas cylinder.
• Lift only with equipment of adequate lifting capacity.
• Be sure the machine is stable when lifting.
• Do not stack more than three high.
• Do not stack the DC-400 on top of any other machine.
The Idealarc DC-400 weighs 473 pounds (215 kilo­grams). A permanent lift bail is located at the top of the machine, positioned at the center of gravity for sta­ble lifting.
TILTING
Place the machine on a secure, level surface. Any sur­faces you place it on other than the ground must be firm, non-skid, and structurally sound.
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STACKING
Idealarc DC-400s may be stacked three high. The bottom machine must be on a stable, hard, level sur­face 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.
IDEALARC DC-400
LINCOLN
ELECTRIC
®
A-4 A-4
INSTALLATION
INPUT CONNECTIONS
Be sure the voltage, phase, and frequency of the input power is as specified on the rating plate, lo­cated on the case front control panel. See Figure A.1.
FIGURE A.1 – RATING PLATE LOCATION
Input supply line entry is through a hole in the case rear top panel. A removable door covers the input connection box, which contains the input contactor (CR1) and reconnect panel assembly for multiple volt­age machines. Input power is connected to the three line terminals on the input contactor. See Figure A.2.
FIGURE A.2 – REAR PANEL
1. INPUT SUPPLY LINE ENTRY HOLE
2. INPUT CONTACTOR CR1
3. RECONNECT PANEL
1. RATING PLATE
GROUND CONNECTION
The frame of the welder must be grounded. An earth grounding lead must be connected to the grounding terminal, marked on the input box floor with the sym­bol ( ).
INPUT SUPPLY CONNECTIONS
Be sure the voltage, phase, and frequency of the input power is as specified on the rating plate.
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ELECTRIC SHOCK can kill.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
IDEALARC DC-400
LINCOLN
ELECTRIC
®
WARNING
• Have a qualified electrician install and service this equip­ment.
• Turn the input power off at the fuse box before working on this equipment.
• Do not touch electrically hot parts.
A-5 A-5
INSTALLATION
FIGURE A.3 – INPUT POWER SUPPLY CONNECTIONS
1. INPUT SUPPLY LINE
2. INPUT CONTACTOR CR1
3. RECONNECT PANEL
Have a qualified electrician connect the input power leads to the L1, L2, and L3 terminals of the input con­tactor. Follow all national and local electrical codes. Use a three-phase line. Refer to the connection dia­gram located on the inside cover of the access panel cover. Also see Figure A.3.
INPUT WIRE AND FUSE SIZE
Fuse the input circuit with the super lag fuses recom­mended on the Technical Specifications page or use delay type circuit breakers. Choose an input and grounding wire size according to local or national codes; also see the Technical Specifications page. Using fuses or circuit breakers smaller than recom­mended 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
RECONNECT PROCEDURE
To reconnect a multiple voltage machine to a different voltage, remove input power. Follow the input con-
Multiple input voltage welders are shipped connected for the highest voltage listed on the machine’s rating plate. Before installing the welder, be sure the recon­nect panel is connected for the proper voltage.
CAUTION
nection diagram, located on the inside access panel cover, appropriate for your machine’s input voltage. These same connection diagrams are shown below.
For 208, 208/230 & 230/460 volts AC - see Figure A.4. For 230/460/575 volts AC - see Figure A.5.
Failure to follow these instructions can cause immedi­ate failure of components in the welder.
FIGURE A.4 - INPUT CONNECTION DIAGRAM FOR 208, 208/230 and 230/460 VOLTS AC, 50/60 HZ
Do not operate with covers removed
Disconnect input power before servicing
Do not touch electrically live parts
Only qualified persons should install, use or service this equipment
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
LINK
LINES INPUT
{
GND
L3 L2 L1
H3
CR1
W
V
CONTACTOR
U
H1
PILOT TRANSF.
H2
CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
LINK
L3
LINES
L2
INPUT
{
L1
GND
THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.
H2
CR1
W
V
CONTACTOR
U
H1
PILOT TRANSF.
H3
IMPORTANT: CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS.
NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS. DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE REMAINING HEX NUTS IN PLACE.
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
3-17-95E
DUAL VOLTAGE MACHINE
INPUT SUPPLY CONNECTION DIAGRAM
M15009
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
A-7 A-7
.
INSTALLATION
FIGURE A.5 - INPUT CONNECTION DIAGRAM FOR 230/460/575 VOLTS AC, 60 HZ
Do not operate with covers removed
Disconnect input power before servicing
L3
LINES
L2
INPUT
{
L1
GND
L3
LINES
L2
INPUT
{
L1
GND
L3
LINES
L2
INPUT
{
L1
GND
THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.
H4
H3
H2
CR1
W
V
CONTACTOR
U
H1
PILOT TRANSF.
CR1
W
V
CONTACTOR
U
H1
PILOT TRANSF.
CR1
W
V
CONTACTOR
U
H1
PILOT TRANSF.
Do not touch electrically live parts
Only qualified persons should install, use or service this equipment
6
18
15 5
17
14
4
16
H2 H3
H2 H4
H3 H4
13
8
1
32
9
7
6
3
9 5
2
8 4
1
7
14
16
1817
15
13
9 3
6
8
5
2
4
7
1
14
16
1817
15
13
RECONNECT PANEL
RECONNECT PANEL
RECONNECT PANEL
5-26-95
OUTPUT CONNECTIONS
The output (welding) cables are connected to the output terminals marked “+” and “-”. See Table A.1 for recom­mended cable sizes for the combined lengths of elec­trode and work cables. They are located at the lower right and lower left corners of the front panel. Strain
IDEALARC (230 / 460 / 575)
INPUT SUPPLY CONNECTION DIAGRAM
IMPORTANT: CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS
NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR 575V
CONNECTION FOR 575 VOLTS, 60 HZ.
1. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H4 PILOT TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
2. INSULATE UNUSED H2, H3 LEAD TERMINALS SEPERATELY TO PROVIDE AT LEAST 600V INSULATION.
3. CONNECT TERMINAL MARKED TO SYSTEM GROUND PER NATIONAL ELECTRIC CODES.
4. CONNECT TRANSFORMER LEADS 16, 17, 18, 4 & 13, 5 & 14, 6 & 15 TO RECONNECT PANEL.
5. TAPE SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 1, 2, 3, 7, 8, 9. TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS.
CONNECTION FOR 460 VOLTS, 60 HZ.
1. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H3 PILOT TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
2. INSULATE UNUSED H2, H4 LEAD TERMINALS SEPERATELY TO PROVIDE AT LEAST 600V INSULATION.
3. CONNECT TERMINAL MARKED TO SYSTEM GROUND PER NATIONAL ELECTRIC CODES.
4. CONNECT TRANSFORMER LEADS 1, 2, 3, 4 & 7, 5 & 8, 6 & 9 TO RECONNECT PANEL.
5. TAPE SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 13, 14, 15, 16, 17, 18. TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS.
CONNECTION FOR 230 VOLTS, 60 HZ.
1. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H2 PILOT TRANSFORMER LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
2. INSULATE UNUSED H3, H4 LEAD TERMINALS SEPERATELY TO PROVIDE AT LEAST 600V INSULATION.
3. CONNECT TERMINAL MARKED TO SYSTEM GROUND PER NATIONAL ELECTRIC CODES.
4. CONNECT TRANSFORMER LEADS 1 & 7, 2 & 8, 3 & 9, 4 & 5 & 6, TO RECONNECT PANEL.
5. TAPE SEPERATELY TO PROVIDE AT LEAST 600V INSULATION 13, 14, 15, 16, 17, 18. TAPE INSULATED UNUSED LEADS TOGETHER AWAY FROM LIVE METAL PARTS.
M15666
relief for the cables is provided by routing them through the rectangular holes in the base before connecting them to the output terminals. Lift the output terminal cover to access the output terminals. Lower the cover after making the connections. See Figure A.6.
FIGURE A.6 - OUTPUT TERMINAL CONNECTIONS
1. NEGATIVE (-) WELDING CABLE CONNECTION
2. POSITIVE (+) WELDING CABLE CONNECTION
3. CABLE STRAIN RELIEF HOLE LOCATION
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
A-8 A-8
INSTALLATION
TABLE A.1 - CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE
AND WORK CABLES
Up to 50 ft 50 - 100 ft 100 - 150 ft 150 - 200 ft 200 - 250 ft
Machine Size (15 m) (15 - 30 m) (30 - 46 m) (46 - 61 m) (67 - 76 m) 400 Amp 3/0 3/0 3/0 3/0 4/0
(100% Duty 85 mm
2
85 mm
2
85 mm
2
85 mm
2
107 mm
Cycle) 500 Amp 2/0 2/0 3/0 3/0 4/0
(50% Duty 67 mm
2
67 mm
2
85 mm
2
85 mm
2
107 mm
Cycle)
WIRE FEEDER CONNECTIONS
See the Accessories section of this manual for spe­cific instructions on connecting the following semi­automatic and automatic wire feeders to the Idealarc DC-400:
Automatic Wire Feeders:
• NA-3
• NA-5
Semi-automatic Wire Feeders:
• LN-7
• LN-8
• LN-9
The work and electrode cables for stick, TIG, or air/carbon arc cutting are connected as described ear­lier, under the heading Output Connections. A TIG torch is connected to the electrode (+) terminal of the welder. Select cable size according to Table A.1.
WARNING
Do not connect a TIG torch and stick electrode cable at the same time. They will both be electrically HOT.
If the Idealarc DC-400 is already set up for wire feeder operation, all wire feeder unit control, electrode, and work cables must be disconnected first before you can connect the cables for stick, TIG, or air/carbon arc operation.
2
2
• LN-25
• LN-742
CONNECTIONS FOR STICK, TIG, OR AIR/CARBON ARC CUTTING OPERA­TIONS
The output terminals are energized at all times when the Idealarc DC-400 is used for stick, TIG, or air/car­bon arc cutting.
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WARNING
However, the Idealarc DC-400 can be used for both wire feeder operation and stick, TIG, air/carbon arc operation if a K804-1 Multiprocess Switch is used. See the Accessories section of this manual for spe­cific instructions on connecting and using the Multiprocess Switch.
IDEALARC DC-400
LINCOLN
ELECTRIC
®
96OCT
Section B-1 Section B-1
- OPERATION SECTION -
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
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
Auxiliary Power...........................................................................................................................B-9
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section of operating instructions before operating the machine.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet cloth­ing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
B-2
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.
WELDING SPARKS can cause fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held com­bustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
Observe additional Safety Guidelines detailed in the beginning of this manual.
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
B-3 B-3
OPERATION
GENERAL DESCRIPTION
The Idealarc DC-400 is an SCR controlled three-phase input, DC output power source for welding and cut­ting. It uses a single range potentiometer control. The welder’s unique combination of transformer, three­phase semiconverter rectifier, capacitor bank, arc con­trol choke, and solid state control system deliver out­standing arc characteristics in the constant voltage mode. For stick welding, an Arc Force Control enables the Idealarc-400 to perform much like the R3R-500.
RECOMMENDED PROCESSES
The Idealarc DC-400 is recomended for all open arc processes including Innershield®and all solid wire and gas procedures within its capacity of 60 to 500 amps. It also can perform stick and TIG welding and air/car­bon arc gouging up to 5/16” (8 mm) diameter. A mode switch on the front control panel selects CV (FCAW, GMAW), CV Submerged Arc, or CC (stick/TIG).
The Idealarc DC-400 can be connected to wire feed­ing equipment, including:
• Automatic wire feeders NA-3, NA-5, and NA-5R. (Requires the DC-400 Diode Kit option to use the cold start and cold electrode sensing features of these feeders.)
• Semi-automatic wire feeders LN-7, LN-7 GMA, LN­8, LN-9, LN-9 GMA, LN23P, LN-25, LN-742.
• Tractors LT-56, LT-7.
OPERATIONAL FEATURES AND CONTROLS
The following operational controls are standard on the Idealarc DC-400:
• Power Source Pilot Light
• ON/OFF Power Toggle Switch
• Output Control Potentiometer
• Output Control Switch (with Local or Remote posi­tions)
• Output Terminals On or Remote Switch
• Arc Force Selector (for CC stick or TIG processes only)
• Auxiliary Power Connections for Wire Feeder and Other Equipment (115V and 42V)
• DC Ammeter
• DC Voltmeter
• Voltmeter “+” Electrode or “-” Electrode Switch
DESIGN FEATURES AND ADVANTAGES
• Input line voltage compensation keeps output con­stant for fluctuations of ± 10%.
• SCR control extends life of mechanical contactors.
• Hinged front control panel provides easy access to printed circuit boards and other control circuitry.
• Fully enclosed fan motor with permanently lubri­cated, sealed ball bearings needs no maintenance.
• Fully recessed control panel protects controls and minimizes accidental contact.
• Recessed output terminals and hinged terminal cover reduce chance of accidental contact.
• Low profile case permits installation under a work­bench.
• Removable rear access panel provides easy access to input contactor and input lead connections.
• Removable case sides provide easy access for ser­vice or inspection, even when machines are stacked.
• Dripproof enclosure design permits outdoor operation.
• Double-dipped transformer, SCR bridge, and choke resist corrosion.
WELDING CAPABILITY
The Idealarc DC-400 has the following duty cycle ratings. If the duty cycle is exceeded, a thermal pro­tector will shut off the machine output until it cools to normal operating temperature. The amber thermal protection indicator light will turn on until the machine cools.
Duty Cycle* Amps Volts
100% 400 36
60% 450 38 50% 500 40
*Based on a 10 minute time period. For example, a 60% duty cycle means 6 minutes on and 4 minutes off.
• Mode Switch
• Arc Control
• Thermal Protection Indicator Light
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LIMITATIONS
The Idealarc DC-400 has no provisions for paralleling.
IDEALARC DC-400
LINCOLN
ELECTRIC
®
B-4 B-4
OPERATION
CONTROLS AND SETTINGS
All operator controls and settings are located on the case front assembly. See Figure B.1 for their loca­tions.
FIGURE B.1 – CASE FRONT CONTROLS
1. Power Source Pilot Light
2. ON/OFF Power Toggle Switch
3. Output Control Potentiometer
4. Output Control Switch (with Local or Remote positions)
5. Output Terminals Switch (with On or Remote positions)
6. Arc Force Selector (for CC stick or TIG processes only)
7. Auxiliary Power Connections for Wire Feeder and Other Equipment (115V and 42V)
1. POWER SOURCE PILOT LIGHT: This light indi- cates that the power source input contactor is energized (closed). This also means that the main power transformer and all auxiliary control trans­formers are energized.
2. ON/OFF POWER TOGGLE SWITCH: Energizes or de-engergizes the input contactor which is pow­ered by the 115 volt auxiliary transformer. The switch turns the machine ON or OFF. Position “I” is ON; position “0” is OFF.
3. OUTPUT CONTROL POTENTIOMETER: Con- trols voltage in CV mode and current in CC mode.
4. OUTPUT CONTROL SWITCH (WITH LOCAL OR REMOTE POSITIONS): Selects the mode of con­trol. In the “Local” position, control is by the machine control panel. In the “Remote” position, control is by either a wire feeder unit or through an optional remote control device.
8. Mode Switch
9. Arc Control
10. Thermal Protection Indicator Light
11. DC Ammeter
12. DC Voltmeter
13. Voltmeter “+” Electrode or “-” Electrode Switch
5. OUTPUT TERMINALS “ON” OR “REMOTE” SWITCH: When in the “Remote” position, leads #2 and #4 have to be jumpered externally to ener­gize the output terminals. When in the “ON” posi­tion, this switch internally jumpers leads #2 and #4, which energizes the output terminals.
6. ARC FORCE SELECTOR: Allows you to select the ideal arc force according to the pr ocedur e and electrode being used for CC stick or TIG welding. It controls the amount of current added to the welding current when the electrode shorts to the work. At minimum setting, no extra short circuit current is added. The arc will be softer and have less spatter but may be more prone to sticking. At maximum setting, the arc will be more forceful and less prone to sticking but will produce more spat­ter.
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
B-5 B-5
OPERATION
7. AUXILIARY POWER AND REMOTE CONTROL
CONNECTIONS FOR WIRE FEEDER AND OTHER EQUIPMENT (115V AND 42V): The 14-
pin amphenol receptacle provides either 115 or 42 volts AC as well as remote control connec­tions. Terminal strips with screw connections are located behind the hinged control panel for hard wired control. Only 115 volts AC is available on the terminal strip. A strain relief connector is pro­vided for cable entry.
8. MODE SWITCH: Selects between Constant Voltage FCAW/GMAW and Constant Voltage Submerged Arc (Red range on dial), and Constant Current Stick/TIG (Blue range on dial).
9. ARC CONTROL: A five-position switch that changes the pinch effect of the arc when in the CV FCAW/GMAW mode. It allows control of spatter, fluidity , and bead shape. The Arc Control is set to provide optimum welding depending on the process, position, and electrode. Pinch effect is increased by turning the control clockwise. It can also be adjusted while the machine is in opera­tion.
10. THERMAL PROTECTION INDICATOR LIGHT: This amber light indicates that either of the two protective thermostats has opened. Output power is removed, but input power is still being applied to the machine.
11. DC AMMETER: Displays output current when welding.
12. DC VOLTMETER: Displays output voltage when welding.
13. VOLTMETER “+” ELECTRODE OR “-” ELEC- TRODE SWITCH: Selects the electrode polarity for the remote work sensing lead (#21) when using automatic or semiautomatic wire feeders.
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
B-6 B-6
OPERATION
WELDING OPERATION
OPERATING STEPS
LOCAL CONTROL
The following procedures are for using the Idealarc DC-400 in the local control mode of operation. For remote control of the machine, see the REMOTE CONTROL section.
Before operating the machine, make sure you have all materials needed to complete the job. Be sure you are familiar with and have taken all possible safety pre­cautions before starting work. It is important that you follow these operating steps each time you use the machine.
1. Turn on the main AC input power to the machine.
2. Set the VOLTMETER “+” or “-” switch to the appropriate position.
• Set toggle to “´Electrode Negative” position if the electrode is connected to the negative (-) output terminal.
• Set toggle to “Electrode Positive” position if the electrode is connected to the positive (+) output terminal.
3. Set the welding MODE switch to welding process being used.
• CV FCAW/GMAW
• CV Submerged Arc
• CC Stick/Tig
4. Set the OUTPUT CONTROL switch to “Local.” (Exception: when using an LN-9, LN-9 GMA, or NA-5 wire feeder, set the switch to “Remote.” Otherwise, the wire feeder may automatically shut down.
5. Set the OUTPUT TERMINALS switch to the desired mode.
6. Set the ARC FORCE CONTROL to midrange, 5-6. This control is for CC stick or TIG welding only. Adjust for best characteristics as necessary.
7. Set the ARC CONTROL to midrange, 3. This con­trol is for CV FCAW/GMAW welding only. Adjust as necessary for best pinch control.
8. Set the ON/OFF POWER toggle switch to the ON position (1).
• The power source pilot light glows.
• The fan starts.
9. Set OUTPUT CONTROL potentiometer to desired voltage or current.
10. Make the weld.
REMOTE CONTROL
The toggle switch on the control panel labeled “Output Control Remote” gives you the option of controlling the machine output from a remote location. In the “Remote” position a wire feeder with remote control capabilities or a remote control device such as a K775 must be connected to the DC-400. Refer to the Accessories section for wire feeder installation infor­mation.
WELDING PROCEDURE RECOMMENDATIONS
Select Mode Switch position based on type of welding to be done.
1. FCAW/GMAW Welding/Other Open Arc Processes: Use the CV FCAW/GMAW mode.
2. Submerged Arc Welding: Use the CV Submerged Arc mode. If performing high speed welding, switch between the CV Submerged Arc and the CV FCAW/GMAW mode and use the mode that pro­duces the best welding results.
3. Air/Carbon Arc Cutting / Stick Welding / High Current, Large Puddle Submerged Arc Welding: Use the CC mode. When the Idealarc DC-400 is used for Air/Carbon Arc cutting, the OUTPUT CONTROL potentiometer should be set to “9” ini­tially. Based on the size of the carbon being used or the process, turn the potentiometer to a lower setting as required by the process. You can use carbon rods up to 5/16” (8 mm) in diameter at cur­rents as high as 450 amps with excellent arc con­trol. The welder protection circuit protects the machine from extremely high short circuiting pulses.
SEMIAUTOMATIC AND AUTOMATIC WIRE FEEDING WITH AN IDEALARC DC-400
When using the Idealarc DC-400 with semiautomatic or automatic wire feeding equipment and for stick welding or air/carbon arc cutting, it is recommended that the optional MULTIPROCESS switch be used. This switch permits you to easily change the polarity of the connected wire feeding equipment or switch to stick welding or air/carbon arc cutting.
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
B-7 B-7
OPERATION
NA-3 AUTOMATIC WIRE FEEDER
1. Set the DC-400 OUTPUT CONTROL switch to “Remote.”
NOTE: Later model NA-3 automatic wire feeders
are capable of cold starts when the NA-3 Mode switch is in the CV or CC mode posi­tion. Some earlier models are capable of cold starting only in the CC mode position. Cold starting enables you to inch the wire down to the work, automatically stop, and automatically energize the flux hopper valve. The cold start feature requires the factory installed diode option. See the Accessories section.
2. Set the DC-400 welding MODE switch for the desired process: CV Submerged Arc, CV FCAW/GMAW mode or CC mode.
3. Set the NA-3 mode switch position to either CV or CC to match the DC-400 mode selected in step 2.
4. Set the OUTPUT CONTROL switch to “Remote.”
5. Set the OUTPUT TERMINALS switch to “Remote.”
6. For CC welding, set the ARC FORCE CONTROL to midrange, 5-6. After welding starts, adjust as nec­essary.
7. For CV FCAW/GMAW welding, set the ARC CON­TROL to midrange, 3. After welding starts, adjust as necessary.
NOTE: The open circuit voltage of the Idealarc
DC-400 varies from apporximately 12 volts to 45 volts in the CV FCAW/GMAW or CV Submerged Arc modes. The open circuit voltage is constant in the CC mode.
3. Run a test weld. Set proper current, voltage, and travel speed.
a. For the best starting performance, the NA-3
Open Circuit Voltage Control and Voltage Control setting should be the same. Set the Inch Speed Control for the slowest inch speed possible.
b. To adjust the Open Circuit Voltage Control to
get the best starting performance, make repeated starts observing the NA-3 voltmeter.
When the voltmeter pointer swings smoothly up to the desired arc voltage, without undershooting or overshooting the desired arc voltage, the Open Circuit Voltage Control is set properly.
If the voltmeter pointer overshoots the desired voltage and then returns to the desired voltage, the Open Circuit Voltage Control is set too high. This can result in a bad start where the wire tends to “blast off.”
If the voltmeter pointer hesitates before coming up to the desired voltage, the Open Circuit Voltage Control is set too low. This can cause the elec­trode to stub.
8. Refer to the NA-3 operator’s manual for instructions on how to use the NA-3 in conjunction with the DC-
400.
9. Follow the guidelines for good arc striking detailed below for each welding mode.
GOOD ARC STRIKING GUIDELINES FOR THE NA-3 WITH THE IDEALARC DC-400 IN THE CV FCAW/GMAW, CV SUBMERGED ARC OR STICK/TIG CC WELDING MODES.
Following are some basic arc striking techniques that apply to all wire feed processes. Using these proce­dures should provide trouble-free starting. These pro­cedures apply to single, solid wires and Innershield wires.
1. Cut the electrode to a sharp point.
2. Set the NA-3 Open Circuit Voltage Control to the same dial setting as the Arc Voltage Control. If this is a new welding procedure, a good starting point is to set the Open Circuit Voltage Control to #6.
4. Start and make the weld. a. Cold starts. For cold starts, be sure the work
piece is clean and the electrode makes posi­tive contact with the work piece.
b. Hot “On the Fly” starts. For hot starts, travel
should begin before the wire contacts the work piece.
ARC STRIKING WITH THE NA-3 START BOARD
When electrical stickouts exceed 1-3/4” (44.4 mm) an NA-3 Start Board may be required to impr ove ar c strik­ing.
When the NA-3 Start Board is used to improve arc striking, use the following procedures:
1. Set start time at 0.
2. Set NA-3 start current and start voltage at mid­range.
3. Set the NA-3 output current and voltage to the proper settings for the welding procedure to be used.
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
B-8 B-8
OPERATION
4. Turn the Start Board Timer to maximum.
5. Set Start Board current and voltage control. a. Set the Start Board current control to 1-1/2
dial numbers below that set on the NA-3 cur­rent control.
b. Set the Start Board voltage control equal with
the NA-3 voltage control setting.
NOTE: These Start Board current and voltage set-
tings result in a start up current that is lower than the NA-3 current setting and approximately equal with the NA-3 voltage setting for the desired welding procedure.
6. Establish the correct arc striking procedure with the NA-3 Start Board timer set at maximum.
a. For the best starting performance, the NA-3
Open Circuit Voltage Control and Voltage Control setting should be the same. Set the Inch Speed Control for the slowest inch speed possible.
b. To adjust the Open Circuit Voltage Control to
get the best starting performance, make repeated starts observing the NA-3 voltmeter.
NA-5 AUTOMATIVE WIRE FEEDER
When using the Idealarc DC-400 with the NA-5 wire feeder, set the controls on the Idealarc DC-400 as fol­lows for the best performance:
1. Turn OFF main AC input power to the Idealarc DC-
400.
2. Connect the electrode cables to the terminal polarity to be used.
3. Set the VOLTMETER “+” or “-” switch to the same polarity as the electrode cable connection.
4. Set the OUTPUT CONTROL switch to “Remote.”
5. Set the OUTPUT TERMINALS switch to “Remote.”
6. Set the Idealarc DC-400 welding MODE switch to the position that matches the welding process being used.
a. For submerged arc welding, set welding
MODE SWITCH TO CV SUBMERGED ARC position.
b. For all open arc welding processes, set weld-
ing MODE switch TO CV FCAW/GMAW posi­tion.
When the voltmeter pointer swings smoothly up to the desired arc voltage, without undershooting or overshooting the desired arc voltage, the Open Circuit Voltage Control is set properly.
If the voltmeter pointer overshoots the desired voltage and then returns to the desired voltage, the Open Circuit Voltage Control is set too high. This can result in a bad start where the wire tends to “blast off.”
If the voltmeter pointer hesitates before coming up to the desired voltage, the Open Circuit Voltage Control is set too low. This can cause the elec­trode to stub.
c. Set NA-3 Start Board current and voltage as
close to the welding procedure current and voltage as possible.
NOTE: The Start Board current and voltage
should be as close as possible to the welding procedure current and voltage, while still getting satisfactory starts.
d. Set the start time to as low a time as possible
while still getting satisfactory starts.
7. Set the ARC CONTROL to midrange, 3. After welding starts, adjust as necessary.
LN-8 SEMIAUTOMATIC WIRE FEEDER
To use the LN-8 Semiautomatic Wire Feeder with the Idealarc DC-400:
1. Set the Idealarc DC-400 welding MODE switch to either CV FCAW/GMAW mode or CV Submerged Arc mode, depending on the welding process being used.
2. Set the Idealarc DC-400 OUTPUT CONTROL switch to “Remote.”
3. Set the OUTPUT TERMINALS switch to “Remote.”
4. Set the ARC CONTROL to midrange, 3.
5. Set the LN-8 Welding Mode switch to the CV posi­tion. The LN-8 Welding Mode switch is located on the variable voltage (CC) board.
6. Refer to the LN-8 Operator’s Manual for instruc­tions on how to use the LN-8.
7. Start and make the weld.
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
B-9 B-9
OPERATION
LN-7 AND LN-9 SEMIAUTOMATIC WIRE FEEDERS OR OTHER CONSTANT SPEED WIRE FEEDERS
To use the LN-7, LN-9, or other constant wire feed speed semiautomatic wire feeders with the Idealarc DC-400:
1. Set the Idealarc DC-400 welding MODE switch to either CV FCAW/GMAW mode or CV Submerged Arc mode, depending on the welding process being used.
NOTE: These semiautomatic wire feeders cannot
be used in the CC mode.
2. Set the Idealarc DC-400 OUTPUT CONTROL switch.
a. LN-7: Use either an optional K775 Remote
Control Box Assembly or set the Idealarc DC­400 OUTPUT CONTROL switch in the “Local” position.
b. LN-9: Refer to the LN-9 Operator’s Manual for
instructions on how to use the LN-9.
c. LN-25: Refer to the LN-25 Operator’s Manual
for instructions on how to use the LN-25.
d. LN-742: Refer to the LN-742 Operator’s
Manual for instructions on how to use the LN-
742.
OVERLOAD PROTECTION
The power source is thermostatically protected with proximity thermostats against overloads or insufficient cooling. One thermostat is located on the nose of the center bottom primary coil. A second thermostat is attached to the lead connecting the secondaries. If the machine is overloaded, the primary thermostat opens, the output becomes zero, and the amber thermal pro­tection light comes on. The fan will continue to run. The secondary thermostat opens with either an exces­sive overload or insufficient cooling. The output becomes zero, and the amber thermal protection light comes on. When the machine cools, the thermostats reset, and the thermal protection light goes off.
The power source is also protected against overloads on the SCR bridge asssembly through an electronic protection circuit. This circuit senses an overload on the power source and limits the output to 550 amps by phasing back the SCRs.
The Idealarc DC-400 also has self-restoring fusing to prevent damage to the machine in the event of an accidental grounding of the remote control leads (#75, #76 or #77).
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 panel and/or at the terminal strip behind the hinged control panel on the case front. On the amphenol, 115 volts AC is available at pins A and J (Domestic and Export models only); 42 volts AC is available at pins I and K. On the terminal strip, 115 volts AC is available at terminals 31 and 32; 42 volts AC is not available. The two circuits, 115 volts AC and 42 volts AC, are iso­lated; and each is protected by a 10 amp circuit break­er.
On European and export models, a Continental European receptacle is provided on the rear panel for supplying 220 volts AC to a water cooler. A 2 amp cir­cuit breaker, also located on the rear panel, protects this circuit from overloads or short circuits.
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
Section C-1 Section C-1
TABLE OF CONTENTS
- 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
Capacitor Discharge Circuit (K828-1)............................................................................C-6
Hi-Freq Kit (K799) ..........................................................................................................C-6
Amptrol Adapter for K799 (K915) ..................................................................................C-6
Undercarriages (K817, K817R, K841) ............................................................................C-6
Connection of Lincoln Electric Automatic or Semiautomatic Wire Feeders..............................C-6
Automatic Wire Feeders.......................................................................................................C-6
NA-3 (Terminal Strip)......................................................................................................C-6
NA-5 (Terminal Strip)......................................................................................................C-7
NA-3 or NA-5 (14-Pin Amphenol)..................................................................................C-8
Semiautomatic Wire Feeders...............................................................................................C-9
LN-7 (14-Pin Amphenol) ................................................................................................C-9
LN-7 (Terminal Strip)....................................................................................................C-10
LN-8 or LN-9 (Terminal Strip) .......................................................................................C-11
LN-8 or LN-9 (14-Pin Amphenol).................................................................................C-12
LN-742 (14-Pin Amphenol) ..........................................................................................C-13
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
C-2 C-2
ACCESSORIES
OPTIONS/ACCESSORIES
FACTORY INSTALLED OPTION
DIODE OPTION
This factory installed option allows use of the cold­start and cold electrode sensing features of the NA-3, NA-5, or NA-5R automatic wire feeders. See the topic,
Connecting the NA-3 [NA-5] to the Idealarc DC-400
in this section of the manual.
FIELD INSTALLED OPTIONS
The following options/accessories are available for your Idealarc DC-400 from your local Lincoln Distributor.
COVER FOR 14-PIN AMPHENOL (LINCOLN ELECTRIC PART NUMBER S17062-3)
Protects the amphenol from dirt and moisture when the amphenol is not being used.
MULTIPROCESS SWITCH (K804-1. ALSO AVAILABLE AS A FACTORY INSTALLED OPTION.)
The Multiprocess Switch gives you the ability to:
• Switch between “Stick Welding/Air-Carbon Arc Cutting” or “Positive Wire Feeder” or “Negative Wire Feeder .”
• Change the polarity of a semi-automatic or auto­matic wire feeder without changing any electrical cable connections. See Figure C.1.
The Multiprocess Switch has two sets of output termi­nals. You connect the wire feeder unit cables to the set of terminals on the left side of the box (facing the front of the machine) and the stick or air/carbon arc cables to the set of terminals on the right side as shown in Figure C.1.
When the Multiprocess Switch is in the “Stick W elding/ Air-Carbon Arc” position, only those terminals are energized. The wire feeder nozzle or gun and elec­trode are not electrically “hot” when in this mode.
Refer to installation instructions (M17137) included with Multiprocess Kit for installation.
Required when using the DC-400 for both automat­ic/semiautomatic and stick/air carbon arc. This field or factory installed kit mounts on the front of the DC-400. It includes hinged covers over its output studs.
The switch has three positions.
• Wire Feeder Positive
• Wire Feeder Negative
• Stick/Air Carbon Arc
FIGURE C.1
MULTIPROCESS SWITCH
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
C-3 C-3
ACCESSORIES
Multiprocess Switch Operation
The operation of the Multiprocess Switch is as follows: A semiautomatic or automatic wire feed unit electrode
and work cables are connected to the terminals on the left side of the box. Stick or air carbon arc electrode and work cables are connected to the terminals on the switch. With the switch in the left position, the wire feed terminals are electrode negative. In the center position, the wire feeder terminals are electrode posi­tive. In both the left and center switch position, the right side stick terminals are disconnected. In the right switch position, the wire feed terminals are discon­nected from the DC-400 and the stick terminals con­nected. The polarity of the stick terminals is marked on the end of the box. To change polarity, the elec­trode and work cables must be interchanged. In the stick position, the stick terminals are energized at all times.
Connections
(For those applications where it is not necessary to have separate work cables for stick and semiautomat­ic welding.)
If both stick and semiautomatic welding is done on the same workpiece, only one work cable is required. To do this, connect a 4/0 (107 mm2) jumper from the work terminal on the semiautomatic side to the terminal to be used for work on the stick side. The work cable from the semiautomatic side then serves as the work cable for both semiautomatic and stick welding. See Figure C.2.
To change stick polarity, reverse the leads at the (+) and (-) terminals on the right side of the Multiprocess Switch.
NOTE: When a DC-400 equipped with Multiprocess
Switch is mounted on an undercarriage, the undercarriage handle in the resting position can hit the case of the Multiprocess Switch. This does no harm, but if the user desires, a 1/4” or 3/8” bolt and nut may be placed in the hole in the undercarriage tow bar to limit the travel of the undercarriage handle.
To semi-auto or auto equipment
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FIGURE C.2 – SINGLE WORK CABLE WITH JUMPER
To stick electrode holder or air carbon arc torch
User supplied 4/0 (107 mm2) jumper
IDEALARC DC-400
LINCOLN
ELECTRIC
®
C-4 C-4
ACCESSORIES
REMOTE OUTPUT CONTROL (K857 WITH K864 ADAPTER PLUG OR K775)
The K857 has a 6-pin MS-style connector. The K857 requires a K864 adapter cable which connects to the 14-pin connector on the machine.
An optional “remote output control” is available. This is the same remote control that is used on the Lincoln R3R and DC-600 power sources (K775). The K775 consists of a control box with 28 ft (8.5m) of four con­ductor cable. This connects to terminals 75, 76, and 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 front. This device will give the same control as the out­put control on the machine.
REMOTE CONTROL ADAPTER CABLE (K864)
A “V” cable 12 inches (.30 m) long to connect a K857 Remote Control, K812 Hand Amptrol or K870 Foot Amptrol (6-pin connector) with a wire-feeder (14-pin connector) and the machine (14-pin connector). If a remote control or amptrol is used alone, the wir e-feed­er connection is not used. See Figure C.3.
K843 AMPTROL™ADAPTER INSTALLATION INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
• Turn the input supply power OFF before installing plugs or cables or when connecting or disconnecting plugs to the welder.
This K843 adapter is used to connect Amptrol (K812, K813 or K870), remote control (K775), and Hi-Freq™ (K799) accessories to the DC-400. The OUTPUT CONTROL switch must be in “Remote” for Amptrol™ to control current. Accessories may be combined and connected in four different ways, as shown on the fol­lowing page.
AMPTROL™ ADAPTER CABLE (K843)
A five wire cable, 12 inches (.30 m) long, is available for easy connection of standard K812 Hand Amptrol or K870 Foot Amptrol. The cable has a 6-pin MS-style connector which connects to the Amptrol, and termi­nals which connect to 75, 76 and 77 on the machine terminal strip and to the case grounding screw. The Amptrol will control the same range of output as the current control on the welder. (If a smaller range of control is desired for finer adjustment, a K775 Remote may be used in conjunction with the Amptrol Adapter Cable Kit. Connection information is included with the Amptrol Adapter Cable Kit.) The Amptrol arc start switch does not function in this application.
FIGURE C.3 – REMOTE CONTROL ADAPTER CABLE (K864)
STRAIGHT PLUG (14 PIN) TO POWER SOURCE
CABLE RECEPTACLE (6 SOCKET) TO: 1) K857 REMOTE CONTROL
2) K812 HAND AMPTROL
3) K870 FOOT AMPTROL
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
CABLE RECEPTACLE (14 SOCKET) TO: L-7 WIRE FEEDER
C-5 C-5
ACCESSORIES
K843 AMPTROL ADAPTER INSTALLATION INSTRUCTIONS (Continued)
Amptrol Only: The Amptrol provides remote current
control through the full range of the power source.
K812, K813 or K870 Amptrol
K843
Adapter
Black and white leads not used. Tape and insulate.
Power source
terminal
strip
Amptrol and Hi-Freq. Kit: The Amptrol will start the 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.
K799
Hi-Freq Kit
Arc start cable
(included with
K799)
CUT OFF ARC START SWITCH and connect black lead to black and white lead to white.
K812, K813 or K870 Amptrol
K843 Adapter
Amptrol Plus Remote Limit Control: The Amptrol provides remote current control from the minimum of the power source to a maximum set by the remote limit control.
K812, K813 or K870 Amptrol
K843 Adapter
Black and white leads not used. Tape and insulate.
Bolt and nut
connection.
Insulate
and tape.
Amptrol and Hi-Freq. Kit Plus Remote Limit Control: The Amptrolswitch will start the Hi-Freq kit to
turn on gas and high frequency starting for DC TIG welding. The Amptrol controls current from the mini­mum of the power source to a maximum set by the remote limit control.
K775 Remote K799 Hi-Freq Kit
Arc start cable (included with K799)
CUT OFF ARC START SWITCH and connect black lead to black and white lead to white.
Limit Control
K812, K813 or K870 Amptrol
K843 Adapter
Bolt and nut
connection.
Insulate
and tape.
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IDEALARC DC-400
LINCOLN
ELECTRIC
®
C-6 C-6
ACCESSORIES
CAPACITOR DISCHARGE CIRCUIT (K828-1)
Mounts inside the DC-400. Recommended when:
• DC-400 is used in conjunction with any LN-23P or older LN-8 or LN-9 semiautomatic wire-feeder. Eliminates possible arc flash re-start of weld when trigger interlock is used. Not required with current LN-8 (above Code 8700), or LN-9s with serial num­bers above 115187 (manufactured after 12/83), or any LN-9 having an L6043-1 Power PC Board.
• DC-400 is used with an LN-22 equipped with an older K279 Contactor-Voltage Control Option. Eliminates electrode overrun when gun trigger is released. Not required when later K279 (above Code 8800) is used.
• DC-400 is used with any semiautomatic wire-feeder and possible small spark is objectionable if elec­trode touches work just after gun trigger is released.
Install per M17060 instructions included with the kit.
HI-FREQ™ KIT (K799 FOR CODES 8634 AND ABOVE ONLY)
Kit supplies the high frequency plus gas valve for DC TIG welding. The DC-400 is shipped with proper R.F. bypass circuitry installed to protect the control circuit when welding with a HI-FREQ unit. K844 Water Valve Option Kit can be used with K799 when TIG welding with water cooled torches.
AMPTROL ADAPTER FOR K799 HI-FREQ KIT (K915. REQUIRES K864 ADAPTER OR K843 ADAPTER)
A “V” cable to connect a K799 Hi-Freq kit (5-pin con­nector) with either a K812 Hand Amptrol or a K870 Foot Amptrol (6-pin connector) and the machine. The cable going to the machine has a 6-pin connector which requires either a K864 adapter to connect with the 14-pin connector on the machine or a K843 adapter to connect to terminals #75, #76, #77 and the case grounding screw on the machine.
UNDERCARRIAGES (K817, K817R, K841)
For easy moving of the machine, optional undercar­riages are available with either steel (K817) or rubber tired (K817R) wheels or a platform undercarriage (K841) with mountings for two gas cylinders at the rear of the welder.
Installation instructions are included with each kit.
CONNECTION OF LINCOLN ELECTRIC AUTOMATIC OR SEMIAUTOMATIC WIRE FEEDERS
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this maintenance.
• Turn the input power OFF at the dis-
connect switch or fuse box before working on this equipment.
• Do not touch electrically hot parts.
Auxiliary power for wire feeder operation is available at both a 14-pin amphenol and at terminal strips with screw-type connections located behind the hinged control panel on the front of the machine. The 14-pin amphenol can provide both 115 VAC (pins A and J) and 40-42 VAC (pins I and K). The terminal strip pro­vides 115 VAC only (terminals 31 and 32). The two cir­cuits are isolated, and each is protected by a 10A cir­cuit breaker.
The following descriptions show how to connect the wire feeders using either the 14-pin amphenol or the terminal strip.
NOTE: The LN-742 wire feeder, because it operates
on 42 VAC, can be connected only to the 14­pin amphenol.
AUTOMATIC WIRE FEEDERS
CONNECTING THE NA-3 TO THE IDEALARC DC-400 (TERMINAL STRIP)
1. Disconnect main AC input power to the Idealarc DC-400.
2. Set Idealarc DC-400 POWER toggle switch to the OFF (0) position.
3. Connect the wire feeder control cable leads to the Idealarc DC-400 terminal strip as shown in Figure C.4.
Connect the wire feeder control cable ground lead to the frame terminal marked .
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NOTE: The Idealarc DC-400 must be properly
IDEALARC DC-400
LINCOLN
ELECTRIC
®
grounded.
C-7 C-7
ACCESSORIES
FIGURE C.4 – NA-3 WIRE FEEDER
CONNECTION TO THE IDEALARC DC-400
CONNECTING THE NA-5 TO THE IDEALARC DC-400 (TERMINAL STRIP)
1. Disconnect main AC input power to the Idealarc DC-400.
2. Set the Idealarc DC-400 POWER toggle switch to the OFF (0) position.
3. Connect the wire feeder control cable leads to the Idealarc DC-400 terminal strip as shown in Figure C.5.
FIGURE C.5 – NA-5 WIRE FEEDER
CONNECTION TO THE IDEALARC DC-400
5. Extend wire feeder control cable lead #21 so it can be connected directly to the work piece.
a. Make a bolted connection using AWG #14 or
larger insulated wire. Tape the bolted connec­tion with insulating tape.
b. An S-16586- X remote voltage sensing work
lead is available for this purpose.
c. Keep the #21 lead electrically separate from
the work cable circuit and connection.
d. Tape the #21 lead to work cable for ease of
use.
NOTE: The connection diagram shown in Figure C.4
shows the electrode connected for positive polarity. To change polarity:
a. Set the Idealarc DC-400 POWER toggle
switch to the OFF (0) position.
b. Move the electrode cable to the negative (-)
output terminal.
c. Move the work cable to the positive (+) output
terminal.
NOTE: If using a K215 control cable, connect
control cable leads #75, #76, and #77 to the matching #75, #76, and #77 terminals on the terminal strip of the Idealarc DC-
400.
4. Connect the wire feeder control cable ground lead to the frame terminal marked .
NOTE: The Idealarc DC-400 must be properly
grounded.
d. Set the VOLTMETER toggle switch to nega-
6. Set the DC-400 OUTPUT CONTROL switch to the “Remote” position and the OUTPUT TERMINALS switch in the “Remote” position.
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tive (-).
IDEALARC DC-400
LINCOLN
ELECTRIC
®
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