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

View Safety Info View Safety Info View Safety Info View Safety Info

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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. [phone]

®

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

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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

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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

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®

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

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v v

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

RETURN TO MAIN INDEX

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

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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

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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

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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

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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

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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

®