lincoln electric svm122-a idealarc dc-400

8/12/2019 Lincoln Electric Svm122-A Idealarc Dc-400

1/116

SVM 122-AOct. 1996

Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built

w ith sa fety in mind. How ever,

your overall safety c a n be

increased by proper installation. . . and thoughtful operation on

your part. DO NOT INSTALL,OPERATE OR REPAIR THISEQUIPMENT WITHOUT READ-ING THIS MANUAL AND THESAFETY PRECAUTIONS CON-TAINED THROUGHOUT. And,most importantly, think before

you act and be careful.

SERVICE MANUAL

For use w ith mac hine co de numbers 9847, 9848 and 9850

IDEALARC DC-400TM

Re

turntoMasterTOC

Return

toMasterTOC

Returnto

MasterTOC

View

SafetyInfo

View

SafetyInfo

ViewSafetyInfo

RETURN TO MAIN INDEX
http://lemenu.pdf/http://lemenu.pdf/


2/116

Re

turntoMasterTOC

Return

toMasterTOC

Returnto

MasterTOC

SAFETYi i

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b.Operate engines in open, well-ventilated

areas or vent the engine exhaust fumesoutdoors.

____________________________________________________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 refuel-ing to prevent spilled fuel from vaporizing oncontact with hot engine parts and igniting. Donot spill fuel when filling tank. If fuel is spilled,wipe it up and do not start engine until fumeshave 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 orrepairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.

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 Welding Society, P.O. Box 351040,Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety booklet E205 is available from the

Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

ELECTRIC AND

MAGNETIC FIELDS

may be dangerous

2.a. Electric current flowing through any conductor causeslocalized 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.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-

cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines


3/116

Re

turntoMasterTOC

Return

toMasterTOC

Returnto

MasterTOC

SAFETYii ii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observing

open arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

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-freegloves 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 weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; 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 oraccidental contact with the workpiece or ground) usethe 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.

FUMES AND GASEScan 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. Whenwelding with electrodes which require special

ventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors

coming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors to

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 manufacturers instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employers safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.e. Also see item 1.b.


4/116

Re

turntoMasterTOC

ReturntoMasterTOC

Returnto

MasterTOC

SAFETYiii iii

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturersrecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturers recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located: Away from areas where they may be struck or subjected tophysical damage.

A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically hot parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen 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 foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,Precautions for Safe Handling of Compressed Gases inCylinders, available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

WELDING SPARKS cancause 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.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to Safety in Welding and Cutting (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contact cancause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen cleaned. For information, purchase RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear 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 weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate circuits.This can create fire hazards or overheat lifting chains orcables until they fail.

6.h. Also see item 1.c.


5/116

Re

turntoMasterTOC

ReturntoMasterTOC

Returnto

MasterTOC

SAFETYiv iv

PRCAUTIONS DE SRETP our votre propre protec tion lire et obs erver toutes les instructions

et les prcautions de sret specifiques qui parraissent dans ce

manuel aussi bien que les prcautions de sret gnrales suiv-

antes:

Sret Po ur Soudag e A LArc

1. Protegez-vous cont re la secousse lec t rique :

a . Les circuits llectrode et la pice sont sous tension

qua nd la ma chine so uder est en marche. Eviter tou-

jours tout contact entre les parties sous tension et la

peau nue ou les vtements mouills. Po rter des ga nts

secs et sa ns trous pour isoler les ma ins.

b. Faire trs at tention de bien s isoler de la masse q uand

on soude da ns des endroits humides, o u sur un planch-er metallique ou des grilles metalliques, principalement

dans les po sitions a ssis ou c ouch pour lesq uelles une

grande partie du corps peut tre en contact avec la

masse .

c. Maintenir le porte-lectrode, la pince de mass e, le cble

de soudage et la machine souder en bon et sr tat

defonctionnement.

d. Ne jamais plonger le porte-lectrode da ns leau pour le

refroidir.

e. Ne jamais toucher simultanment les parties sous ten-

sion des porte-lectrodes connec ts d eux machines

souder parce q ue la tension entre les d eux pinces peut

tre le total de la tension vide des deux mac hines.

2 . Dans le cas de t rava il au dessus du niveau du sol, se protger

contre les c hutes dans le ca s ou on recoit un choc. Ne jama is

enroule le cble-lectrode autour de nimporte quelle partie

du corps.

3. Un coup darc peut tre plus svre quun coup de soliel,

donc:

a . Utiliser un bon masq ue avec un verre f iltrant appropri

ainsi quun verre blanc afin de se protger les yeux du

rayonnement de larc et des projections qua nd on s oude

ou quand on regarde larc.

b . Porter des vtements convenables a f in de protger la

peau de soudeur et des a ides contre le rayonnementde

larc.

c. Protger lautre personnel travaillant proximit au

soudage laide dcrans appropris et non-inflamma-

bles.

4 . Des gouttes de la iter en fus ion sont mises de l a rc de

souda ge. Se protger avec es vtements de protection libres

de lhuile, tels que les gants en cuir, chemise paisse, pan-

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de scurit dans la zone de

souda ge Utiliser des lunettes avec c rans lateraux dans les

7. Quand on ne soude pas, poser la pince une endroit isol

de la ma sse. Un court-circuit ac cidental peut provoquer un

chauffement et un risque dincendie.

8. Sas surer que la mas se est connecte le plus prs possible

de la zone d e travail q uil est pratiq ue de la faire. Si on place

la masse sur la charpente de la construction ou dautresendroits loigns de la zone de travail, on augmente le

risq ue de voir passer le courant de souda ge pa r les c haines

de levag e, cb les de grue, ou atres circuits. Cela peut

provoquer des risques dincendie ou dechauffement des

chaines et des cbles jusqu ce quils se rompent.

9. Assurer une ventilation suffisa nte dans la zone de souda ge.

Ceci est particulirement important pour le soudage de tles

ga lvanises plombes, o u cad mies o u tout autre mtal qui

produit des fumes toxiques.

10. Ne pas souder en prsence de vapeurs de c hlore provenantdoperations de dg raissa ge, nettoyag e ou pistolage. La

chaleur ou les rayons de larc peuvent ragir avec les

vapeurs du solvant pour produire du phosgne (gas forte-

ment roxique) ou a utres produits irritants .

PRCAUTIONS DE SRET POUR LESMACHINES SOUDER TRANSFOR-

MATEUR ET REDRESSEUR1. Relier la terre le chassis du poste conformement au code

de llectricit et aux rec omme nda tions du fab rica nt. Le dis-

positif de monta ge o u la piece souder doit tre branch

une bonne mise la terre.

2. Autant que possible, l installa t ion et l entret ien du poste

seront effectus par un lectricien qualifi.

3. Avant de fa ires des travaux l interieur de poste, la

debrancher linterrupteur la boite de fusibles.

4. Ga rder tous les couvercles et dispost if is de sret leurplace.


6/116

MASTER TABLE OF CONTENTS FOR ALL SECTIONSv v

P a g e

Safety.................................................................................................................................................i-iv

Installation............................................................................................................................. Section A

Insta lla tion S ec tion Ta ble of Co ntents ........... ............ ............. ............ ............ ............. ............ ...A-1

Tec hnica l S pec ifica tions ........... ............ ............. ............ ............ ............. ............ ............ ............A-2

S afety P reca utions ......................................................................................................................A-3

S elect S uita ble Loca tion (S ta cking, Tilting, Lifting) ............ ............ ............ ............. ............ .......A-3

Input Connections.......................................................................................................................A-4

Reconnect P roced ure .................................................................................................................A-6

Output Connections....................................................................................................................A-7

Operation............................................................................................................................... Section B

S afety Instructions ......................................................................................................................B-2

G enera l Desc ription ....................................................................................................................B-3

Controls and Se ttings .................................................................................................................B-4

Welding Operation ........... ............ ............. ............ ............ ............. ............ ............ ............. ........B -6

Overloa d P rotection....................................................................................................................B-9

Auxiliary Power...........................................................................................................................B-9

Accessories........................................................................................................................... Section C

Maintenance ......................................................................................................................... Section D

S afety P reca utions ......................................................................................................................D-2

Routine a nd P eriodic Maintenance ............................................................................................D-2

G enera l Compo nent Loca tions...................................................................................................D-3

Theory of Operation ............................................................................................................. Section E

Troubleshooting and Repair................................................................................................. Section F

How To Use Troubles hooting Guide ........... ............ ............. ............ ............ ............. ............ ......F-2

Troubles hooting G uide ........... ............ ............. ............ ............ ............. ............ ............ ............. ..F-4

Tes t P roc edures ............. ............ ............ ............. ............ ............ ............. ............ ............ .........F-15

RETURN TO MAIN INDEX
http://lemenu.pdf/http://lemenu.pdf/


7/116

Re

turntoMasterTOC

ReturntoMasterTOC

Returnto

MasterTOC

TABLE OF CONTENTS- INSTALLATION SECTION -

Section A-1 Section A-1

Installation

Tec hnica l S pec ifica tions Idea la rc DC-400...... ............ ............ ............. ............ ............ ............. ..A-2

Input a nd Output S pec ifica tions ............ ............ ............ ............ ............. ............ ............ .....A-2

Ca ble a nd Fuse S izes ...........................................................................................................A-2

P hysica l Dimensions ............................................................................................................A-2

Sa fety P reca utions ......................................................................................................................A-3

Select Suitable Location.............................................................................................................A-3Lifting .................................................................................................................................A-3

Tilting .................................................................................................................................A-3

Stacking................................................................................................................................A-3

Input Connections.......................................................................................................................A-4

G round Co nnection ........... ............ ............ ............. ............ ............ ............. ............ ............ .A-4

Input S upply Co nnections ........... ............. ............ ............ ............. ............ ............ ............. ..A-4Input Wire and Fuse S ize ............ ............. ............ ............ ............. ............ ............ .........A-5

Reconnect P roce dure .................................................................................................................A-6

Output Connections....................................................................................................................A-7

Wire Feede r Co nnections ............ ............ ............. ............ ............ ............. ............ ............ ...A-8

Co nnections for S tick, TIG , Air/ca rbon Arc Operations ............ ............ ............. ............ ......A-8


8/116

Re

turntoSectionTOC

Return

toSectionTOC

Returnto

SectionTOC

ReturntoMasterTOC

ReturntoMasterTOC

Returnto

MasterTOC

INSTALLATIONA-2 A-2

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 OpenMode Range Circuit Voltage Auxiliary Power

C ons ta nt C urrent 60 to 500 Amps 57 VDC 115 VAC , 10 Amps

C ons ta nt Volta ge 60 to 500 Amps 45.5 VDC 42 VAC , 10 Amps

RECOMMENDED INPUT WIRE AND FUSE SIZES

Input Wire S ize G ro und Wire Size

Input Volta ge / Fuse Input Ampere Type 75 C Type 75 C

Freq uenc y (S uper La g) Ra ting on C opper Wire in C opper G round

or B rea ker S ize Na mepla te C onduit AWG Wire in C onduit

Volts/Hz (IEC ) S izes AWG (IEC ) S izes

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)


9/116

Read this entire installation section before youstart installation.

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

Do not touch electrica lly live

parts or electrodes with your

skin or w et c lothing.

Insulate yo urse lf from the w orkand ground.

Alwa ys wea r dry insulating gloves.

Only qualified personnel should install, use, or ser-vice this equipment.

SELECT SUITABLE LOCATION

P lac e the Idealarc DC-400 where clean, co oling a ir ca n

flow freely in through the front louvers and out through

the rea r louvers. Keep dust, dirt, and o ther foreign

materia ls tha t ca n be d ra wn into the mac hine to a min-

imum. Failure to ob se rve these preca utions ca n lea d

to excessive operating temperatures and nuisanceshut-downs.

LIFTING

FALLING EQUIPMENT can causeinjury.

Do not lift this ma chine using the

lift ba il if it is eq uippe d w ith a hea vy

ac cess ory such as a trailer or a ga s

cylinder.

Lift only with equipment of a deq uate lifting c a pa city.

Be sure the ma chine is sta ble when lifting.

Do not sta ck more than three high.

Do not s tac k the DC-400 on top of a ny other

machine.

The Idea la rc DC -400 w eighs 473 pound s (215 kilo-

gra ms ). A permane nt lift ba il is loca ted a t the top of

the ma chine, positioned a t the ce nter of gra vity for sta-

ble lifting.

TILTING

P la ce the ma chine on a se cure, level surfac e. Any sur-

faces you place it on other than the ground must be

firm, non-skid, a nd s tructurally s ound.

STACKING

Idea la rc DC-400s ma y be sta cked three high. The

bottom machine must be on a stable, hard, level sur-

face capable of supporting the weight of up to three

ma c hines (1419 pound s/645 kilog ram s). B e sure tha t

the two pins in the roof of the bottom machine fit intothe holes in the ba se o f the ma chine abo ve. The lift

bail is positioned so that it fits without interference

under the base of the second machine.

INSTALLATIONA-3 A-3

Re

turntoSectionTOC

Return

toSectionTOC

Returnto

SectionTOC

ReturntoMasterTOC

ReturntoMasterTOC

Returnto

MasterTOC

WARNING

WARNING


10/116

A 5 A 5


11/116

Have a qualified electrician connect the input power

lea ds to the L1, L2, a nd L3 terminals o f the input co n-

ta cto r. Follow a ll na tiona l a nd loc a l electrica l co des .Us e a three-phas e line. Refer to the co nnection dia-

gram located on the inside cover of the access panel

co ver. Also se e Fig ure A.3.

INPUT WIRE AND FUSE SIZE

Fuse the input circuit with the super lag fuses recom-

mended o n theTechnical Specifications page or usedelay type circuit brea kers. Cho os e a n input a nd

grounding wire size according to local or national

codes; also see the Technical Specifications page.

Using fuses or circuit breakers smaller than recom-

mended may result in nuisance shut-offs from

welder inrush currents, even if you are not welding at

high currents.

INSTALLATIONA-5 A-5

Re

turntoSectionTOC

ReturntoSectionTOC

Returnto

SectionTOC

ReturntoMasterTOC

ReturntoMasterTOC

Returnto

MasterTOC FIGURE A.3 INPUT POWER SUPPLY CONNECTIONS

1. INPUT SU P P LY LINE

2. INPUT C ONTACTOR C R1

3. RECONNECTPANEL


12/116

A-7 A-7


13/116

OUTPUTCONNECTIONSThe output (we lding) ca bles a re c onnecte d to the output

terminals marked + and -. S eeTable A.1 for reco m-

mended cable sizes for the combined lengths of elec-

trode a nd work ca bles. They are loca ted a t the low er

right a nd low er left corners of the front panel. S train

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 termina l

cover to acc ess the output terminals. Low er the cover

a fter making the co nnections. S ee Figure A.6.

INSTALLATIONA-7 A-7

Re

turntoSectionTOC

ReturntoSectionTOC

Returnto

SectionTOC

ReturntoMasterTOC

Retur

ntoMasterTOC

Returnto

MasterTOC

FIGURE A.5 - INPUT CONNECTION DIAGRAM FOR 230/460/575 VOLTS AC, 60 HZ

THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A. M15666

INPUT SUPPLY CONNECTION DIAGRAM

H3GNDH2

Do not touch electrically live parts

Only qualified persons should install,use or service this equipment

removed

servicing

Do not operate with covers

Disconnect input power before

INPUT

LINES

L1

H1

L2

L3

{CR1

V

U

W

CONTACTOR

H4PILOT

TRANSF.

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.

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.

IDEALARC (230 / 460 / 575)

NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR 575V

CONNECTION FOR 575 VOLTS, 60 HZ.

3. CONNECT TERMINAL MARKED TO SYSTEM GROUND PER NATIONAL ELECTRIC CODES.













RECONNECT

PANEL

4. CONNECT TRANSFORMER LEADS 1, 2, 3, 4 & 7, 5 & 8, 6 & 9 TO RECONNECT PANEL.



4. CONNECT TRANSFORMER LEADS 1 & 7, 2 & 8, 3 & 9, 4 & 5 & 6, TO RECONNECT PANEL.



18

17

16

6

15

5

14

4

13

987321

H4GNDH2

INPUT

LINES

L1

H1

L2

L3

{CR1

V

U

W

CONTACTOR

H3PILOT

TRANSF.

RECONNECT

PANEL

3

2

1

6

9

5

8

4

7

151413181716

H4GNDH3

INPUT

LINES

L1

H1

L2

L3

{CR1

V

U

W

CONTACTOR

H2PILOT

TRANSF.

RECONNECT

PANEL6

5

4

93

8

2

7

1

151413181716

IMPORTANT: CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS .

5-26-95

FIGURE A.6 - OUTPUT TERMINAL CONNECTIONS

A-8 A-8


14/116

ReturntoSectionTOC

ReturntoSectionTOC

Returnto

SectionTOC

ReturntoMasterTOC

Retur

ntoMasterTOC

Returnto

MasterTOC

INSTALLATIONA 8 A 8

TABLE A.1 - CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODEAND WORK CABLES

Up to 50 ft 50 - 100 ft 100 - 150 ft 150 - 200 ft 200 - 250 ftMachine 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 mm2 85 mm2 85 mm2 85 mm2 107 mm2

Cycle)

500 Amp 2/0 2/0 3/0 3/0 4/0(50% Duty 67 mm2 67 mm2 85 mm2 85 mm2 107 mm2

Cycle)

WIRE FEEDER CONNECTIONS

See theAccessories section of this manual for spe-

cific instructions on connecting the following semi-

automatic and automatic wire feeders to the Idealarc

DC-400:

Automatic Wire Feeders:

NA-3

NA-5

S emi-a utoma tic Wire Feed ers:

LN-7

LN-8

LN-9

LN-25

LN-742

CONNECTIONS FOR STICK, TIG, OR

AIR/CARBON ARC CUTTING OPERA-TIONS

Th t t t i l i d t ll ti h

The w ork a nd e lec trode c a bles for s tick, TIG , or

a ir/ca rbon arc cutting a re c onnected a s d esc ribed ea r-

lier, under the heading Output Connections. A TIG

torch is c onnec ted to the electrode (+ ) termina l of the

w elder. S elect ca ble size ac co rding to Ta ble A.1.

Do not c onnect a TIG torch a nd s tick electrode c a ble

a t the s a me time. They w ill bo th be e lec tric a lly HOT.

If the Idea la rc DC -400 is a lrea dy se t up for wire feed er

operation, all wire feeder unit control, electrode, and

work cables must be disconnected first before youca n co nnect the ca bles for s tick, TIG , or a ir/ca rbon a rc

operation.

However, the Idealarc DC-400 can be used for both

w ire feede r opera tion a nd stick, TIG , a ir/ca rbon a rc

operation if a K804-1 Multiprocess Switch is used.

See theAccessories section of this manual for spe-

cific instructions on connecting and using the

Multiprocess Switch.

WARNING

WARNING

Section B-1 Section B-1


15/116

ReturntoMasterTOC

Retur

ntoMasterTOC

Returnto

MasterTOC

- OPERATION SECTION -Operation............................................................................................................................... Section B

S afety Instructions ......................................................................................................................B-2

G eneral Desc ription ....................................................................................................................B-3

Recommend ed P roce ss es ...................................................................................................B-3

Operational Features a nd Co ntrols ......................................................................................B-3

Design Features a nd Adva ntag es ........................................................................................B-3

Welding Ca pa bility....... ............ ............ ............. ............ ............ ............. ............ ............ .......B -3

Limita tions ............ ............. ............ ............ ............. ............ ............ ............. ............ ............ .B -3

Co ntrols a nd S ettings ................................................................................................................B-4

Welding Operation ............. ............ ............ ............. ............ ............ ............. ............ ............ .......B -6

Operating Steps ...................................................................................................................B-6

Local Control..................................................................................................................B-6

Remote Control..............................................................................................................B-6

Welding P roced ure Recomme nda tions .........................................................................B-6

S emiautoma tic a nd Automa tic Wire Feeding with a n Idea la rc DC -400 ............ ............. .....B -6

NA-3 Automatic Wire Feeder.........................................................................................B-7

Good Arc Striking Guidelines for the NA-3.............................................................B-7

Arc S triking w ith the NA-3 S ta rt Bo a rd ............ ............ ............ ............. ............ ......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

Overloa d P rotection....................................................................................................................B-9

Auxiliary Power...........................................................................................................................B-9

B 2 B 2OPERATION


16/116

ReturntoSectionTOC

ReturntoSectionTOC

Returnto

SectionTOC

R

eturntoMasterTOC

Retur

ntoMasterTOC

Returnto

MasterTOC

B-2 B-2

OPERATING INSTRUCTIONS

Read and understand this entire section of operating

instructions before operating the machine.

SAFETY INSTRUCTIONS


Do not touch e lec trica lly live pa rts orelectrodes with your skin or wet cloth-

ing.

Insulate yourself from the w ork a nd ground.

Alwa ys wea r dry insulating gloves.

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 fla mmab le materia l aw a y.

Do not weld on conta iners tha t have held c om-

bustibles.

ARC RAYS can burn.

Wea r eye, ear, a nd bod y protection.

Observe additional Safety Guidelines detailed inthe beginning of this manual.

WARNING

OPERATION

OPERATIONB-3 B-3


17/116

GENERAL DESCRIPTION

The Idea la rc DC -400 is a n S CR co ntrolled three-phas e

input, DC output power source for welding and cut-

ting. It uses a single rang e potentiometer control. The

welders unique combination of transformer, three-phase semiconverter rectifier, capacitor bank, arc con-

trol choke, and solid state control system deliver out-

standing arc characteristics in the constant voltage

mod e. For stick welding, a n Arc Force Co ntrol enab les

the Ide a la rc-400 to pe rform muc h like the R3R-500.

RECOMMENDED PROCESSES

The Idea la rc DC-400 is rec omend ed for all open a rc

proces se s including Innershield and all solid wire and

ga s proced ures within its c apa city of 60 to 500 amps .

It a lso ca n perform s tick a nd TIG w elding a nd a ir/ca r-

bo n a rc go uging up to 5/16 (8 mm) dia mete r. A mod e

sw itc h on the front c ontrol panel selec ts C V (FCAW,

G MAW), C V S ubm erged Arc, or C C (s tick/TIG).

The Idea la rc DC-400 ca n be c onnec ted to w ire feed-

ing equipment, including:

Automa tic w ire feed ers NA-3, NA-5, a nd NA-5R.

(Requires the DC-400 Diode Kit option to use the

cold start and cold electrode sensing features of

these feeders.)

S emi-a utoma tic w ire fee ders LN-7, LN-7 GMA, LN-

8, LN-9, LN-9 G MA, LN23P, LN-25, LN-742.

Tra c tors LT-56, LT-7.

OPERATIONAL FEATURES ANDCONTROLS

The follow ing o perationa l co ntrols a re sta nda rd o n the

Idea la rc DC-400:

P ow er S ource P ilot Light

ON/OFF Po w er Tog gle S w itch

Output Co ntrol Potentiometer

Output Control S w itch (w ith Loc a l or Remote po si-

tions)

Output Termina ls On or Remote S w itch

DC Ammeter

DC Voltmeter

Voltmeter + Electrode or - Electrode S witch

DESIGN FEATURES AND ADVANTAGES

Input line voltag e c ompensa tion keeps o utput c on-

sta nt for fluctuations of 10%.

S CR c ontrol extends life of mechanica l conta ctors.

Hinged front control panel provides ea sy a cc ess to

printed circuit boa rds a nd other c ontrol circuitry.

Fully e nclose d fan moto r w ith perma nently lubri-

cated, sealed ball bearings needs no maintenance.

Fully recess ed control panel protects controls and

minimizes a cc identa l contac t.

Rece ss ed output terminals a nd hinged terminal

cover reduce chance of accidental contact.

Low profile c a se permits insta lla tion under a w ork-

bench.

Removab le rear acc ess panel provides ea sy a cces s

to input conta ctor a nd input lea d c onnections.

Removab le ca se s ides provide ea sy a cc ess for ser-

vice or inspec tion, even when ma chines a re s tac ked.

Dripproof enclos ure de sign permits o utdoor opera tion.

Double-dipped tra nsformer, S CR bridg e, a nd c hoke

res ist co rros ion.

WELDING CAPABILITY

The Idea la rc DC-400 has the follow ing d uty cy cle

ratings. If the duty cy cle is exc eed ed , a therma l pro-

tec tor w ill shut off the ma chine output until it c ools t o

normal opera ting temperature. The a mbe r thermalprotection indicator light will turn on until the machine

cools.

Duty Cycle* Amps Volts

OPERATION

ReturntoSectionTOC

ReturntoSectionTOC

Returnto

SectionTOC

R

eturntoMasterTOC

Retur

ntoMasterTOC

Returnto

MasterTOC

OPERATIONB-4 B-4


18/116

CONTROLS AND SETTINGS

All operator controls and settings are located on the

ca se front as se mbly. S ee Figure B.1 for their loc a -

tions.

FIGURE B.1 CASE FRONT CONTROLS

1. POWER SOURCE PILOT LIGHT: This light indi-cates that the power source input contactor is

energized (close d). This a lso me a ns tha t the main

power transformer and all auxiliary control trans-

formers are energized.

2. ON/OFF POWER TOGGLE SWITCH: Energizesor de-engergizes the input c ontac tor which is po w-

ered by the 115 volt auxilia ry trans former. The

sw itch turns the ma chine ON or OFF. P os ition I

is ON; position 0 is OFF.

3. OUTPUT CONTROL POTENTIOMETER: Con-trols voltage in CV mode and current in CC mode

5. OUTPUT TERMINALS ON OR REMOTESWITCH: When in the Remote position, leads#2 and #4 have to be jumpered externally to ener-

gize the output terminals. When in the ON po si-

tion, this s w itch internally jumpers lead s #2 a nd #4,

which energizes the output terminals.

6. ARC FORCE SELECTOR: Allows you to selectthe idea l a rc force ac cording to the proced ure a nd

electrode b eing us ed for CC stick or TIG w elding.

It controls the amount of current added to the

welding current when the electrode shorts to the

w ork. At minimum setting, no extra sho rt c ircuit

OPERATION

ReturntoSectionTOC

Retur

ntoSectionTOC

Returnto

SectionTOC

R

eturntoMasterTOC

ReturntoMasterTOC

Returnto

MasterTOC

1. Po wer Source Pilot Light

2. ON/OFF P ow er Tog gle Sw itch

3. Output Co ntrol P otentiometer

4. Output Co ntrol S witch (with Loc al or Remo te pos itions )

5. Output Terminals S witch (with On or Remote pos itions )

6. Arc Force Se lector (for CC s tick or TIG p roces se s only)

7. Auxiliary Power Connections for Wire Feeder and Other

Eq uipment (115V a nd 42V)

8. Mode Sw itch

9. Arc Control

10. Thermal P rotection Indica tor Light

11. DC Ammeter

12. DC Voltme ter

13. Voltmeter + Elec trode or - Electrod e Sw itch


19/116

OPERATIONB-6 B-6


20/116

WELDING OPERATION

OPERATING STEPS

LOCAL CONTROL

The follow ing proc ed ures a re for using the Ide a la rcDC-400 in the loc a l co ntrol mod e of operation. Forremote co ntrol of the ma chine, see the REMOTECONTROL sec tion.

Before operating the mac hine, ma ke s ure you ha ve a llmateria ls need ed to c omplete the job. Be s ure you arefamiliar with and have taken all possible safety pre-ca utions be fore sta rting wo rk. It is importa nt tha t youfollow these operating steps each time you use the

machine.

1. Turn on the ma in AC input pow er to the ma chine.

2. S et the VOLTMETER + o r - sw itch to thea ppropria te po sition.

Se t togg le to Electrode Nega tive pos ition ifthe electrode is connected to the negative (-)output terminal.

Se t toggle to Electrode P ositive position if theelec trod e is co nnecte d to the pos itive (+ ) outputterminal.

3. S et the welding MODE sw itch to we lding processbeing used.

C V FC AW/G MAW

CV S ubmerged Arc

C C Stick/Tig

4. S et the OUTP UT C ONTROL sw itc h to Loc a l.(Exception: when using an LN-9, LN-9 GMA, orNA-5 wire feeder, set the switch to Remote.Otherwise, the wire feeder may automatically shutdown.

5. S et the OUTP UT TERMINALS s w itch to thedesired mode.

6. S et the ARC FORC E CONTROL to midrang e, 5-6.

This c ontrol is for C C s tick or TIG w elding o nly.Adjust for best c harac teristics a s nec ess ary.

7. S et the ARC C ONTROL to midrang e, 3. This co n-trol is for C V FC AW/G MAW w eld ing only. Adjustas neces sa ry for bes t pinch control.

8. S et the ON/OFF P OWER tog gle sw itch to the ON

REMOTE CONTROL

The tog gle sw itch o n the co ntrol panel la beled Output

Control Remote gives you the option of controlling

the mac hine output from a remote loc a tion. In the

Remote position a wire feeder with remote controlcapabilities 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 infor-

mation.

WELDING PROCEDURE RECOMMENDATIONS

S elect Mode S witch position ba sed on type of welding

to be done.

1. FCAW/G MAW Welding /Othe r Ope n Arc P roc es ses :

Us e the C V FCAW/G MAW mod e.

2. S ubmerged Arc Welding: Us e the C V S ubmerged

Arc mode . If performing high spee d welding,

sw itch betw een the CV S ubmerged Arc a nd the CV

FCAW/G MAW mod e a nd us e the mod e tha t pro-

duces the bes t we lding results.

3. Air/Ca rbon Arc C utting / S tick Welding / High

Current, La rge P uddle S ubmerged Arc Welding:

Us e the CC m od e. When the Idea la rc DC-400 is

use d fo r Air/C a rbon Arc c utting, the OUTP UT

CONTROL potentiometer sho uld be se t to 9 ini-

tia lly. Ba sed on the size of the carbon being used

or the process, turn the potentiometer to a lower

setting a s required by the proces s. You can use

ca rbon rod s up to 5/16 (8 mm) in dia mete r at c ur-rents as high as 450 amps with excellent arc con-

trol. The w elder protec tion circuit protec ts the

machine from extremely high short circuiting

pulses.

SEMIAUTOMATIC AND AUTOMATIC WIREFEEDING WITH AN IDEALARC DC-400

When using the Idealarc DC-400 with semiautomatic

or automatic wire feeding equipment and for stick

w elding o r air/ca rbon a rc cutting, it is recomm ended

tha t the optiona l MULTIP ROC ESS sw itch be us ed.

This s w itch p ermits you to e a sily c ha nge t he polarity of

the connected wire feeding equipment or switch to

OPERATION

ReturntoSectionTOC

Retur

ntoSectionTOC

Returnto

SectionTOC

R

eturntoMasterTOC

ReturntoMasterTOC

Returnto

MasterTOC

OPERATIONB-7 B-7


21/116

NA-3 AUTOMATIC WIRE FEEDER

1. S et the DC -400 OUTP UT C ONTROL sw itc h to

Remote.

NOTE: Later model NA-3 automatic wire feedersare capable of cold starts when the NA-3Mode s witch is in the CV or CC m od e pos i-

tion. S ome earlier models are ca pab le 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

va lve. The cold sta rt fea ture req uires the

fac tory insta lled diode option. S ee theAccessories section.

2. Set the DC-400 welding MODE switch for the

desired process: CV Submerged Arc, CV

FCAW/G MAW mo de or CC mo de.

3. S et the NA-3 mod e s w itch po sition to either CV or

CC to ma tch the DC-400 mode s elected in step 2.

4. S et the OUTP UT CONTROL sw itch to Re mote.

5. S et the OUTP UT TERMINALS sw itc h to Re mote.

6. For CC w elding, s et the ARC FORC E CONTROL to

midra nge, 5-6. After we lding sta rts, ad just as nec -

essary.

7. For CV FCAW/G MAW w elding , s et the ARC C ON-

TROL to midrange , 3. After w elding s ta rts, a djust

as necessary.

8. Refer to the NA-3 ope rators manua l for ins tructionson how to us e the NA-3 in c onjunction with the DC -

400.

9. Follow the guidelines for go od a rc striking d eta iled

below for each w elding mod e.

GOOD ARC STRIKING GUIDELINES FOR THE

NA-3 WITH THE IDEALARC DC-400 IN THE CVFCAW/GMAW, CV SUBMERGED ARC ORSTICK/TIG CC WELDING MODES.

Follow ing a re s ome ba sic a rc striking tec hniq ues tha t

apply to a ll wire feed proces ses . Using these proce-

dures should provide trouble-free sta rting . Thes e pro-

NOTE: The o pen c ircuit voltag e o f the Idea la rcDC-400 varies from apporximately 12

volts to 45 vo lts in the C V FC AW/G MAW

or C V S ubmerged Arc mod es . The open

circuit voltag e is co nsta nt in the CC mode.3. Run a test weld. Se t proper current, voltag e, and

travel speed .

a. For the best starting performance, the NA-3

Open Circuit Voltage Control and Voltage

Co ntrol setting should be the same. S et the

Inch S peed Control for the slowes t inch s peed

possible.

b. To a djust the Open Circuit Voltag e C ontrol toget the best starting performance, make

repeate d s ta rts ob se rving the NA-3 voltmeter.

When the voltmeter pointer sw ings sm oothly up to

the des ired a rc voltag e, w ithout undershooting or

overshooting the desired arc voltage, the Open

Circuit Voltage Control is set properly.

If the voltmeter pointer overshoots the desired

voltag e a nd then returns to the d esired voltag e, theOpen C ircuit Volta ge C ontrol is set to o high. This

can result in a bad start where the wire tends to

blast off.

If the voltmeter pointer hesitates be fore c oming up

to the d es ired voltag e, the Op en C ircuit Voltag e

Co ntrol is s et too low. This c a n ca use the elec -

trode to stub.

4. S t a rt and m ake the we ld .

a . Cold starts . For cold starts , be sure the work

piece is clean and the electrode makes posi-

tive contact with the work piece.

b. Hot On the Fly starts. For hot sta rts, travel

should b egin before the w ire c ontac ts the w ork

piece.

ARC STRIKING WITH THE NA-3 START BOARDWhen e lectrica l stickouts exc eed 1-3/4 (44.4 mm) an

NA-3 Sta rt Boa rd m a y b e req uired to improve a rc strik-

ing.

When the NA-3 Start Board is used to improve arc

striking use the follow ing proced ures

OPERATION

ReturntoSectionTOC

Retur

ntoSectionTOC

Returnto

SectionTOC

R

eturntoMasterTOC

ReturntoMasterTOC

Returnto

MasterTOC

OPERATIONB-8 B-8


22/116

4. Turn the Start Boa rd Timer to ma ximum.

5. Set S tart Board current and voltage control.

a. Set the Sta rt Boa rd current control to 1-1/2

dial numbers below that set on the NA-3 cur-

rent control.

b . Set the Start Boa rd voltage control equal with

the NA-3 volta ge co ntrol se tting.

NOTE: These S tart Bo ard c urrent and voltag e se t-tings result in a start up current that is

lower than the NA-3 current setting and

a pproxima tely eq ual w ith the NA-3 voltag e

setting for the desired welding procedure.

6. Establish the correct a rc striking procedure w ith

the NA-3 Start Board timer set at maximum.

a. For the best starting performance, the NA-3

Open C ircuit Voltag e C ontrol a nd Voltag e

Co ntrol setting should be the sa me. S et the

Inch S peed Control for the slowes t inch spe ed

possible.

b. To a djust the Open Circuit Voltag e C ontrol toget the best starting performance, make

repea ted sta rts ob se rving the NA-3 voltmeter.

When the voltmeter pointer sw ings sm oothly up to

the des ired arc voltag e, w ithout undershooting o r

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 Ope n C ircuit Voltag e C ontrol is se t to o high.

This c a n res ult in a ba d s ta rt where the wire tend s

to blast off.

If the voltmeter pointer hesitates be fore c oming up

to the d es ired voltag e, the Ope n Circuit Voltag e

C ontrol is se t too low. This ca n ca use the elec -

trode to stub.

c . Set NA-3 Start Board current and voltage a sclose to the welding procedure current and

voltage as possible.

NOTE: The S ta rt Boa rd c urrent a nd voltageshould be as close as possible to the

welding procedure current and voltage

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 fol-

low s for the bes t performance:

1. Turn OFF main AC input powe r to the Idea la rc DC-

400.

2. Connect the e lectrode ca bles to the terminal

pola rity to b e used .

3. Set the VOLTMETER + o r - s witch to the sa me

pola rity a s the electrode c ab le c onnection.

4. Set the OUTPUT CONTROL sw itch to Remote.

5. Se t the OUTP UT TERMINALS sw itch 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 we ld ing , se t we ld ing

MODE S WITC H TO C V S UB MERGED ARC

position.

b. For all open arc welding processes, s e t weld-ing MODE sw itch TO C V FCAW/G MAW po s i-

tion.

7. Set the ARC CONTROL to midrange, 3. After

welding starts, adjust as necessary.

LN-8 SEMIAUTOMATIC WIRE FEEDER

To us e the LN-8 Se miauto ma tic Wire Feed er w ith theIdea la rc DC-400:

1. Set the Idealarc DC-400 welding MODE switch to

either C V FC AW/G MAW mo de or C V S ubm erged

Arc mode, depending on the welding process

being used.

2. Set the Idea larc DC -400 OUTP UT CONTROL

switch to Remote.

3. Se t the OUTP UTTERMINALS s witch to Remote.

4. Set the ARC CONTROL to midrange, 3 .

5. Set the LN-8 Welding Mode switch to the CV posi-

tion. The LN-8 Welding Mode s w itch is loc a ted o n

the variable voltage (CC) board

OPERATION

R

eturntoSectionTOC

Retur

ntoSectionTOC

Returnto

SectionTOC

R

eturntoMasterTOC

ReturntoMasterTOC

Returnto

MasterTOC

OPERATIONB-9 B-9


23/116

R

eturntoSectionTOC

ReturntoSectionTOC

Returnto

SectionTOC

R

eturntoMasterTOC

ReturntoMasterTOC

ReturntoMasterTOC

O O

LN-7 AND LN-9 SEMIAUTOMATIC WIRE FEEDERSOR OTHER CONSTANT SPEED WIRE FEEDERS

To us e the LN-7, LN-9, or other co nst a nt w ire feed

speed semiautomatic wire feeders with the Idealarc

DC-400:1. Set the Idealarc DC-400 welding MODE switch to

either C V FCAW/G MAW mo de or C V S ubm erged

Arc mode, depending on the welding process

being used.

NOTE: Thes e semiauto ma tic w ire feeders c a nnotbe used in the CC mode.

2. S et the Idea la rc DC -400 OUTP UT CONTROL

switch.

a. LN-7: Use either an optional K775 Remote

Control Box Assembly or set the Idealarc DC-

400 OUTP UT C ONTROL s w itc h in the Loca l

position.

b. LN-9: Refer to the LN-9 Opera tors Manual for

instructions o n how to us e the LN-9.

c. LN-25: Refer to the LN-25 Opera tors Manualfor instructions o n how to us e the LN-25.

d. LN-742: Refer to the LN-742 Operators

Manual for instructions on how to use the LN-

742.

OVERLOAD PROTECTION

The pow er source is thermos ta tica lly protecte d w ith

proximity thermostats against overloads or insufficient

coo ling. One thermostat is loca ted on the nose of the

ce nter bo ttom prima ry co il. A se co nd thermos ta t isatta ched to the lea d connecting the sec onda ries. If the

mac hine is overloa ded , the prima ry thermosta t opens ,

the output bec omes zero, a nd the a mber therma l pro-

tec tion lig ht com es o n. The fan w ill co ntinue to run.

The sec onda ry thermostat opens with either a n exces -

s ive ove rloa d o r insuffic ient co oling. The outp ut

bec omes zero, a nd the a mber thermal protection light

comes on. When the mac hine cools, the thermosta ts

reset, and the thermal protection light goes off.

The pow er source is a lso protected ag a inst overloa ds

on the SCR bridge asssembly through an electronic

protection circuit. This c ircuit sense s a n overloa d on

the pow er source and limits the output to 550 amps by

phasing ba ck the SC Rs.

The Idea la rc DC-400 also ha s se lf-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 Idea la rc DC -400 c a n provide nom ina lly 115 volt

AC and 42 volt AC auxiliary power for operating wire

feeding eq uipment and other ac ces sories. This pow er

is available at the 14-pin amphenol on the controlpa nel and /or a t the terminal s trip b ehind the hinged

co ntrol pa nel on the ca se front. On the a mphenol, 115

volts AC is a vaila ble at pins A a nd J (Domes tic a nd

Export models only); 42 volts AC is available at pins I

a nd K. On the termina l s trip, 115 volts AC is ava ilab le

at terminals 31 and 32; 42 volts AC is not available.

The tw o c ircuits , 115 volts AC a nd 42 volts AC , a re iso-

la ted; a nd ea ch is protected by a 10 amp circuit break-

er.

On European and export models, a Continental

European receptacle is provided on the rear panel for

supplying 220 volts AC to a w a ter coo ler. A 2 am p cir-

cuit breaker, also located on the rear panel, protects

this circuit from overloa ds or s hort circuits

Section C-1 Section C-1


24/116

R

eturntoMasterTOC

ReturntoMasterTOC

ReturntoMasterTOC TABLE OF CONTENTS

- ACCESSORIES -

Accessories........................................................................................................................... Section C

Options /Acc es so ries ........... ............ ............. ............ ............ ............. ............ ............ ............. .....C -2

Factory Installed Option.......................................................................................................C-2

Field Insta lled 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 Ada pter for K799 (K915)... ............. ............ ............ ............ ............. ............ .....C -6

Undercarriages (K817, K817R, K841)............................................................................C-6

Co nnection of Linco ln Elec tric Automa tic o r Sem ia utoma tic Wire Feed ers ............ ............ ......C -6

Automatic Wire Feeders.......................................................................................................C-6

NA-3 (Terminal S trip)............... ............ ............ ............. ............ ............ ............. ............ .C-6

NA-5 (Terminal S trip)............... ............ ............ ............. ............ ............ ............. ............ .C-7

NA-3 or NA-5 (14-P in Amphenol)......... ............. ............ ............ ............. ............ ...........C -8

S emiautoma tic Wire Feeders ............ ............ ............. ............ ............ ............. ............ .........C -9

LN-7 (14-Pin Amphenol)................................................................................................C-9

LN-7 (Termina l S trip) ............. ............ ............ ............. ............ ............ ............. ............ .C-10

LN-8 or LN-9 (Terminal S trip).................... ............. ............ ............ ............. ............ .....C -11

LN-8 or LN-9 (14-P in Amphenol)....................... ............ ............ ............. ............ .........C -12

LN-742 (14-P in Amphenol)..... ............ ............. ............ ............ ............. ............ ...........C -13

ACCESSORIESC-2 C-2


25/116

OPTIONS/ACCESSORIES

FACTORY INSTALLED OPTION

DIODE OPTION

This fac tory insta lled option a llow s us e of the co ld-

start and cold electrode sensing features of the NA-3,

NA-5, or NA-5R a utoma tic wire feed ers. S ee the to pic,

Connecting the NA-3 [NA-5] to the Idealarc DC-400

in this section of the manual.

FIELD INSTALLED OPTIONS

The follow ing options/a cc es so ries a re a vaila ble foryour Idealarc DC-400 from your local Lincoln

Distributor.

COVER FOR 14-PIN AMPHENOL (LINCOLNELECTRIC PART NUMBER S17062-3)

Protects the amphenol from dirt and moisture when

the a mphenol is not being used.

MULTIPROCESS SWITCH (K804-1. ALSOAVAILABLE AS A FACTORY INSTALLED OPTION.)

Required when using the DC-400 for both automat-

ic /semiautom a tic and s tick/a ir ca rbon a rc. This field or

fac tory insta lled kit mounts on the front o f the DC -400.

It includes hinged covers over its output studs.

The s w itch ha s three po sitions .

Wire Feeder Pos itive

Wire Feeder Neg a tive

S tick/Air C a rbon Arc

The Multiproces s S w itch gives you the a bility to :

S w itc h be tw een S tick Welding/Air-Ca rbon Arc

Cutting or Positive Wire Feeder or Negative Wire

Feeder.

Cha nge the pola rity of a s emi-automatic or a uto-

matic wire feeder without changing any electrical

ca ble connections. Se e Figure C.1.

The Multiproces s S witch ha s tw o s ets of output termi-

na ls. You connec t the w ire feeder unit ca bles to the

set of terminals on the left side of the box (facing the

front o f the ma chine) a nd the stick or a ir/ca rbon a rc

cables to the set of terminals on the right side as

sho w n in Figure C.1.

When the Multiproc es s S w itc h is in the S tick Welding/

Air-Carbon Arc position, only those terminals are

energized . The wire feede r nozzle or gun a nd elec-

trode are not electrically hot when in this mode.

Refer to installation instructions (M17137) included

with Multiprocess Kit for installation.

R

eturntoSectionTOC

ReturntoSectionTOC

Returnto

SectionTOC

R

eturntoMasterTOC

ReturntoMasterTOC

ReturntoMasterTOC

FIGURE C.1MULTIPROCESS SWITCH

ACCESSORIESC-3 C-3


26/116

R

eturntoSectionTOC

ReturntoSectionTOC

Returnto

SectionTOC

R

eturntoMasterTOC

Retu

rntoMasterTOC

ReturntoMasterTOC Multiprocess Switch Operation

The ope ration of the Multiproces s S w itch is a s follow s:

A semiautomatic or automatic wire feed unit electrode

and wo rk cab les a re connec ted to the terminals on the

left side of the box. S tick or a ir ca rbon arc elec trod eand wo rk cab les a re connec ted to the terminals on the

sw itc h. With the sw itc h in the left pos ition, the w ire

feed termina ls a re elec trode nega tive. In the center

position, the wire feeder terminals are electrode posi-

tive. In both the left and c enter sw itch pos ition, the

right s ide s tick terminals a re disc onnec ted . In the right

switch position, the wire feed terminals are discon-

nected from the DC-400 and the stick terminals con-

necte d. The polarity of the stick termina ls is ma rkedon the end of the box. To cha nge po la rity, the elec -

trode 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 sepa ra te work ca bles for stick a nd semiautomat-

ic welding.)

If both s tick a nd s emia utomatic welding is d one on the

sa me w orkpiec e, only one wo rk ca ble is req uired . To

do this, c onne ct a 4/0 (107 mm2) jumper from the w ork

terminal on the semiautomatic side to the terminal to

be use d for wo rk on the stick side. The work ca ble

from the semiautomatic side then serves as the workca ble for both semiautomatic and stick welding. S ee

Figure C.2.

To c ha nge s tick polarity, reverse the lea ds a t the (+ )

and (-) terminals on the right side of the Multiprocess

Switch.

NOTE: When a DC-400 equipped with MultiprocessSwitch is mounted on an undercarriage, the

undercarriage handle in the resting positioncan hit the case of the Multiprocess Switch.

This do es no ha rm, but if the use r des ires, a

1/4 o r 3/8 b olt and nut ma y be plac ed in the

hole in the undercarriage tow bar to limit the

travel of the undercarriage handle.

FIGURE C.2 SINGLE WORK CABLE WITH J UMPER

T i k l d h ld

ACCESSORIESC-4 C-4


27/116

REMOTE OUTPUT CONTROL (K857 WITH K864ADAPTER PLUG OR K775)

The K857 ha s a 6-pin MS-s tyle co nnec tor. The K857

requires a K864 adapter cable which connects to the

14-pin connector on the machine.An opt iona l remo te output co ntrol is a va ila ble. This

is the same remote control that is used on the Lincoln

R3R and D C -600 pow er source s (K775). The K775

co nsists of a co ntrol box w ith 28 ft (8.5m) of four con-

duc tor ca ble. This co nnects to termina ls 75, 76, a nd

77 on the terminal strip and the case grounding screw

ma rked with the sy mbo l on the ma chine. Thes e

terminals are located behind the control panel on the

front. This device w ill give the sa me c ontrol a s t he out-

put 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

co nnec tor) a nd the machine (14-pin c onne ct or). If a

remote co ntrol or amptrol is used a lone, the w ire-feed-

er co nnection is not used . S ee Figure C. 3.

AMPTROL ADAPTER CABLE (K843)

A five w ire c a ble, 12 inches (.30 m) long , is a va ilab le for

easy connection of standard K812 Hand Amptrol or

K870 Foot Amptrol. The ca ble has a 6-pin MS-s tyle

connector which connects to the Amptrol, and termi-

nals which connect to 75, 76 and 77 on the machine

termina l strip and to the ca se g rounding sc rew. The

Amptrol will control the same range of output as the

current c ontrol on the welde r. (If a s ma ller rang e of

co ntrol is des ired for finer ad justment, a K775 Remote

may be used in conjunction with the Amptrol Adapter

Ca ble Kit. Co nnection informa tion is included w ith the

Amptrol Ada pter Ca ble Kit.) The Amptrol arc st a rt

switch does not function in this application.

K843 AMPTROL ADAPTER INSTALLATIONINSTRUCTIONS


Turn the input sup ply pow er OFF

before installing plugs or cables or

when connecting or disconnecting

plugs to the welder.

This K843 a da pter is used to c onne c t Amptrol (K812,

K813 or K870), remo te c ont rol (K775), a nd Hi-Freq

(K799) a c ce sso ries to the DC -400. The OUTP UT

C ONTROL sw itch must b e in Re mote for Amptrol

to control current. Acc ess ories ma y be c ombined a nd

connected in four different wa ys, a s show n on the fol-

lowing page.

R

eturntoSectionTOC

ReturntoSectionTOC

Returnto

SectionTOC

R

eturntoMasterTOC

Retu

rntoMasterTOC

ReturntoMasterTOC

FIGURE C.3 REMOTE CONTROL ADAPTER CABLE (K864)

S TRAIG HTP LUG (14 P IN) CAB LE REC EP TAC LE (6 S OC KET)

WARNING

ACCESSORIESC-5 C-5


28/116

R

eturntoSectionTOC

ReturntoSectionTOC

ReturntoSectionTOC

R

eturntoMasterTOC

Retu

rntoMasterTOC

ReturntoMasterTOC

Amptrol Only: The Amptrol provides remote c urrentcontrol through the full range of the power source.

Amptrol Plus Remote Limit Control: The Amptrolprovides remote current control from the minimum of

the power source to a maximum set by the remote

limit control.

Amptrol and Hi-Freq. Kit: The Amptrol w ill sta rt theHi-Freq kit to turn on gas and high frequency starting

for DC TIG welding. The Amptrol c ontrols current

through the full range of the power source.

Amptrol and Hi-Freq. Kit Plus Remote LimitControl:The Amptrols w itch w ill s ta rt the Hi-Freq kit toturn on g as a nd high freq uency s tarting for DC TIG

w elding. The Amptrol controls c urrent from the mini-

mum of the power source to a maximum set by theremote limit c ontrol.

K812, K813 or

K870 Amptrol

Pow er source

terminalstrip

K843

Adapter

Black and white leads

not used. Tape

and insulate.

K812, K813

or K870

Amptrol

K843 Ada pterArc start cable

(included with

K799)

K799

Hi-Freq Kit

K812, K813

or K870

Amptrol

K775 Remote

Limit Control

K843 Ada pterArc start cable

(included

h )

K799

Hi-Freq

Kit

K812, K813 or

K870 Amptrol

K843

Adapter

Bolt and nut

connection.

Insulate

and tape.

Bo lt and nut

connection.

CUTOFF

ARC S TARTSWITCH a nd co nnect b lack

lead to black and w hite

lead to w hite.

K843 AMPTROL ADAPTER INSTALLATION INSTRUCTIONS (Continued)

ACCESSORIESC-6 C-6


29/116

R

eturntoSectionTOC

ReturntoSectionTOC

ReturntoSectionTOC

R

eturntoMasterTOC

Retu

rntoMasterTOC

ReturntoMasterTOC

CAPACITOR DISCHARGE CIRCUIT (K828-1)

Mounts inside the DC-400. Recomme nded w hen:

DC -400 is us ed in co njunction w ith any LN-23P o r

older LN-8 or LN-9 semiautomatic wire-feeder.

Eliminates possible arc flash re-start of weld whentrigg er interlock is used . Not req uired with c urrent

LN-8 (above Code 8700), or LN-9s with serial num-

be rs a bo ve 115187 (ma nufactured a fter 12/83), or

a ny LN-9 having a n L6043-1 P ow er PC Boa rd.

DC -400 is us ed w ith an LN-22 equipped w ith an

older K279 Cont a ct or-Voltag e C ontrol Option.

Eliminates electrode overrun when gun trigger is

relea se d. Not required w hen la ter K279 (a bo veCode 8800) is used.

DC-400 is used w ith any semia utomatic w ire-feeder

and possible small spark is objectionable if elec-

trode touc hes w ork just a fter gun trigg er is relea se d.

Install per M17060 instructions included with the kit.

HI-FREQ KIT (K799 FOR CODES 8634 ANDABOVE ONLY)

Kit supplies the high frequency plus gas valve for DC

TIG w elding. The DC -400 is s hippe d w ith proper R.F.

bypass circuitry installed to protect the control circuit

w hen w elding w ith a HI-FREQ unit. K844 Wa ter Va lve

Option Kit c a n be used w ith K799 w hen TIG w elding

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 con-

nector) with either a K812 Hand Amptrol or a K870

Foot Amptrol (6-pin co nnec tor) a nd the ma chine. 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

a da pter to connect to terminals #75, #76, #77 a nd the

case grounding screw on the machine.

UNDERCARRIAGES (K817, K817R, K841)

For easy moving of the machine, optional undercar-

riages are available with either steel (K817) or rubber

tired (K817R) wheels or a platform undercarriage

(K ) h f l d h

CONNECTION OF LINCOLN ELECTRICAUTOMATIC OR SEMIAUTOMATIC WIREFEEDERS


Only q ualified personnel should

perform this maintenance.

Turn the input powe r OFF at the d is-

connect switch or fuse box before working on this

equipment.

Do not touch electrica lly hot pa rts.

Auxilia ry pow er for wire feed er opera tion is a vaila ble a t

both a 14-pin amphenol and at terminal strips with

screw-type connections located behind the hinged

co ntrol pa nel on the front of the ma c hine. The 14-pin

a mphenol ca n provide bo th 115 VAC (pins A a nd J )

a nd 40-42 VAC (pins I a nd K). The te rminal s trip pro-vides 115 VAC o nly (te rminals 31 a nd 32). The tw o c ir-

cuits are isolated , a nd ea ch is protected by a 10A cir-

cuit breaker.

The follow ing d es criptions s how how to c onnec t the

wire feeders using either the 14-pin amphenol or the

terminal s trip.

NOTE: The LN-742 w ire feede r, be c a use it ope rate s

on 42 VAC, c a n be c onnec ted only to the 14-pin a mphenol.

AUTOMATIC WIRE FEEDERS

CONNECTING THE NA-3 TO THE IDEALARCDC-400 (TERMINAL STRIP)

1. Disc onnect ma in AC input power to the Idea larc

DC-400.

2. Set Idealarc DC-400 POWER toggle switch to the

OFF (0) pos ition.

3. Connect the wire feeder control ca ble lead s to the

Idealarc DC-400 terminal strip as shown in Figure

WARNING

ACCESSORIESC-7 C-7


30/116

FIGURE C.4 NA-3 WIRE FEEDERCONNECTION TO THE IDEALARC DC-400

5. Extend w ire feeder control ca ble lead #21 so it ca n

be connected directly to the w ork piece.

a. Make a bolted connection using AWG #14 or

la rger insulated wire. Ta pe the bo lted c onnec -

tion w ith insulating ta pe.

b. An S-16586- X remote voltage sensing w ork

lead is available for this purpose.

c. Keep the #21 lead electrica lly separate from

the work cable circuit and connection.

d. Tape the #21 lead to w ork ca ble for eas e of

use.

NOTE: The c onnec tion d ia gra m s how n in Figure C.4shows the electrode connected for positive

pola rity. To cha nge po larity:

a . Se t the Idea larc DC-400 POWER togg le

sw itch to the OFF (0) pos ition.

b Move the electrode ca ble to the negative (-)

CONNECTING THE NA-5 TO THEIDEALARC DC-400 (TERMINAL STRIP)

1. Disco nnect main AC input power to the Idea larc

DC-400.

2. Set the Idea larc DC-400 POWER toggle sw itch tothe OFF (0) pos ition.

3. Connect the wire feeder control ca ble leads to the

Idea la rc DC -400 terminal s trip a s sho w n in Figure

C.5.

FIGURE C.5 NA-5 WIRE FEEDER

CONNECTION TO THE IDEALARC DC-400

NOTE: If using a K215 control cable, connectcontrol 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 ca ble ground lead

to the fra me termina l ma rked .

R

eturntoSectionTOC

ReturntoSectionTOC

ReturntoSectionTOC

R

eturntoMasterTOC

Retu

rntoMasterTOC

ReturntoMasterTOC

ACCESSORIESC-8 C-8


31/116

5. Extend w ire feeder control ca ble lead #21 so it ca n

be connected directly to the w ork piece.

a. Make a bolted connection using AWG #14 or

la rger insulated w ire. Ta pe the bo lted c onnec -

tion w ith insulating ta pe.b. An S-16586- X remote voltage sensing w ork

lead is available for this purpose.

c. Keep the #21 lead electrica lly separate from

the work cable circuit and connection.

d. Tape the #21 lead to w ork ca ble for eas e of

use.

6. Co nnect NA-5 wire feeder control jumpers onVoltag e Co ntrol Bo a rd. S ee NA-5 Operato rs

Manual.

NOTE: The c onnec tion d ia gra m s how n in Figure C.5shows the electrode connected for positive

pola rity. To cha nge po la rity:

a . Se t the Idea larc DC-400 POWER togg le

sw itch to the OFF (0) pos ition.

b. Move the electrode ca ble to the negative (-)output terminal.

c. Move the work ca ble to the positive (+ ) output

terminal.

d. S et the VOLTMETER toggle switch to nega tive

(-).

NOTE: For proper NA-5 operation, the electrodeca bles must b e s ecured under the c lamp ba r

on the left side of the NA-5 Control Box.

7. Se t the DC-400 OUTP UT CONTROL sw itch to the

R emo te pos ition a nd the OUTP UT TERMINALSsw itch to the Remote position.

CONNECTING THE NA-3 OR NA-5 TO THEIDEALARC DC-400 (14-PIN AMPHENOL)

1. Disconnect main AC input power to the Idealarc

DC-400.

2. S et the Idea la rc DC-400 POWER sw itch to the OFF

(0) position.

3. Connect the electrode cable from the K597-XX

Input Ca ble Ass emb ly to the + termina l of the

welder a nd to the wire feeder. Co nnect the work

ca ble to the - terminal of the welder. Reverse this

hookup for nega tive polarity. S ee Figure C.6.

NOTE: Welding c a ble must b e s ized for the cur-rent and duty cycle of the application.

4. S et the w elder VOLTMETER sw itch to the d es iredpo larity, either DC (-) or DC (+ ).

5. Set the MODE switch to a CV (constant voltage)

position.

6. Se t the DC-400 OUTP UT CONTROL sw itch to the

R emo te pos ition a nd the OUTP UT TERMINALS

sw itch to the Remote position.

R

eturntoSectionTOC

Retu

rntoSectionTOC

ReturntoSectionTOC

R

eturntoMasterTOC

Retu

rntoMasterTOC

Returnt

oMasterTOC

FIGURE C.6IDEALARC DC-400/NA-3/NA-5 14-PIN AMPHENOL CONNECTION

TO NA-3 or NA-5 INPUTCABLE PLUG

K597-XX INPUT CABLE ASSEMBLY

ACCESSORIESC-9 C-9


32/116

R

eturntoSectionTOC

Retu

rntoSectionTOC

ReturntoSectionTOC

R

eturntoMasterTOC

Retu

rntoMasterTOC

Returnt

oMasterTOC

FIGURE C.7IDEALARC DC-400/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM

SEMIAUTOMATIC WIRE FEEDERS

CONNECTING THE LN-7 TO THE IDEALARCDC-400 (14-PIN AMPHENOL)

1. Disco nnect main AC input power to the Idealarc

DC-400.

2. Set the P OWER toggle sw itch to the OFF (0) posi-

tion.

3. Connect the electrode c ab le from the K584-XX

Input Ca ble Ass emb ly to the + termina l of the

w elder a nd to the LN-7 w ire feeder. Co nnect the

work cable to the - terminal of the welder.

Reverse this hookup for nega tive po la rity.

NOTE: Welding c a ble must be sized for the currenta nd d uty cycle of the a pplica tion.

4. Connect K584-XX Input Ca ble between the DC-

400 a nd the LN-7. S ee Figure C.7.

5. S et the welder VOLTMETER toggle sw itch to the

des ired polarity, either DC (-) or DC (+ ).

6. Set the MODE sw itch to a CV (consta nt voltage)

position at the welder.

7. Adjust wire feed speed at the LN-7 and set the

w elding volta ge w ith the OUTP UT CONTROL.

NOTE: If optional remote control is used, place theOUTP UT C ONTROL and the OUTP UT TERMI-

NALS switch in the Remote position.


33/116


34/116

ACCESSORIESC-12 C-12

C C


35/116

CONNECTING THE LN-8 OR LN-9 TO THEIDEALARC DC-400 (14-PIN AMPHENOL)

1. Disconnect main AC input power to the Idea larc

DC-400.

2. Set the POWER toggle sw itch to the OFF (0) posi-tion.

3. Connect the electrode ca ble from the LN-8 or

LN-9 to the + terminal of the w elde r. Co nnect

the work cable to the - terminal of the welder.

Reverse this hookup for nega tive pola rity. S ee

Figure C.10.

NOTE: Welding c a ble must b e s ized for the currentand duty cyc le of the a pplica tion.

4. Connect the input ca ble (K595-XX) betw een the

14-pin amphenol on the DC-400 and the input

ca ble plug on the LN-8 or LN-9. S ee Figure C .10.5. Se t the we lder VOLTMETER sw itch to the desired

po larity, either DC (-) or DC (+ ).

6. Set the MODE sw itch to a CV (constant voltag e)

position.

7. Adjust wire feed speed a t the LN-8 or LN-9 and

set the welding voltage with the WIRE FEEDER

VOLTAG E C ONTROL.

P la ce the OUTP UT CONTROL sw itch in the Remote

pos ition and the OUTP UT TERMINALS sw itc h in the

Remote position.

R

eturntoSectionTOC

Retu

rntoSectionTOC

ReturntoSectionTOC

ReturntoMasterTOC

Retu

rntoMasterTOC

ReturntoMasterTOC

FIGURE C.10 IDEALARC DC-400/LN-8 OR LN-9 WITH K595-XX CABLE

TO LN8/LN9 INPUTCABLE PLUG

ACCESSORIESC-13 C-13

C C


36/116

CONNECTING THE LN-742 TO THEIDEALARC DC-400 (14-PIN AMPHENOL)

1. Disc onnect main AC input power to the Idea larc

DC-400.

2. Set the POWER toggle sw itch to the OFF (0) posi-tion.

3. Connect the electrode ca ble from the LN-742 to

the + terminal of the welder. Co nnect the wo rk

ca ble to the - termina l of the w elder. Reverse

this ho okup for nega tive polarity. S ee Figure C.11.

NOTE: Welding c a ble must b e s ized for the currenta nd d uty cycle of the a pplica tion.

4. Connect the K592 Control Ca ble to the 14-pin

amphenol on the IDEALARC DC-400 and to the

input ca ble plug on the LN-742. S ee Figure C.11.

5. S et the w elder VOLTMETER sw itch to the des ired

po larity, either DC (-) or DC (+ ).

6 . Set the MODE switch to a CV (constant voltage)

position.

7. Adjust wire feed speed a t the LN-742 and set the

w elding voltag e w ith the o utput ARC C ONTROL to

a CV (constant voltage) position at the welder.

NOTE: If optional remote control is used, set theOUTP UT CONTROL sw itch to the Re mote

pos ition a nd the OUTP UT TERMINALS sw itchto the Remote position.

R

eturntoSectionTOC

Retu

rntoSectionTOC

Returnt

oSectionTOC

ReturntoMasterTOC

Retu

rntoMasterTOC

ReturntoMasterTOC

FIGURE C.11 IDEALARC DC-400/LN-742 CONNECTION DIAGRAM

C

Section D-1 Section D-1

TABLE OF CONTENTS


37/116

ReturntoMasterTOC

Retu

rntoMasterTOC

ReturntoMasterTOC

-MAINTENANCE-Maintenance ......................................................................................................................... Section D

S a fety P reca utions .........................................................

lincoln electric svm122-a idealarc dc-400

Documents