lincoln electric svm122-a idealarc dc-400
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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
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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
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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.
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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.
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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.
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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
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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
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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)
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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
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WARNING
WARNING
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A 5 A 5
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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
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1. INPUT SU P P LY LINE
2. INPUT C ONTACTOR C R1
3. RECONNECTPANEL
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A-7 A-7
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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
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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.
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.
CONNECTION FOR 460 VOLTS, 60 HZ.
3. CONNECT TERMINAL MARKED TO SYSTEM GROUND PER NATIONAL ELECTRIC CODES.
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.
CONNECTION FOR 230 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.
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.
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.
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
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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
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- 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
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B-2 B-2
OPERATING INSTRUCTIONS
Read and understand this entire section of operating
instructions before operating the machine.
SAFETY INSTRUCTIONS
ELECTRIC SHOCK can kill.
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
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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
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OPERATIONB-4 B-4
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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
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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
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OPERATIONB-6 B-6
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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
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OPERATIONB-7 B-7
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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
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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
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OPERATIONB-9 B-9
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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
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- 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
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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.
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FIGURE C.1MULTIPROCESS SWITCH
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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
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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
ELECTRIC SHOCK can kill.
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.
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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
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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)
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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
ELECTRIC SHOCK can kill.
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
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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 .
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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.
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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
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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.
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ACCESSORIESC-12 C-12
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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.
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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
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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.
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FIGURE C.11 IDEALARC DC-400/LN-742 CONNECTION DIAGRAM
C
Section D-1 Section D-1
TABLE OF CONTENTS
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-MAINTENANCE-Maintenance ......................................................................................................................... Section D
S a fety P reca utions .........................................................