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Lincoln IDEALARC DC-400, Operator'S Manual

The Lincoln IDEALARC DC-400 is a reliable and powerful welding machine that guarantees excellent performance. Operating this state-of-the-art equipment is made easier with the comprehensive Operator's Manual available for free download from our website. Master your welding skills with this manual and unlock the full potential of your Lincoln IDEALARC DC-400.

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TABLE OF CONTENTS

Page

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

Technical Specifications ........................................................................................A-1

Safety Precautions ..........................................................................................A-2
Correct Operational use ..................................................................................A-2
Stacking and Lifting.........................................................................................A-2
Input Power Connections ................................................................................A-2
Output Connections ........................................................................................A-3

Installation of Field Installed Options .....................................................................A-3
K843 Amptrol Installation Instructions ...................................................................A-4
Installation of Equipment Requied for Recommended Processes..........A-5 Thru A-6

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Operational ......................................................................................................Section B

Safety Precautions.................................................................................................B-1
Meaning of Graphic Symbols...................................................................B-1 thru B-3
General Machine Description ................................................................................B-4
Recommended Processes & Equipment ...............................................................B-4
Operational Features and Control .........................................................................B-4
Power Source Operation and Controls ....................................................B-5 thru B-7

Auxiliary Power Connections ..........................................................................B-8
Solid State Output Control ..............................................................................B-8
Case Features.................................................................................................B-8
Stick Welding ..................................................................................................B-9
Paralleling .......................................................................................................B-9
Machine & Circuit Protection ...........................................................................B-9

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

TIG Welding Options / Accessories.......................................................................C-1
Optional Equipment .............................................................................................C-1 thru C-2

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

Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1

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Troubleshooting ..............................................................................................Section E

Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-5
Procedure for Replacing P.C. Boards ............................................................E-6, E-7

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Wiring Diagrams ..............................................................................................Section F

________________________________________________________________________

Parts Pages .................................................................................................P-234, P-239

Summary of Contents for IDEALARC DC-400

Page 1: ...creased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 9847 thru 9852 9854 9855 9857 10008 10275 10276 10859 10880 11083 11084 11277 11278 11279 11348 11349 1135...

Page 2: ...AKER 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 ava...

Page 3: ...or 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 GASES can be dangerous 5 a Welding may produce fu...

Page 4: ...s to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode ...

Page 5: ...nflammables 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier 6 Eloigner les mat...

Page 6: ...important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www linc...

Page 7: ...rocesses Equipment B 4 Operational Features and Control B 4 Power Source Operation and Controls B 5 thru B 7 Auxiliary Power Connections B 8 Solid State Output Control B 8 Case Features B 8 Stick Welding B 9 Paralleling B 9 Machine Circuit Protection B 9 Accessories Section C TIG Welding Options Accessories C 1 Optional Equipment C 1 thru C 2 Maintenance Section D Safety Precautions D 1 Routine Ma...

Page 8: ...100 REN 100 60 RES 60 60 RES 60 60 RES 60 50 RES 50 INPUT VOLTAGE FREQUENCY 230 60Hz 460 60Hz 575 60Hz INPUT AMPERE RATING ON NAMEPLATE 100 Duty Cycle 78 39 31 TYPE 75 C COPPER WIRE IN CONDUIT AWG IEC SIZES mm2 40 C 104 F 3 25 8 10 10 6 TYPE 75 C GROUND WIRE IN CONDUIT AWG IEC SIZES mm2 6 16 10 6 10 6 BUSSMANN SUPER LAG FUSE SIZE AND CATALOG NUMBER FUSE SIZE CATALOG NUMBER 100 REN 100 50 RES 50 40...

Page 9: ...he three line terminals on the input contactor and the earth grounding lead to the grounding terminal on the input box floor marked with the symbol Install and reconnect panel for the proper input voltage per the diagram pasted inside the access panel cover See Technical Specification Page ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate ...

Page 10: ...nnector on the case front REMOTE CONTROL ADAPTER CABLE K864 A V cable 12 30m long to connect a K857 Remote Control 6 pin connector with a wire feeder 14 pin connector and the machine 14 pin connec tor If a remote control is used alone the wire feeder connection is then not used AMPTROL ADAPTER CABLE 843 A five wire cable 12 30m long used for easy connection of standard K963 Hand Amptrol or K870 Fo...

Page 11: ... E R S O U R C E 7 5 7 7 7 6 K 9 6 3 K 8 1 3 o r K 8 7 0 A m p t r o l K 7 9 9 H i F r e q K i t A r c s t a r t c a b l e i n c l u d e d w i t h K 7 9 9 K 8 4 3 A d a p t e r C U T O F F A R C S T A R T S W I T C H a n d c o n n e c t b l a c k l e a d t o b l a c k a n d w h i t e l e a d t o w h i t e F I G 3 P O W E R S O U R C E 7 5 7 7 7 6 7 6 7 7 C U T O F F A R C S T A R T S W I T C H a n...

Page 12: ...ONNECTION AND OPERATION PURPOSE A Multiprocess Switch has been designed for use with the DC 400 or DC 600 With this switch installed on the DC 400 it permits easy changing of the polarity of the wire feed unit connected and also provides sepa rate terminals for connection of stick or air carbon arc The Multiprocess Switch is available as either a facto ry installed or field installed option NOTE I...

Page 13: ...ck side The work lead from the semiautomatic side then serves as the work lead for both semiautomatic and stick welding To change stick polarity reverse the leads at the and terminals on the right side of the Multiprocess Switch NOTE When a DC 400 equipped with Multiprocess Switch is mounted on an undercarriage the undercarriage handle in the resting position can hit the case of the Multiprocess S...

Page 14: ...C SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts This next section applies to DC 400ʼs without the Capacitor Discharge Option WARNING WARNING MEANINGS OF GRAPHIC SYMBOLS The DC 400 nameplate has been redesigned to use international symbols in describing the function of t...

Page 15: ...tive Electrode Negative Electrode Three Phase Power RATING PLATE Transformer Rectifier Rectified DC Output Constant Voltage Characteristic MODE SWITCH Do not switch if output voltage or current is present Constant Voltage Submerged Arc Welding Constant Voltage Flux cored arc weldin gas metal arc weld ing C o n s t a n t Current shield metal arc weld ing gas tung sten arc weld ing EARTH GROUND CONN...

Page 16: ...th EMC directive Export Model only Designates welder complies with International Electrotechnical Commission requirements 60974 1 European model only NEMA EW 1 IEC 60974 1 Three Phase Power Transformer Rectifier Rectified DC Output Constant Voltage Characteristic Line Connection Shielded Metal Arc Welding Designates Welder can be used in environments with increased hazard of electric shock IEC mod...

Page 17: ...a voltage control in the CV position and a current control in the CC position MACHINE OUTPUT CONTROL SWITCH LOCAL OR REMOTE The machine output can be controlled by either the OUTPUT control on the machine control panel the output control on the wire feed unit or an optional remote control that is available This switch selects the mode of control either LOCAL or REMOTE OUTPUT TERMINALS ON OR OUTPUT...

Page 18: ...re feed unit control or by con necting a K775 control to terminals 75 76 and 77 on the terminal strip at the front of the machine or by connecting a K857 control to the 14 pin connector on the front of the machine For control at the machine control panel the toggle switch is set in the LOCAL Exception When used with an LN 9 LN 9 GMA or NA 5 wire feeder the OUTPUT CONTROL switch must be in the REMO...

Page 19: ...ding applications adjust this control to a minimum for best operating character istics ARC CONTROL SWITCH Effective only in CV FCAW GMAW mode The ARC CONTROL is a tapped switch numbered from 1 to 5 and changes the pinch effect of the arc This control is most useful in processes that utilize a shorting metal transfer and controls the spatter fluid ity and bead shape The pinch effect is increased by...

Page 20: ...ed on the rear panel for supplying 230V AC to a water cooler A 3 5 amps 2 amps below code 11277 circuit breaker which is also located on the rear panel protects this circuit from excessive overloads or short circuits Machine and Circuit Protection The power source is thermostatically protected with proximity thermostats against overload or insufficient cooling One thermostat is located on the nose...

Page 21: ...ing circuit 5 the power up delay circuit and 6 the power circuit The SCR snubber board consists of a capacitor and resistor connected across each SCR and across the entire bridge and MOVʼs to protect the control circuitry and SCRʼs from transient voltages The snubber board is mounted on the back of the case front The SCR firing circuit the control fault protection cir cuit the power up delay circu...

Page 22: ...must be dis connected from the DC 400 for maximum safety unless the Multiprocess switch option is installed PARALLELING There are no provisions on the DC 400 to permit par alleling DIODE OPTION The DC 400 Diode option is required to utilize the cold start and cold electrode sensing features of the NA 3 NA 5 or NA 5R When this option is not used with an NA 3 NA 5 or NA 5R see the DC 400 NA 3 DC 400...

Page 23: ...rode touches work just after gun trigger is released is objectionable Install per M17060 instructions included with the Kit 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 K841 with mountings for two gas cylinder at rear of welder Install per instructions provided wi...

Page 24: ...tuds The switch has three positions Positive semiautomat ic automatic negative semiautomatic automatic and stick air carbon arc Required when using the DC 400 for both semiautomatic automatic and stick air carbon arc The field installed kit is equivalent to the factory installed option For details on the Multiprocess Switch see the section for Installation of Equipment Required for Recommended Pro...

Page 25: ...nsulating gloves See additional warning information throughout this operatorʼs manual and the Engine manual as well ROUTINE MAINTENANCE 1 The fan motor has sealed bearings which require no service 2 In extremely dusty locations dirt may clog the air channels causing the welder to run hot Blow out the machine at regular intervals 3 In extremely dusty locations dirt may accumulate on the remote cont...

Page 26: ...tep 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be ...

Page 27: ...een 2 and 4 leads is not being closed 2 Electrode or work lead loose or broken 3 Open main transformer T1 pri mary or secondary circuit 4 Defective Control PC Board 5 Primary or secondary thermostats open 1 Terminals 75 76 or 77 grounded to positive output 1 Repair or Replace 2 Check input power 1 Replace if blown look for reason first 2 Check control transformer T2 and associated leads 3 Check in...

Page 28: ...pen lead 75 1 One input fuse blows 2 One phase of main transformer open 3 Faulty Control PC Board 4 OUTPUT control potentiometer 5 OUTPUT control potentiometer leads 210 211 or 75 open 1 Input contactor contacts frozen 2 Defective POWER 1 0 switch S1 1 Check 75 76 or 77 for ground to negative output circuit Nearly zero ohms to ground indicates a grounded circuit A value greater than a few thousand...

Page 29: ...PUT control poten tiometer 4 Leads or connections open in control circuit 5 Faulty Control PC Board 1 OUTPUT CONTROL switch in wrong position 2 Faulty OUTPUT CONTROL switch 3 Faulty remote control potentiome ter 4 Leads or connections open in control circuit 5 Faulty Control PC Board 1 Check and clean all connections 2 Check table in instruction manual 3 Check procedures for recom mended settings ...

Page 30: ...ective R1 L1 S4C S4D actu ator or S5 1 Circuit Breaker Tripped 2 Defective Circuit Breaker 3 Broken connection in wiring 1 Check Start PC Board and reed switch CR3 2 Work connection must be ade quate for application 3 Adjust procedures for improved starting 4 Replace See Procedure for Replacing PC Boards 1 Short reed switch CR3 leads together If welding improves replace reed switch 2 If problem is...

Page 31: ...m 10 to 46 volts in CV In the CC mode the open circuit voltage should be approximately 57 volts 54 volts on 50 60 Hz except at near minimum settings of the output control where it may be lower If any other condition exists refer to the Troubleshooting Guide FAULT PROTECTION OPERATION The overload protection circuit in the Control PC Board will limit the welding current heat to 550 amps if a short ...

Page 32: ...h triple 204 leads e Perform the following steps 2 and 3 If diodes and SCRʼs are not shorted bridge test is com pleted If any device appears shorted discon nect the cathode lead of each diode 4 total and repeat Steps 2 and 3 2 Power Diode Test a Establish the polarity of the ohmmeter leads and set to X10 scale b Connect the ohmmeter positive lead to anode and negative lead to cathode c Reverse the...

Page 33: ...F 1 DIAGRAMS F 1 IDEALARC DC 400 ...

Page 34: ... covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number WIRING DIAGRAM FOR CODES 9847 THRU 9852 9854 9855 9857 10008 10275 11350 11351 ...

Page 35: ...ll machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number A L9107 WIRING DIAGRAM FOR CODES 10859 10880 11083 11084 ...

Page 36: ...urate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number WIRING DIAGRAM FOR CODE 9847 11349 ...

Page 37: ...es covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number WIRING DIAGRAM FOR CODES 11277 11278 AND 11279 11348 11352 11353 and 11567 ...

Page 38: ...NOTES IDEALARC DC 400 ...

Page 39: ...NOTES IDEALARC DC 400 ...

Page 40: ... electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrod...

Page 41: ... gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öffnen Maschine anhalten Não opere co...

Page 42: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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