Lincoln Electric IDEALARC DC-400 Operator's Manual
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Lincoln Electric IDEALARC DC-400 Operator's Manual

Lincoln electric welder user manual
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IDEALARC
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
• Sales 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
RETURN TO MAIN MENU
DC-400
®
9847 thru 9852, 9854, 9855, 9857, 10008,
10275, 10276, 10859, 10880, 11083, 11084,
11277, 11278, 11279 11348, 11349, 11350,
11351, 11352, 11353, 11567
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
IM474-E
February, 2011

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Summary of Contents for Lincoln Electric IDEALARC DC-400

  • Page 1 IDEALARC For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.

  • Page 2: California Proposition 65 Warnings

    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.
  • Page 3 SAFETY...
  • Page 4 SAFETY...
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.

  • Page 7: Table Of Contents

    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 ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––...
  • Page 8 (1) Based upon 10 minute time period (i.e., for 60% duty cycle, it is 6 minutes on an 4 minutes off). Use only bussmann Super-Lag fuses specified. Other fuses may not protect the welder and may cause overheating and possible fire damage.

  • Page 9: Installation

    SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. ------------------------------------------------------------------------ FUMES AND GASES can be danger- ous.

  • Page 10: Output Connections

    Amptrol will control the same range of output as the 107 mm current control on the welder. (if a smaller range of control is desired for finer adjustment, a K775 Remote may be used in conjunction with the Amptrol Adapter Cable Kit.) The Amptrol arc start switch is nonfunc-...
  • Page 11 INSTALLATION...

  • Page 12: Installation Of Equipment Requied For Recommended Processes

    See the appropriate connection diagram for the exact instructions for the wire feeder being used. A cover (Lincoln Electric Part Number S17062-3) is available for the unused 14-pin connector to protect it against dirt and moisture.
  • Page 13 The operation of the switch is as follows: A semiautomatic or automatic wire feed unit electrode and work cables are connected to the terminals on the left side of the box. Stick or air carbon arc electrode and work leads are connected to the terminals on the right side of the box.

  • Page 14: Safety Precautions

    SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK • 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-400’s without the Capacitor Discharge Option: When using a DC-400 power source with wire feeders which do not have an electrical trigger interlock (or...
  • Page 15 OUTPUT TERMINALS SWITCH Output (Voltage) Remote On/Off ARC FORCE CONTROL DIAL Shielded Metal Arc Welding Gas Tungsten Arc Welding Arc Force Current Increase/Decrease of Current VOLTMETER SWITCH Voltmeter Positive Electrode Negative Electrode EARTH GROUND CONNECTION Signifying the Earth (Ground) Connection OPERATION RATING PLATE MODE SWITCH...
  • Page 16 Submerged Arc Welding Designates Welder can be used in environments with increased hazard of electric shock. (IEC model only) Degree of protection provided by the enclosure Designates welder complies with low voltage directive and with EMC directive. (Export Model only) IDEALARC® DC-400...

  • Page 17: General Machine Description

    GENERAL MACHINE DESCRIPTION The DC-400 is an SCR controlled three phase DC power source. It is designed with a single range potentiometer control. RECOMMENDED PROCESSES & EQUIPMENT The DC-400 model is designed for all open arc processes including Innershield ® and GMAW all solid wire and gas procedures within the capacity of the machine, plus the capability of stick and TIG welding...

  • Page 18: Power Source Operation And Controls

    The amber thermal protection light will be lit if either of the two protective thermostats have opened. The out- put power will be disabled but input power will still be applied to the welder. (Refer to Machine and Circuit Protection section). MODE SWITCH The large MODE SWITCH on the left side of the...
  • Page 19 The OUTPUT TERMINALS toggle switch on the con- ® welding, other trol panel labeled “REMOTE - ON” allows the welder output to be activated remotely or to be always on. For remote operation, the toggle switch is set in “REMOTE” position and the welder output will be acti- vated when 2 and 4 are closed when using a wire- feeder.
  • Page 20 To gain access to the terminal strips simply remote the six #10 sheet metal screws from the perimeter of the welder nameplate as shown below. Tilt panel for- ward so it rests in a horizontal position. See Table showing Front View of 14-Pin Connector Receptacle for lead number functions.

  • Page 21: Auxiliary Power Connections

    This is accomplished through the feedback net- work in the control circuit. SOLID STATE OUTPUT CONTROL The output of the welder is electronically controlled by SCR’s instead of mechanical contactors, providing extra long life for highly repetitive welding applica- tions.

  • Page 22: Stick Welding

    The case rear, top section, is equipped with a remov- able access panel. This provides easy access to the input contactor, easy connection and reconnection of input leads, and easy access for service or inspection. The total construction of the machine permits outdoor operation.

  • Page 23: Accessories

    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 with trailer. OPTIONAL EQUIPMENT Factory Installed Options...
  • Page 24 The Amptrol will control the same range of output as the current control on the welder. (If a smaller range of control is desired for finer adjustment, a K775 Remote may be used in conjunction with the Amptrol Adapter Cable Kit.

  • Page 25: 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 control terminal strip TS1.

  • Page 26: Troubleshooting

    HOW TO USE TROUbLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 27 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Input contactor (CR1) chatters. Machine input contactor does not operate. Machine input contactor operates, but no output when trying to weld. Machine has minimum output and no control. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 28 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Machine has high output or pulsing output and no control. Machine has low output and no control. Machine does not have maximum output. Machine will not shut off. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 29 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Variable or sluggish welding arc. OUTPUT control not functioning on the machine. OUTPUT control not functioning on “REMOTE” control. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 30 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Poor arc striking with semiautomatic or automatic wire feeders. Poor arc characteristics. ARC CONTROL has no effect in CV (FCAW/GMAW) mode with short cir- cuit transfer processes. 115VAC Receptacle not working. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

  • Page 31: Procedure For Replacing Pc Boards

    PROCEDURE FOR REPLACING PC bOARDS WARNING ELECTRIC SHOCK • 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. ---------------------------------------------------------------------- When a PC Board is suspected to be defective, the follow- ing procedure must be followed: 1.
  • Page 32 REMOTE CONTROL CHECK Disconnect the remote output control and connect an ohmmeter across 75 to 76 and rotate the rheostat in the remote control. The resistance reading should go from zero to 10K ohms. Repeat with ohmmeter across 75 and 76 with same results. Connect ohm- meter across 75 and 77.
  • Page 33 DIAGRAMS IDEALARC® DC-400...
  • Page 34 DIAGRAMS WIRING DIAGRAM FOR CODES 9847 THRU 9852, 9854, 9855, 9857, 10008, 10275, 11350, 11351 IDEALARC® DC-400...
  • Page 35 L 9 1 0 7 DIAGRAMS WIRING DIAGRAM FOR CODES 10859, 10880,11083, 11084 L9107 IDEALARC® DC-400...
  • Page 36 DIAGRAMS WIRING DIAGRAM FOR CODE 9847, 11349 IDEALARC® DC-400...
  • Page 37 DIAGRAMS WIRING DIAGRAM FOR CODES 11277, 11278 AND 11279, 11348, 11352, 11353 and 11567 IDEALARC® DC-400...
  • Page 38 NOTES IDEALARC® DC-400...
  • Page 39 NOTES IDEALARC® DC-400...
  • Page 42 • World's Leader in Welding and Cutting Products • • Sales 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...

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