Lincoln Electric DC-400 manual PRObLEMS, Symptoms, POSSIbLE, Cause Recommended Course of Action

Page 27

E-2

TROUbLESHOOTING

E-2

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

PRObLEMS

(SYMPTOMS)

POSSIbLE

CAUSE

RECOMMENDED

COURSE OF ACTION

Input contactor (CR1) chatters.

1.

Faulty input contactor (CR1).

1.

Repair or Replace.

 

2.

Low line voltage.

2.

Check input power.

 

 

 

 

 

Machine input contactor does not

1.

Supply line fuse blown.

1.

Replace if blown - look for reason

operate.

 

 

 

first.

 

2.

Contactor power circuit dead.

2.

Check control transformer T2 and

 

 

 

 

associated leads.

 

3.

Broken power lead.

3.

Check input voltage at contactor.

 

4.

Wrong input voltage.

4.

Check voltage against instruc-

 

 

 

 

tions.

 

5.

Open input contactor coil.

 

 

 

 

 

5.

Replace coil.

 

6.

POWER “I/0” switch (S1) not

 

 

 

 

closing.

6.

Replace switch.

 

 

 

 

 

Machine input contactor operates,

1.

Trigger circuit between #2 and #4

1.

Make sure trigger circuit is being

but no output when trying to weld.

 

leads is not being closed.

 

closed.

 

2.

Electrode or work lead loose or

2.

Repair Connection.

 

 

broken.

 

 

 

3.

Open main transformer (T1) pri-

3.

Repair.

 

 

mary or secondary circuit.

 

 

 

4.

Defective Control PC Board.

4.

Replace. See Procedure for

 

 

 

 

Replacing PC Boards.

 

5.

Primary or secondary thermostats

5.

Amber thermal protection light is

 

 

open.

 

on: Check for overheating; make

 

 

 

 

sure fan is operating and there is

 

 

 

 

no obstruction to free air flow.

 

 

 

 

 

Machine has minimum output and no

1.

Terminals 75, 76 or 77 grounded

1.

Check 75, 76, or 77 for ground to

control.

 

to positive output.

 

positive output circuit. Nearly

 

 

 

 

zero ohms to ground indicates a

 

 

 

 

grounded circuit. A value greater

 

 

 

 

than a few thousand ohms is nor-

 

 

 

 

mal. Self-restraining fuses on PC

 

 

 

 

Board automatically reset within a

 

 

 

 

few seconds after ground is

 

 

 

 

cleared.

 

 

 

 

 

CAUTION

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.

IDEALARC® DC-400

Image 27
Contents Idealarc DC-400 Safety Depends on YouSafety Electric Shock can kill Iii Welding and Cutting Sparks can Cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéOn-Line Product Registration Please Examine Carton and Equipment For Damage ImmediatelyTAbLE of Contents Technical Specifications DC-400 Correct Operational USE Safety PrecautionsInput Power Connections FALLING EQUIPMENT can causeRemote Output Control K857 or K857-1 with K864 Adapter Installation of Field Installed OptionsOutput Cable Connections Output CablesK870 Amptrol K843 Amptrol Adapter Installation InstructionsConnections Multiprocess Switch Connection and Operation PurposeConnection of DC-400 to LN-22 or LN-25 DesignSTICK, TIG or AIR/CARbON ARC Multiprocess SwitchELECTRIC SHOCK can kill Safety PrecautionsARC Force Control Dial Output Terminals Switch Rating PlateMode Switch Voltmeter SwitchRating Plate NEMA EW 1 IEC 60974-1Operational Features & Controls General Machine DescriptionRecommended Processes & Equipment Duty Cycle and Time Period Power Source Operation and ControlsFront View of 14-PIN Connector Receptacle ARC FORCE CONTROL Dial Effective only in CC modeARC CONTROL SWITCH Effective only in CV FCAW/GMAW mode OUTPUT TERMINALS SWITCHMachine and Circuit Protection Terminal Strip ConnectionsOutput Connections Auxiliary Power ConnectionsRemote Control Connections Case FeaturesMachine & Circuit Protection Thermal Protection Light TIG Options Factory Installed OptionsField Installed Options Optional EquipmentUndercarriages K817, K817R, K817P K841 Amptrol ADAPTER CAbLE K843HI-FREQUENCY KIT K799 Codes 8634 and AbOVE onlyRoutine Maintenance 1MAINTENANCED-1TROUbLESHOOTING Cause Recommended Course of Action PRObLEMSSymptoms POSSIbLEOutput Control Local TROUbLESHOOTING TROUbLESHOOTING Output Voltage Connecting the Remote Control to the MachineFault Protection Operation Power I/0 Switch CheckPower Silicon Controlled Rectifier Test Power Diode TestPower RECTIFIER bRIDGE ASSEMbLY CHECKING PROCEDUREDiagrams Code is pasted inside Number Wiring Diagram for Codes 10859, 10880,11083 Idealarc DC400 Diagram for Code 9847 Wiring Idealarc DC-400Code is pasted inside Number Idealarc DC-400 Idealarc DC-400 Precaucion Warnung
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DC-400 specifications

The Lincoln Electric DC-400 is a versatile and robust DC arc welding power source designed to meet the demands of various industrial applications. Known for its reliability and performance, the DC-400 is ideal for both professional welders and fabrication shops requiring robust equipment that can handle challenging welding tasks.

One of the main features of the DC-400 is its ability to provide a smooth, stable arc, which is essential for achieving high-quality welds. This welding machine is capable of delivering a wide amperage range, typically from 20 to 400 amperes, making it suitable for various welding processes, including MIG, TIG, and Stick welding. The unit's high output capabilities allow it to effectively weld a variety of materials, such as steel, stainless steel, and various alloys.

In terms of technology, the DC-400 integrates advanced power conversion technology that enhances energy efficiency while minimizing heat loss during operation. This not only contributes to lower operating costs but also ensures a longer service life for the machine. The DC-400 features a durable, rugged design, with a robust steel frame that can withstand the rigors of heavy industrial use while providing an IP23 rating for protection against moisture and dust.

Another notable characteristic of the DC-400 is its ease of use. The intuitive controls allow for quick adjustments to settings, enabling welders to easily adapt to different job requirements. The arc characteristics of the DC-400 can be fine-tuned to optimize performance for different welding applications, ensuring consistent results every time.

Moreover, the DC-400 is equipped with built-in safety features such as thermal overload protection, which prevents damage to the machine in case of prolonged operation under heavy loads. This feature enhances the safety of the operator and extends the life of the welding machine.

Overall, the Lincoln Electric DC-400 stands out as a reliable and efficient welding power source. Its combination of high-performance capabilities, advanced technology, and next-level usability makes it a popular choice in the industry. Whether for heavy fabrication, maintenance, or repair work, the DC-400 continues to prove itself as an indispensable tool for professional welders seeking quality and durability in their equipment.