Lincoln Electric DC-400 manual Output Control Local

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E-3

TROUbLESHOOTING

E-3

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

PRObLEMS

(SYMPTOMS)

POSSIbLE

CAUSE

RECOMMENDED

COURSE OF ACTION

Machine has high output or pulsing

1.

Terminals 75, 76, or 77 grounded

1.

Check 75, 76, or 77 for ground to

output and no control.

 

to negative output.

 

negative output circuit. Nearly

 

 

 

 

zero ohms to ground indicates a

 

 

 

 

grounded circuit. A value greater

 

 

 

 

than a few thousand ohms is nor-

 

 

 

 

mal. Self-restoring fuses on PC

 

 

 

 

Board automatically reset within a

 

 

 

 

few seconds after ground is

 

 

 

 

cleared.

 

 

 

 

Machine has low output and no

1. OUTPUT CONTROL “LOCAL-

1.

Check position of switch.

control.

 

REMOTE” switch (S2) in wrong

 

 

 

 

position.

 

 

 

2.

OUTPUT CONTROL switch

2.

Check switch & replace if faulty.

 

 

faulty.

 

 

 

3.

Open in feedback circuitry.

3.

Check wiring and control PC

 

 

 

 

Board wiring harness plugs.

 

4.

Faulty Control PC Board.

4.

Replace. See Procedure for

 

 

 

 

Replacing PC Boards.

 

5.

OUTPUT control potentiometer

5.

Check and replace potentiometer

 

 

circuit open (lead 75).

 

if faulty. Check wiring of lead

 

 

 

 

#75.

 

 

 

 

 

Machine does not have maximum

1.

One input fuse blows.

1.

Check and replace if blown after

output.

 

 

 

checking for reason for blown

 

 

 

 

fuse.

 

2.

One phase of main transformer

2.

Check for open and repair.

 

 

open.

 

 

 

3.

Faulty Control PC Board.

3.

Replace. See Procedure for

 

 

 

 

Replacing PC Boards.

 

4.

OUTPUT control potentiometer.

4.

Check and Replace if faulty.

 

5.

OUTPUT control potentiometer

5.

Check and repair broken leads.

 

 

leads 210, 211 or 75 open.

 

 

 

 

 

 

 

Machine will not shut off.

1.

Input contactor contacts frozen.

1.

Check and replace if necessary.

 

2.

Defective POWER “1/0” switch,

2.

Replace.

 

 

(S1).

 

 

 

 

 

 

 

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

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Contents Safety Depends on You Idealarc DC-400Safety Electric Shock can kill Welding and Cutting Sparks can Cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcPlease Examine Carton and Equipment For Damage Immediately On-Line Product RegistrationTAbLE of Contents Technical Specifications DC-400 Safety Precautions Input Power ConnectionsFALLING EQUIPMENT can cause Correct Operational USEInstallation of Field Installed Options Output Cable ConnectionsOutput Cables Remote Output Control K857 or K857-1 with K864 AdapterK843 Amptrol Adapter Installation Instructions K870 AmptrolMultiprocess Switch Connection and Operation Purpose Connection of DC-400 to LN-22 or LN-25Design ConnectionsMultiprocess Switch STICK, TIG or AIR/CARbON ARCSafety Precautions ELECTRIC SHOCK can killOutput Terminals Switch Rating Plate Mode SwitchVoltmeter Switch ARC Force Control DialNEMA EW 1 IEC 60974-1 Rating PlateGeneral Machine Description Operational Features & ControlsRecommended Processes & Equipment Power Source Operation and Controls Duty Cycle and Time PeriodARC FORCE CONTROL Dial Effective only in CC mode ARC CONTROL SWITCH Effective only in CV FCAW/GMAW modeOUTPUT TERMINALS SWITCH Front View of 14-PIN Connector ReceptacleTerminal Strip Connections Machine and Circuit ProtectionAuxiliary Power Connections Remote Control ConnectionsCase Features Output ConnectionsMachine & Circuit Protection Thermal Protection Light Factory Installed Options Field Installed OptionsOptional Equipment TIG OptionsAmptrol ADAPTER CAbLE K843 HI-FREQUENCY KITK799 Codes 8634 and AbOVE only Undercarriages K817, K817R, K817P K8411MAINTENANCED-1 Routine MaintenanceTROUbLESHOOTING PRObLEMS SymptomsPOSSIbLE Cause Recommended Course of ActionOutput Control Local TROUbLESHOOTING TROUbLESHOOTING Connecting the Remote Control to the Machine Fault Protection OperationPower I/0 Switch Check Output VoltagePower Diode Test Power RECTIFIER bRIDGE ASSEMbLYCHECKING PROCEDURE Power Silicon Controlled Rectifier TestDiagrams Code is pasted inside Number Idealarc DC Wiring Diagram for Codes 10859, 10880,11083400 Wiring Idealarc DC-400 Diagram for Code 9847Code 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.