Lincoln Electric DC-400 manual TROUbLESHOOTING

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E-4

TROUbLESHOOTING

E-4

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

PRObLEMS

(SYMPTOMS)

POSSIbLE

CAUSE

RECOMMENDED

COURSE OF ACTION

Variable or sluggish welding arc.

1.

Poor work or electrode connec-

1.

Check and clean all connections.

 

 

tion.

 

 

 

 

 

2.

Check table in instruction manual.

 

2.

Welding leads too small.

 

 

 

 

 

3.

Check procedures for recom-

 

 

 

 

mended settings.

 

3.

Welding current or voltage too

 

 

 

 

low.

4.

Check and replace if defective.

 

4.

Defective main SCR bridge.

5.

Check and replace if defective.

 

 

 

 

(If S4C or S4D actuator is found

 

5.

Microswitch S4C or S4D actuator

 

defective, replace mode switch

 

 

defective.

 

cam also.)

OUTPUT control not functioning on 1. OUTPUT CONTROL switch in

1.

Place switch in “LOCAL”.

the machine.

wrong position.

 

 

2.

Faulty OUTPUT control switch.

2.

Check and replace if found faulty.

3.

Faulty OUTPUT control poten-

3.

Check and replace if found faulty.

 

tiometer.

 

 

4.

Leads or connections open in

4.

Check lead continuity and con-

 

control circuit.

 

nections for an open and repair if

 

 

 

necessary.

5.

Faulty Control PC Board.

5.

Replace. See Procedure for

 

 

 

Replacing PC Boards.

OUTPUT control not functioning on 1. OUTPUT CONTROL switch in

1.

Place switch in “REMOTE”.

“REMOTE” control.

wrong position.

 

 

2.

Faulty OUTPUT CONTROL

2.

Check and replace if found faulty.

 

switch.

 

 

 

 

3.

Check and replace if found faulty.

3.

Faulty remote control potentiome-

 

 

 

ter.

4.

Check all leads and connections,

 

 

 

internal or remote, for continuity.

4.

Leads or connections open in

 

Repair if necessary.

 

control circuit.

 

 

5.

Faulty Control PC Board.

5.

Replace. See Procedure for

 

 

 

Replacing PC Boards.

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 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 Input Power Connections Safety PrecautionsFALLING EQUIPMENT can cause Correct Operational USEOutput Cable Connections Installation of Field Installed OptionsOutput Cables Remote Output Control K857 or K857-1 with K864 AdapterK870 Amptrol K843 Amptrol Adapter Installation InstructionsConnection of DC-400 to LN-22 or LN-25 Multiprocess Switch Connection and Operation PurposeDesign ConnectionsSTICK, TIG or AIR/CARbON ARC Multiprocess SwitchELECTRIC SHOCK can kill Safety PrecautionsMode Switch Output Terminals Switch Rating PlateVoltmeter Switch ARC Force Control DialRating Plate NEMA EW 1 IEC 60974-1Recommended Processes & Equipment Operational Features & ControlsGeneral Machine Description Duty Cycle and Time Period Power Source Operation and ControlsARC CONTROL SWITCH Effective only in CV FCAW/GMAW mode ARC FORCE CONTROL Dial Effective only in CC modeOUTPUT TERMINALS SWITCH Front View of 14-PIN Connector ReceptacleMachine and Circuit Protection Terminal Strip ConnectionsRemote Control Connections Auxiliary Power ConnectionsCase Features Output ConnectionsMachine & Circuit Protection Thermal Protection Light Field Installed Options Factory Installed OptionsOptional Equipment TIG OptionsHI-FREQUENCY KIT Amptrol ADAPTER CAbLE K843K799 Codes 8634 and AbOVE only Undercarriages K817, K817R, K817P K841Routine Maintenance 1MAINTENANCED-1TROUbLESHOOTING Symptoms PRObLEMSPOSSIbLE Cause Recommended Course of ActionOutput Control Local TROUbLESHOOTING TROUbLESHOOTING Fault Protection Operation Connecting the Remote Control to the MachinePower I/0 Switch Check Output VoltagePower RECTIFIER bRIDGE ASSEMbLY Power Diode TestCHECKING PROCEDURE Power Silicon Controlled Rectifier TestDiagrams Code is pasted inside Number 400 Wiring Diagram for Codes 10859, 10880,11083Idealarc DC 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.