Lincoln Electric IM420-D manual Troubleshooting

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TROUBLESHOOTING

E-2

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

Input contactor (1CR) chatters.

1.

Faulty input contactor (1CR).

1.

Repair or replace.

 

 

2.

Low line voltage.

2.

Check input power.

 

 

3.

Faulty 2CR relay.

3.

Repair relay.

 

 

 

 

 

 

Machine input contactor does not oper-

1.

Supply line fuse blown.

1.

Replace if blown - look for reason

ate.

 

 

 

first.

 

 

2.

Contactor power circuit dead.

2.

Check pilot transformer T2 and asso-

 

 

 

 

 

ciated leads.

 

 

3.

Broken power lead.

3.

Check input voltage at contactor.

 

 

4.

Wrong input voltage.

4.

Check voltage against instructions.

 

 

5.

Secondary or choke thermostat open.

5.

Check for overheating; make sure fan

 

 

 

 

 

is operating and there is no obstruc-

 

 

 

 

 

tion to free air flow. Replace faulty

 

 

 

 

 

thermostat.

 

 

6.

Open input contactor coil.

6.

Replace coil.

 

 

7.

Faulty stop/start push button switch.

7.

Replace switch.

 

 

8.

Faulty 2CR relay.

8.

Replace relay.

 

 

9.

Defective control board.

9.

Replace control board. See P.C.

 

 

 

 

 

board troubleshooting guide.

 

 

 

 

 

 

Input contactor pulls in when start button

1.

Defective start/stop push button.

1.

Check and replace if necessary.

is pressed, but immediately drops out.

2.

Defective 1CR interlock.

2.

Repair or replace.

 

 

3.

Ground fault between control termi-

3.

Check 73, 74, 75, 76 or 77 for ground

 

 

 

nals 73, 74, 75, 76 or 77 and nega-

 

to negative output circuit.

 

 

 

tive output terminal.

 

 

 

 

4.

Short on output terminals with 2-4

4.

Remove short.

 

 

 

jumpered.

 

 

 

 

5.

Defective control board.

5.

Replace control board. See P.C.

 

 

 

 

 

board troubleshooting guide.

 

 

 

 

 

Machine input contactor operates but no

1.

Electrode or work lead loose or bro-

1.

Repair connection.

output when trying to weld.

 

ken.

 

 

 

 

2.

Open main transformer (T1) primary

2.

Repair.

 

 

 

or secondary circuit.

 

 

 

 

3.

Output pilot relay 4CR not operating

3.

Check relay pull-in by connecting a

 

 

 

or faulty.

 

jumper across terminals 2 and 4 on

 

 

 

 

 

DC-1000 terminal strip. Replace if

 

 

 

 

 

faulty.

 

 

4.

Firing circuit P.C. board not connect-

4.

All nine light emitting diodes (LED1

 

 

 

ed or is faulty.

 

thru LED9) must be lit. See P.C.

 

 

 

 

 

board troubleshooting guide.

 

 

5.

If using 500 amp stud, choke circuit

5.

Repair.

 

 

 

may be open.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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-1000

Page 17 Page 19
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Page 17 Page 19
Contents Idealarc DC-1000 Safety California Proposition 65 WarningsElectric Shock can kill Welding and Cutting Sparks can Cause fire or explosion Précautions DE Sûreté Thank You Table of Contents Installation Stacking Input WiringLocation Falling Equipment can causeReconnect Procedure Installation Output Connections ELECTRODE, Work and #21 LeadOperation To SET PolarityFumes and Gases can be danger SET-UP for Various Procedures Remote Output Control OptionalNL Option Kit Not Required with NA-3, NA-5, LT-7 or LT-56 Maintenance General MaintenanceOverload Protection Troubleshooting HOW to USE Troubleshooting GuideTroubleshooting Not control Immediately when wire feed unitMachine has maximum output but Machine has minimum output and noInnershield mode Electric Shock can kill Board Troubleshooting GuideCONTROL/FAULT Protection P.C. Board Firing Circuit P.C. Board6TROUBLESHOOTINGE-6 Procedure for Replacing P.C BoardsPossible Jumper 2-4 but Trips203-204 73, 74, 75, 76, 77 forConnection of DC-1000 to LN-8 DiagramsConnection of DC-1000 with NL Option KIT to LAF-3 Obsolete M13321 90F to WorkConnection of DC-1000 or DC-1500 to NA-3, LT-5 or LT-7 M13322 90FS15534 90F Connection of DC-1000 to NA-5 S16889 90FConnection of DC-1000 to LN-9 S17177 90FS17185 90F Diagrams Diagrams Idealarc DC-1000 Idealarc DC-1000 Idealarc DC-1000 Precaucion Warnung

IM420-D specifications

The Lincoln Electric IM420-D is a high-performance industrial welding machine that offers advanced features and technologies tailored for demanding welding environments. Designed for arc welding applications, the IM420-D is a versatile solution suitable for various welding processes, including MIG, TIG, and stick welding. This flexibility makes it an excellent choice for both professional welders and industries that require a reliable and efficient welding system.

One of the standout features of the IM420-D is its impressive output range. With a maximum output of 420 amps, this machine can handle thick materials and deliver deep penetration, making it ideal for heavy-duty applications. The machine also provides consistent arc stability, ensuring high-quality welds with minimal spatter. This functionality is essential in maintaining productivity and reducing the need for post-weld cleanup.

The IM420-D incorporates advanced digital control technology that enhances user experience and precision. The intuitive interface allows operators to quickly adjust settings for voltage, wire feed speed, and other parameters, ensuring optimal performance for diverse welding tasks. Additionally, the machine is equipped with a memory function that saves preferred settings, enabling quick setup for repetitive jobs.

Another notable characteristic of the IM420-D is its robust construction. Built to withstand the rigors of a manufacturing environment, the machine features a durable casing designed to protect key components from dust, moisture, and impact. This reliability results in fewer maintenance issues and extended service life, contributing to lower operational costs over time.

The IM420-D also includes a range of safety features that prioritize operator protection. Overheat protection, voltage fluctuation safeguards, and high-quality electrical insulation ensure a safe working environment, minimizing the risk of accidents during operation.

In conclusion, the Lincoln Electric IM420-D is an exceptional welding machine that combines high output, advanced digital technology, and robust design. With its user-friendly controls and safety features, it meets the needs of professional welders and industries seeking efficiency and quality in their welding operations. Whether for manufacturing, construction, or repair work, the IM420-D stands out as a top-tier choice in the welding equipment market.
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