Lincoln Electric IM420-D Machine has maximum output but, Not control, Control, Output, Machine1

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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 maximum output but

1.

Output control switch (SW3) in wrong

1.

Check position of switch.

 

not control.

 

position.

 

 

 

 

2.

Output control switch faulty.

2.

Check switch and replace if faulty.

 

 

3.

Open in feedback circuitry.

3.

Check wiring and control and firing

 

 

 

 

 

circuit P.C. board wiring harness

 

 

 

 

 

plugs.

 

 

4.

Faulty control or firing circuit P.C.

4.

All light emitting diodes must be lit,

 

 

 

boards.

 

except LED4 on the control/fault

 

 

 

 

 

board. See P.C. board troubleshoot-

 

 

 

 

 

ing guide.

 

 

5.

Output control potentiometer circuit

5.

Check and replace potentiometer if

 

 

 

open (Lead 75).

 

faulty. Check wiring of Lead #75.

 

 

 

 

 

 

 

Machine has minimum output and no

1.

Terminals 73, 74, 75, 76 or 77

1.

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

 

control.

 

grounded to positive output.

 

to positive output circuit.

 

Machine does not have maximum

1.

One input fuse blown.

1.

Check and replace if blown after

 

output.

 

 

 

checking for reason for blown fuse.

 

 

2.

One phase of main transformer open.

2.

Check for open and repair.

 

 

3.

Faulty control or firing circuit P.C.

3.

All light emitting diodes must be lit on

 

Machine has output but trips off

 

boards.

 

both P.C. boards, except LED4 on

 

immediately when wire feed unit

 

 

 

control/fault board. See P.C. board

 

start button is pressed.

 

 

 

troubleshooting guide.

 

4.

Output control potentiometer defec-

4.

Check and replace if faulty.

 

 

 

 

 

tive.

 

 

 

 

5.

Output control potentiometer leads

5.

Repair.

 

 

 

open - 76, 77, 226, 236, 237, 238.

 

 

 

 

 

 

 

 

 

Variable or sluggish welding arc.

1.

Machine has either an internal or

1.

Check internally and externally for

 

 

 

external short circuit on the output.

 

any shorts and remove or repair.

 

 

2.

Faulty control P.C. board.

2.

Replace control board. See P.C.

 

 

 

 

 

board troubleshooting guide.

 

 

3.

Terminals 73, 74, 75, 76, 77 ground-

3.

Check for grounded 73, 74, 75, 76,

 

 

 

ed to negative output terminal.

 

77.

 

 

 

 

 

 

 

Machine will not shut off.

1.

Poor work or electrode connection.

1.

Check and clean all connections.

 

 

2.

Welding leads too small.

2.

Check table in instruction manual.

 

 

3.

Welding current or voltage too low.

3.

Check procedures for recommended

 

 

 

 

 

settings.

 

 

4.

Defective main SCR bridge.

4.

Check and replace if defective.

 

 

 

 

 

 

 

Output control not functioning on the

1.

Input contactor contacts frozen.

1.

Check and replace if necessary.

 

machine(1).

2.

Faulty 2CR relay.

2.

Check and replace if necessary.

 

 

 

 

 

 

 

(1)If connected to an LN-9 or NA-5, disconnect leads 73, 74, 75 before troubleshooting.

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

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Contents Idealarc DC-1000 California Proposition 65 Warnings SafetyElectric Shock can kill Welding and Cutting Sparks can Cause fire or explosion Précautions DE Sûreté Thank You Table of Contents Installation Falling Equipment can cause Input WiringLocation StackingReconnect Procedure Installation ELECTRODE, Work and #21 Lead Output ConnectionsTo SET Polarity OperationFumes and Gases can be danger Remote Output Control Optional SET-UP for Various ProceduresNL Option Kit Not Required with NA-3, NA-5, LT-7 or LT-56 General Maintenance MaintenanceOverload Protection HOW to USE Troubleshooting Guide TroubleshootingTroubleshooting Machine has minimum output and no Immediately when wire feed unitMachine has maximum output but Not controlInnershield mode Firing Circuit P.C. Board Board Troubleshooting GuideCONTROL/FAULT Protection P.C. Board Electric Shock can killProcedure for Replacing P.C Boards 6TROUBLESHOOTINGE-673, 74, 75, 76, 77 for Jumper 2-4 but Trips203-204 PossibleM13321 90F to Work DiagramsConnection of DC-1000 with NL Option KIT to LAF-3 Obsolete Connection of DC-1000 to LN-8M13322 90F Connection of DC-1000 or DC-1500 to NA-3, LT-5 or LT-7S15534 90F S16889 90F Connection of DC-1000 to NA-5S17177 90F Connection of DC-1000 to LN-9S17185 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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