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Lincoln Electric IDEALARC DC-400 User's Manual

1. 548 ELM eG oc Lo 600 V INSULATION F 216 21 219 yne T ro o 217 S4D 224 NO ACTUATED 0 23 CV ECAWIGMAW im 219 ONLY st 218 21 No s o 9 214 ACTUATED VOLTMETER 55 228204 SWITCH OUTPUT CONTROL C6 0047MFD 1400V SWITCH X ZEN 7 It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the If the diagram is illegible write to the Service Department for a replacement Give the equipment code number CIRCUITRY PRESENT ON 204 208 209 do DIODE OPTION i 7 211 R5 Ra oy 10K 2W 10K N 2W ARC FORCE CONTROL OUTPUT CONTROL Screen GROUNDING D i 8 MULTLPROCESS OUTPUT 4 TERMINALS L ELECTRODE SWITCH 42 vy TO TERM TONEG TO POS STRIP TERM TERM L11460 This diagram is for reference only machine on one of the enclosure panels NOTE IDEALARC DC 400 LINCOLN 5 Fo DIAGRAMS m WIRING DIAGRAM FOR CODES 11277 11278 AND 11279 11348 11352 11353 11567 TT NET so EN EM Z2098040 VOLTAGE SHOWN CONNECTED FOR ELECTRICAL CODE SHOWN CONNECTED ELECTRICAL cope SHOWN CONNECTED ELECTRICAL
2. 16 T1 MAIN TRANSFORMER X1 SEC 0 5 0 50W R7 Rare OPTION RECTIFIER 204 ASSEMBLY 31 000 MFD 50V EACH REED WITCH SHUNT 5 S CR3 SS re o 204 205 206 11 pw 216 R3 M 215 SNUBBER amp 204 7 5 1 100W BOARD 264 lie N 50W 225 PA LEAD NOT PRESENT WITH ei 232 DIODE OPTION 203 3 PILOT LIGHT ELECTRICAL SYMBOLS PER 204 4 lt E1537 2256 lt 5 233 220 6 1 KARE Um 5 a 4 k8 3 42 31 7 4 POWER 4 2l 84 105 2 9 Wy SWITCH Y 10 240 6PIN 10PIN 12PIN THERMAL 231 J3 J6 J5 J1 J2 PROTECTION LIGHT CONNECTOR CAVITY CONTROL BOARD i NUMBERING SEQUENCE MODE SWITCH 25 s zz 225 COMPONENT SIDE OF P C FRONT GANG 206 BOARD CV FCAW GMAW e 205 oCV SUB ARC STARTING 206 NOTES ARC CONTROL BOARD METERS N A CIRCUITRY PRESENT ON L1 SWITCH CAPACITOR DISCHARGE OUTPUT S5 ONLY CV FCAW GMAW CHOKE MIN IND 5 J6 if na B TAPE UP SEPARATELY p GV SUB ARC 15 f1 100W 234 TO PROVIDE AT LEAST 3
3. eu AINO wi lO S92Jnos JAMO B OWAS JIM 014 pue 01 082 1 10 2 092 28 0 seuosseooe 6629 w 03H4 1H pue 9277 078M JO 2187 2967 w lOH LdlAV 1 0 pesn s SIUL NOILVTIVLSNI 140414 330 ADYNOS YAMOd AHL NYNL ONINHVM Sseo nos 041UOO YIM Old pue 01 052 1emoduepje JO YEY 0SZ 2d asn 104 SNOILONULSNI NOILVTIVLSNI H3 LdVQV wi 10HLdNV v85 me INSTALLATION Aro INSTALLATION OF EQUIPMENT REQUIRED FOR RECOMMENDED PROCESSES WIRE FEEDER CONTROL CABLE CONNECTIONS For control cable with 14 pin connector Connect control cable to 14 pin connector on the front panel of the machine See the appropriate connection diagram for the exact instructions for the wire feeder being used Refer to Section 2 4 1 for connector pin functions For control cable with terminal strip connectors The control cable from the wire feeding equipment is connected to the terminal strips behind the control panel A strain relief box connector is provided for access into the terminal strip section A chassis ground screw is also provided below the terminal strip marked with the symbol for connecting the auto matic equipment grounding wire See the appropriate connection diagram for the exact instructions for the wire feeder being used
4. EYR ea ETSAI BICI x ale Saal a lal il gl easly ud al gll qall gal aq l il LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
5. Section C TIG Welding Options Accessories kk KEK Ak KK ne C 1 Optional Equipment ins C 1 thru C 2 Maintenance 52 AERAR Section D Safety Pr cautions oda naz n daba Leading aud D 1 ierusalem D D 1 Troubleshooting D Section E Safety Precaution 8 Gaeta tenes deeded a nue E 1 How to Use Troubleshooting QGuU de E kk kk ek kk kek kk K k kK E 1 Troubleshooting Guide 2 eicit kara al k d n ka ak din E 2 thru E 5 Procedure for Replacing P C Boards E 6 E 7 Wiring Diagfatms 2 ccce ocio crece reina A e aa k We k ark RRA kir e a ak ka cree kak Section F Parts Pages P 234 P 239 LINCOLN M B INSTALLATION TECHNICAL SPECIFICATIONS DC 400 INPUT THREE PHASE ONLY Standard Input Current at Rated Output CVI Voltage Frequency 100 Duty Cycle 60 Duty Cycle 50 Duty Cycle 400Amps 36V 450Amps 38V 500Amps 40V 230 460 575V 60Hz 78 39 31 Amps 83 41 33Amps 84 42 34Amps 400Amps 36V 450Amps 38V 500Amps 40V 220 230 380 400 415 440V 50 60Hz 81 77 47 45 43 41Amps 85 81 49 47 45 42Amps 86 82 50 48 46 43Amps RATED OUTPUT DuyCyden Amps VoltsatRatedAmps 400 36 38 40 OUTPUT OUTPUT MAXIMUM OPEN CIRCUIT VOLTAGE AUXILIARY POWER Min 60A 12V CV 22V CC 57V
6. REED SHUNT SWITCH CR3 N um SNUBBER BOARD 205 206 204 204 31 000MFD 50V EACH 75 Tao oi 225 v LIGHT 42 Wi THERMAL PROTECTION 29 MODE SWITCH FRONT GANG CV FCAW GMAW CV SUB ARC S4A L1 OUTP CV FCAW GMAW UT CHOKE CONTROL BOARD Pa 134 209 2 214 8 217 471 204 4 gt 51 206 6 gt 206 7 1 208 8 gt 213 92 75 910 212 1 1 205 12 1 205 ARC CONTROL STARTING SWITCH BOARD S5 MIN IND 5 J6 METERS CV SUB ARC S4B 15N 100W 1 MAX IND 234 poc Rt 216 aD 219 ne o 217 2 234A EO ie fes r nc sta 218 21 7 4D 224 TUATED et No 0 214 204 1 228 TUATED CC ONLY LUY Ho V FCAW GMAW 4 r 2A 204 208 209 225 R5 10K 2W ARC FORCE CONTROL 10A CIRCUIT s 56 VOLTMETER SWITCH BREAKER 6 0047MFD 1400V 7 75 t 211 Ra 10K A 2W OUTPUT CONTROL R
7. SHOWN CONNECTED N B e H3 TO S pe RECONNECT PANEL H2 L3 L2 L1 AP TO GROUND PER NATIONAL ELECTRICAL CODE S H2 xr peu Li RECONNECT PANEL TO SUPALY C 220 380 440 VOLTAGE SHOWN CONNECTED FOR 220 V TO GROUND 6 PER NATIONAL o w a CR1 N CONTACTOR 233 Hi 2A CIRCUIT Le ELECTRICAL 3 2 Q vod 1 vot CR1 CONTACTOR 233 TO PRIMARY COILS FAN MOTOR 115V 5 CODE FLEX LEAD JUMPER TO PRIMARY COILS BREAKE 50 SS 10AMP Ho Ho CR1 CONTACTOR 233 H TOP PRIMARY E AUXILIARY COILS BOTTOM 4 PRIMARY 10 5 amp m 7 CIRCUIT 42 BREAKER 3 241 2 SECONDAR PRIMARY THERMOSTAT THERMOSTAT 41 41 doi 21V A CONNECT OR INSULATE AS SHOWN ON INPUT CONNECTION DIAGRAM H H8o H4o Col x2 231 T2 CONTROL TRANSFORMER 204 CAPACITOR IT T RECTIFIER ASSEMBLY DISCHARGE 1 MAIN OPTION RANSFORMER ern Jl teza ll CAPACITOR DISCHARGE RELAY sakal DIODE OPTION M
8. H4 __ _ suPPLY LINES TO GROUND PER NATIONAL ELECTRICAL CODE CONNECT OR INSULATE AS T AUXIL TARY COILS SHOWN ON D T2 INPUT H2 CONNECTION j HSV CONTROL DIAGRAM H3o 3 4 lt x2 SECONDARY PRIMARY TOP PRIMARY THERMOSTATS 41 Al BOTTOM PRIMARY iT MAIN TRANSFORMER 0 5 2 50W 0 5 N 50W i RECTIFIER ASSEMBLY 31 000 MFD 50V EACH SNUBBER BOARD PRU 201 1 lt 2021024 20 204 1544 225 1 54 220 L 6 41 674 4 8 12 2 k 9 X9 240 40 THERMAL PROTECTION EIGHT CONTROL BOARD MODE SWITCH FRONT GANG CV FCAW GMAW of EV SUB ARC CONTROL SWITCH 55 MIN IND 5 225 LEAD NOT PRESENT WITH DIODE OPTION 3 gt 2I1T ELECTRICAL SYMBOLS PER 4 204 5 gt 7206 6 gt 206 7 H208 8215 sald 9715 4 PIN 6 PIN 8 PIN 10 PIN 12 PIN 10 gt 4 212 Je 5 J2 CONNECTOR CAVITY NUMBERING SEQUENCE COMPONENT SIDE OF P C BOARD NOTES N A CIRCUITRY PRESENT ON CAPACITOR DISCHARGE ONLY 232 PILOT o LIGHT 1 EU Pe STARTING 31 1 4 e BOARD N B UP SEPARATELY TO PROVIDE AT LEAST 600 V INSULATION 2 15 N 100W 234 LS ES 216 j et 19 f Ns 204 268 269 ara 10A 10K 2W CIRCUIT j BREAKER PR se ARC FORCE CONTROL VOLTMETER I
9. A five wire cable 12 30m long used for easy connection of standard K963 Hand Amptrol or K870 Foot amptrol The cable has a 6 pin MS style connector which connects to the Amptrol and termi nals which connect to 75 76 and 77 on the machine terminal strip and to the case grounding screw the Amptrol will control the same range of output as the current control on the welder if a smaller range of control is desired for finer adjustment a K775 Remote may be used in conjunction with the Amptrol Adapter Cable Kit The Amptrol arc start switch is nonfunc tional unless used with a K799 Hi Frequency Kit See Amptrol Adapter installation Instructions on next page IDEALARC DC 400 LINCOLN A 4 pue uonoeuuoo v Sls 8JIUM Pes 9 IUM pue 0 peal yoe q pue HOLIMS 1 5 330 LNO 667 v 83 LU e 66 M ejs 3ounos X as o H3MOd y be4 IH 667M SU Aq 198 e eoinos amod eui JO EU WO jueJno eu DIL 40 Buruejs pue seb uo wi b9JJ IH eu YAMS eu p TOYLNOD 5 LM w 0344 1H w1104LdINV gt wi 0289 10 218 2967 lt 1 eJOWSH
10. CONTACTOR AUXILIARY 202 203 m 1v 21V CAPACITOR s CAPACITOR DISCHARGE S DISCHARGE 233 H COILS THESE CONNECTIONS APPEAR T1 MAIN OPTION ONLY ON 380 500V AND 415V TRANSFORMER Ka MACHINES 1 PRIMARY bas 0 5 50W OPTION uS do 254 204 41 0 5 N 50W P5 ji 1 220 gt 2 gt 221 D2 3 gt 222 42 223 REED i SWITCH 95 gt 5 gt 225 E sora SHUNT CR 6 224 v M Z 35 GREEN L e Le e 204 E m 205 206 z 75 fi A00W SNUBBER 204 BOARD LL 204 R2 40 225 He 225 1 gt 209 LEAD NOT PRESENT WITH 2 214 232 DIODE OPTION 83 gt 2174 v PILOT 4 4 204 LIGHT ELECTRICAL SYMBOLS PER E1537 5 gt 7 206 fe 233 THERMAL 6 gt 206 233 PROTECTION 72 208 4 EO JE POWER 4 5 1 9 gt 75 SWITCH 31 2 10 gt 212 4 2 6 3 8 4 905 4 MODE SWITCH KO 205 6PIN 8PIN 10PIN 12PIN FRONT GANG CONTROL BOARD 12 gt 4 205 CV FCAW GMAW J3 J6 J5 J1 J2 0 ARC M U Pe STARTING CONNECTOR CAVITY NUMBER SEQUENCE ARC CONTROL TARTINI SN Li SWITCH COMPONENT SIDE OF P C BOARD OUTPU
11. l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur LINCOLN 5 place V V for selecting a QUALITY product by Lincoln Electric We want you OU to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our pos
12. s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 RUBUS PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER l a TRANSFORMATEUR ET a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage
13. 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be cert
14. 5277 lt o KI lt Sls O peel pue 0 peel xoe q 199uuo9 pue HOLIMS LHVLS 430 1N9 gjqeo yeys 0 89 10 UM wibeJ4 IH 18 jounos 667 2187 2967 Edi eoJnos JeMod y eBuei nj eui u amp nouu 1ueuno s onuoo OJ1duuv y 911 OG 10 pue seb uo 1 ni D914 IH OY HVIS IIM w 04 duJ y wu O3Hd IH UMOUS S S eM uaip 1 pejoeuuoo pue eq seuosseooy juaJno 01 UO9 O 0J1dul y JO 4 910U184 ISNUW YO UMS eoJnos eu pue pesn jou spee SYM edej pue eye nsu uonoeuuoo jnu pue jog 04100 9joul8H 9277 3ounos w lon dui 078 Ed JO 18M 96M 01U09 30w31 eu 195 e 0 Jewod eu JO eui jueuno SepiAOJd eu TOYULNOD LIINF13 LOIN3H SfYld L Sid pue ede pesn jou Speo pue Om E BS 2 7 Jede 99Jnos JOMOd eys w lO Hduuy 079M JO 2187 96M ELECTRIC Jjounos H3MOd 62Jnos eu JO jin yno 101U09 JUSIIND
15. 77 for ground to 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 LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Machine has high output or pulsing 1 Terminals 75 76 or 77 grounded 1 output and no control Machine has low output and no control Machine does not have maximum output Machine will not shut off to negative output OUTPUT CONTROL LOCAL REMOTE switch S2 in wrong position OUTPUT CONTROL switch faulty Open in feedback circuitry Faulty Control PC Board OUTPUT control potentiometer circuit open lead 75 One input fuse blows One phase of main transformer open Faulty Control PC Board OUTPUT control potentiometer OUTPUT control potentiometer leads 210 211 or 75 open Input contactor contacts frozen Defective POWER 1 0 switch S1 Check 75 76 or 77 for ground to negative output circuit Nearly zero o
16. LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piracion Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaustao para remover fumo da zona respirat ria etai ADP53AmtRE 207 METE Ze OF OR Ez fE JL Ek HEEL SR ER TR S e SWA e s amp xiossH 247 8 HS THARA MESHA u U iua dul aay e js bia ja 4 92 e Les galt All oe oaa us Turn power off before servicing Desconectar el ca
17. a K963 Hand Amptrol or a K870 Foot Amptrol 6 pin connector and the machine The cable going to the machine has a 6 pin connector which requires a K864 adapter to connect with the 14 pin connector on the DC 400 Refer to 520909 instructions for connection information MULTIPROCESS SWITCH K804 1 Kit that mounts on the front of the DC 400 and includes hinged covers over its output studs The switch has three positions Positive semiautomatic automatic negative semiautomatic automatic and stick air carbon arc Required when using the DC 400 for both semiautomatic automatic and stick air carbon arc Install per M17137 instructions included with the field installed kit CAPACITOR DISCHARGE CIRCUIT K828 1 Circuit that mounts inside the DC 400 Recommended when 1 DC 400 is used in conjunction with any LN 23P or older LN 8 or LN 9 semiautomatic wire feeder Eliminates possible arc flash re start of weld when trigger interlock is used Not required with current LN 8 above Code 8700 or LN 9 s with serial num bers above 115187 manufactured after 12 83 or any LN 9 having an L6043 1 Power PC Board 2 DC 400 is used with an LN 22 equipped with an older K279 Contactor Voltage Control Option Eliminates electrode overrun when gun trigger is released Not required when later K279 above Code 8800 is used 3 DC 400 is used with any semiautomatic wire feeder and possible small spark if electrode touches work just after gun
18. avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign
19. factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility A WARNING e ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts 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
20. feeder the OUTPUT CONTROL switch must be in the REMOTE position or automatic shut down of the LN 9 or NA 5 may occur POLARITY SELECTION Polarity selection is made by appropriately connecting the electrode and work welding cables to either the stud or to the stud Select VOLTMETER Go switch for or electrode for the remote 21 work sensing lead VOLTMETER SWITCH Select for positive electrode or for negative electrode polarity for the remote 721 work sensing lead of automatic or semiautomatic equipment THERMAL PROTECTION LIGHT The amber thermal protection light will be lit if either of the two protective thermostats have opened The out put power will be disabled but input power will still be applied to the welder Refer to Machine and Circuit Protection section MODE SWITCH The large MODE SWITCH on the left side of the machine labeled Constant Voltage Submerged Arc Constant Voltage FCAW GMAW and Constant Current Stick TIG is used to select the proper welder characteristics for the process being used The CV FCAW GMAW Mode permits the DC 400 to produce essentially a flat output characteristic that can be varied from approx 12 to 42 volts IDEALARC DC 400 LINCOLN hi OPERATION In this position the dynamic characteristics of the machine under welding conditions provide optimum welding characteristics for Innershield weldi
21. trigger is released is objectionable Install per M17060 instructions included with the Kit UNDERCARRIAGES K817 K817R K841 For easy moving of the machine optional undercar riages are available with either steel K817 or rubber tired K817R wheels or a platform undercarriage K841 with mountings for two gas cylinder at rear of welder Install per instructions provided with trailer OPTIONAL EQUIPMENT Factory Installed Options DIODE OPTION This internally installed option allows the use of the cold start and cold electrode sensing features of the NA 3 NA 5 or NA 5R MULTIPROCESS SWITCH Factory or field installed kit that mounts on the front of the DC 400 and includes hinged covers over its out put studs The switch has three positions Positive semiautomatic automatic negative semiautomatic automatic and stick air carbon arc Required when using the DC 400 for both semiautomatic automatic and stick air carbon arc The field installed kit equiva lent is identified as K804 1 For details on the Multiprocess Switch see the Installation of Equipment section Field Installed Options REMOTE OUTPUT CONTROL K857 WITH K864 ADAPTER OR 775 The K857 has a 6 pin MS style connector The K857 requires a K864 adapter cable which connects to the 14 pin connector on the machine An optional remote output control is available This is the same remote control that is used on the Lincoln and DC 60
22. 0 200 ft 46 61 m 200 250 ft 67 76 m Remote Output Control K857 or K857 1 with K864 Adapter An optional remote out control is available The K857 or K857 1 are the same remote control options that are used on other Lincoln power sources The K857 or K857 1 consist of a control box with 25 feet 7 6 meters or 100 feet 30 3 meters The K857 and K857 1 have a 6 pin connector and K857 require a K864 adapter cable which connects to the 14 pin connector on the case front INSTALLATION STRAIGHT PLUG 14 PIN TO POWER SOURCE A 3 REMOTE CONTROL ADAPTER CABLE K864 CABLE RECEPTACLE 6 SOCKET TO 1 K857 REMOTE CONTROL Sat B 2 K963 HAND AMPTROL i E 3 K870 FOOT AMPTROL dii A V cable 12 30m long to connect a K857 Remote Control 6 pin connector with a wire feeder 14 pin connector and the machine 14 pin connec tor If a remote control is used alone the wire feeder connection is then not used A WARNING ELECTRIC SHOCK can kill Turn the power switch of the an welding power source OFF before installing plugs on cables or when connecting or disconnecting plugs to weld ing power source DEG Din Qi 000 CABLE RECEPTACLE 14 SOCKET TO LN 7 WIRE FEEDER AMPTROL ADAPTER CABLE 843
23. 0 power sources K775 The K775 consists of a control box with 28 ft 8 5m of four con ductor cable This connects to terminals 75 76 and 77 on the terminal strip and the case grounding screw so marked with the symbol onthe machine These terminals are located behind the control panel on the front of the power source This control will give the same control as the output control on the machine IDEALARC DC 400 LINCOLN C 2 AMPTROL ADAPTER CABLE K843 A five wire cable 12 30m long is available for easy connection of standard K963 Hand Amptrol or K870 Foot Amptrol The cable has a 6 pin MS style connec tor which connects to the Amptrol and terminals which connect to 75 76 and 77 on the machine terminal strip and to the case grounding screw The Amptrol will control the same range of output as the current control on the welder If a smaller range of control is desired for finer adjustment aK775 Remote may be used in conjunction with the Amptrol Adapter Cable Kit Connection information is included with the Amptrol Adapter Cable Kit The Amptrol arc start switch is nonfunctional in this application REMOTE CONTROL ADAPTER CABLE K864 STRAIGHT PLUG 14 PIN TO POWER SOURCE E 25 LN 7 WIRE FEEDER A V cable 12 30m long to connect a K857 Remote Control K963 Hand Amptrol or K870 Foot Amptrol 6 pin connector with a wire feeder 14 pin connector and the machine 14 pin connector
24. A cover Lincoln Electric Part Number S17062 3 is available for the unused 14 pin connector to protect it against dirt and moisture See Terminal Strip Connections section for access to the terminal strips CONNECTION OF DC 400 TO LN 22 OR LN 25 a Turn off all power b Place output terminals switch into the ON posi tion c Connect the electrode cable to the output terminal of polarity required by electrode Connect the work lead to the other terminal d Place the OUTPUT CONTROL Switch at LOCAL position unless a Remote Control is connected to the DC 400 e Place MODE SWITCH in CONSTANT VOLTAGE FCAW GMAW NOTE The output terminals are energized at all times MULTIPROCESS SWITCH CONNECTION AND OPERATION PURPOSE A Multiprocess Switch has been designed for use with the DC 400 or DC 600 With this switch installed on the DC 400 it permits easy changing of the polarity of the wire feed unit connected and also provides sepa rate terminals for connection of stick or air carbon arc The Multiprocess Switch is available as either a facto ry installed or field installed option NOTE IF THE DC 400 IS TO BE USED FOR BOTH SEMIAUTOMATIC AUTOMATIC AND STICK AIR CARBON ARC THEN A MULTI PROCESS SWITCH IS REQUIRED DESIGN The Multiprocess Switch consists of a 3 position switch assembly that is mounted in a sheet metal enclosure that has two output terminals on each end of the box The two terminals on the
25. C Board Install a new PC Board only after a visual inspection of the PC Board and machine wiring is satisfactory 2 If the problem is remedied by a new PC Board install the old PC Board and see if the problem still exists If the problem does not return with the old board a Check the PC Board harness plug and PC Board plug for contamination corrosion or oversize b Check leads in the harness for loose connections CONNECTING THE REMOTE CONTROL TO THE MACHINE Extreme caution must be observed when installing or extending the wiring of a remote control Improper connec tion of this unit can lead to failure of the output control rheo stat or the control circuit Only the green lead can and should be grounded to the machine case When extending the standard remote control make sure the leads are the same and the splice is waterproof Be very careful not to ground the cable when in use and don t let the lugs touch against the case OUTPUT VOLTAGE The output circuit voltage of the machine should be adjustable from 10 to 46 volts in CV In the CC mode the open circuit voltage should be approximately 57 volts 54 volts on 50 60 Hz except at near minimum settings of the output control where it may be lower If any other condition exists refer to the Troubleshooting Guide FAULT PROTECTION OPERATION The overload protection circuit in the Control PC Board will limit the welding current heat to 550 amps if a short or overload i
26. CC 45 5V CVI 60Hz 115 VAC 15 AMPS Max 500A 42V CC CV 54V CC 45 5V CVI 50 60 Hz 42 VAC 10 AMPS RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT IN ADDITION FOLLOW LATEST NATIONAL ELECTRICAL CODE AND LOCAL CODE INPUT INPUT AMPERE TYPE 75 C TYPE 75 C BUSSMANN SUPER LAG VOLTAGE RATING ON COPPER WIRE IN GROUND WIRE IN FUSE SIZE AND FREQUENCY NAMEPLATE CONDUIT AWG CONDUIT AWG CATALOG NUMBER 100 IEC SIZES mm IEC SIZES mm Duty Cycle 40 C 104 F FUSE SIZE CATALOG NUMBER 230 60Hz 78 3 25 6 16 100 REN 100 460 60Hz 39 8 10 10 6 50 RES 50 575 60Hz 31 10 6 10 6 40 RES 40 220 50 60Hz 230 50 60Hz 380 50 60Hz 400 50 60Hz 415 50 60Hz 440 50 60Hz PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 27 50 in 22 25 in 32 0 in 473 lbs 699 mm 565 mm 988 mm 215 kg TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 22 F to 104 F 30 C 40 C 40 F to 140 F 40 C 60 C 1 Based upon 10 minute time period i e for 60 duty cycle it is 6 minutes on an 4 minutes off Use only Bussmann Super Lag fuses specified Other fuses may not protect the welder and may cause overheating and possible fire damage Insulation class 155 F IDEALARC DC 400 LINCOLN A 2 SAFETY PRECAUTIONS A WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insul
27. CODE a SHOWN CONNECTED FOR 220 V LOW VOLTAGE 5 FOR 230 V FOR 380 V E N B e io suppLy N B9 HS3 TO SUPPLY LINES LINES RECONNECT PANEL N B H3 TO SUPPLY TO SUPPLY A LINES LINES H2 RECONNECT PANEL RECONNECT PANEL RECONSECDEANEE H2 H2 r C xi le LIN 1 fs Tum xi Lal L He TO GROUND j E 3121 5 r xt 1802 PER NATIONAL 11 3 113 918 9 5 yo ELECTRICAL 2 CODE o FH o o o 555 8 4 232 Q eae 2 17 n 3 U CRI 4 PASE 12 CRI 1 16 CONTACTOR 74 CONTACTOR ANA NUES rad el 33 CRI T gt FLEX ean PRIMARY CONTACTOR JUMPER 233 H1 R qo primary COLS 7 coins H1 A TO PRIMARY COILS SINGLE VOLTAGE OVER FAN MOTOR 345 VOLTS 3 5A 115V 232 TO GROUND PER CIRCUIT 32A 1 NATIONAL ELECTRICAL CODE amp BREAKE 31 CONNECT OR N B e H2 Inggretv THIS CONNECTION SHOWN ON L NJ 10AMP INSULATE AS CIRCUIT 42 SHOWI H 115V BREAKER CONNECTION 1 Ec im ou DIAGRAM Ho een SECONDAR PRIMARY T2 CONTROL 2 THERMOSTAT THERMOSTAT TRANSFORMER 41 DOES NOT APPEAR ON H3 Am 220 380 440V AND 13 L2 L1 230 400V MACHINES 3 A m 3 we ro 10 V Ho TOP t 5V 232 U 4 PRIMARY i 2 7 9 5
28. D AUSTRALIAN 22 e WORK WELDERS ONLY NK FOR AUSTRALIAN WELDERS 32 LEAD L ELECTRODE F FROM 14 PIN RECEPTACLE IS SHIPPED CONNECTED TO UNUSED TERMINAL 4 2 QO ON TS2 INSTEAD OF THE 32 TERMINAL TO TERM TO NEG TO POS STRIP TERM TERM BOX COVER TERMINAL STRIP BASE LIFT z CONTROL BACKET BALE L L12722 IDEALARC DC 400 LINCOLN It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the If the diagram is illegible write to the Service Department for a replacement Give the equipment code number This diagram is for reference only machine on one of the enclosure panels NOTE NOTES IDEALARC DC 400 LINCOLN NOTES IDEALARC DC 400 LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Nelaissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension solez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mi
29. IM474 E IDEALARL DC 400 panan aon For use with machines having Code Numbers 9847 thru 9852 9854 9855 9857 10008 10275 10276 10859 10880 11083 11084 11277 11278 11279 11348 11349 11350 11351 11352 11353 11567 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation EE anys and thoughtful operation on 5 AE NN NS your part DO NOT INSTALL N KW OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful E OPERATOR S MANUAL a ee SSS ISO 9001 Pam S t3 nam N i EE XV Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 Copyright O Lincoln Global Inc LINCOLN amp World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductiv
30. INCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Poor arc striking with semiautomatic 1 Defective start circuit or automatic wire feeders Poor arc characteristics Poor work connection Improper procedures Defective Control PC Board Start circuit energized at all times read switch CR3 not closing Defective Start PC Board Defective Control PC Board Capacitor s in output circuit failed A failure is indicated if the small vent plug on top of a capac Check Start PC Board and reed switch CR3 Work connection must be ade quate for application Adjust procedures for improved starting Replace See Procedure for Replacing PC Boards Short reed switch CR3 leads together If welding improves replace reed switch If problem is still present with reed switch shorted unplug Start PC Board If problem disap pears replace Start PC Board Replace See Procedure for Replacing PC Boards Replace entire bank of capaci tors Do not replace individual capacitors itor is raised or blown out WARNING The liquid electrolyte in these capacitors is toxic Avoid contact with any portion of your body Clean up vented electrolyte using rubber gloves and a water damped cloth Any electrolyte which gets on skin clean with soap and water ARC CONTROL has no effect in CV FCAW GMAW mode with short cir cuit tr
31. If a remote control or amptrol is used alone the wire feed er connection is then not used Din i S CABLE RECEPTACLE 6 SOCKET 2 K963 HAND AMPTROL 3 K870 FOOT AMPTROL 000 Dal WE MULTIPROCESS SWITCH K804 1 Field installed kit that mounts on the front of the DC 400 and includes hinged covers over its output studs The switch has three positions Positive semiautomat ic automatic negative semiautomatic automatic and stick air carbon arc Required when using the DC 400 for both semiautomatic automatic and stick air carbon arc The field installed kit is equivalent to the factory installed option For details on the Multiprocess Switch see the section for Installation of Equipment Required for Recommended Processes HI FREQUENCY KIT K799 CODES 8634 AND ABOVE ONLY Kit supplies the high frequency plus gas valve for DC TIG welding The DC 400 is shipped with proper R F bypass circuitry installed to protect the control circuit when welding with a HI FREQ unit K844 Water Valve Option Kit can be used with K799 when TIG welding with water cooled torches UNDERCARRIAGES K817 K817R K817P K841 ACCESSORIES TO 1 K857 REMOTE CONTROL CABLE RECEPTACLE 14 SOCKET C 2 For easy moving of the machine optional undercar riages are available with
32. N 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 LINCOLN F 1 DIAGRAMS F 1 POWER RECTIFIER BRIDGE DIAGRAM 1 PLUG TO SNUBBER BOARD 220 P5 C 220 223 204 221 X4 222 X2 X3 side of capacitor bank CATHODE D4 ANODE VV a SHUNT 204 204 To G1 G2 G3 204 SE 204 Gate leads plug to control P C board To plug P1 To T1 main transformer IDEALARC DC 400 LINCOLN F 2 DUAL amp SINGLE VOLTAGE UNDER 346 VOLTS SHOWN CONNECTED FOR LOW VOLTAGE N B TO SUPPLY TO GI ROUND PER NATIONAL ELECTRICAL CODE RECONNECT PANEL 230 400 VOLTAGE SHOWN CONNECTED FOR 230 V N B9 H3 syppLY H2 H2 LINES e we 3 2 1 CR1 CONTACTOR TO PRIMARY SINGLE VOLTAGE OVER 345 VOLTS TO GROUND PER NATIONAL ELECTRICAL CODE N B e H2 suPPLY H3 LINES 1 EA THIS CONNECTION DOES NOT APPEAR ON 220 380 440V AND 230 400V MACHINES L2 L1 li TO GROUND PER NATIONAL ELECTRICAL CODE RECONNECT PANEL DIAGRAMS WIRING DIAGRAM FOR CODES 9847 THRU 9852 9854 9855 9857 10008 10275 11350 11351 380 500 V FOR 380 V xi
33. N CC ONLY 32 0047MFD 1400V GROUNDING STUD zz 225 R N C CIRCUITRY PRESENT ON DIODE OPTION 15 au 244 R4 m p OWORK MULTI PROCESS SWHCH 1 LCELECTRODE 9 peus qe ni TO NEG TO POS STRIP TERM TERM L9107 IDEALARC DC 400 LINCOLN TRANSFORMER F 3 It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the If the diagram is illegible write to the Service Department for a replacement Give the equipment code number This diagram is for reference only NOTE machine on one of the enclosure panels ES DIAGRAMS F 4 WIRING DIAGRAM FOR CODE 9847 11349 H3 230 460 575V NB TosuppLy SHOWN CONNECTED FOR UU LINES 230 V RECONNECT PANEL GROUND STUD ON OUTPUT PANEL is TO GROUND PER NATIONAL FAN MOTOR ELECTRICAL CODE amp SILVER 10 AMP CIRCUIT BREAKER CONNECT OR INSULATE AS x1 AUXILIARY SHOWN ON COILS T2 INPUT CONNECTION 115V CONTROL 32A 3 42A pup DIAGRAM 4 TRANSFORMER t 66V ev Aas 241 e 231 5 SECONDARY PRIMARY 231 203 THERMOSTATS TOP pas T s E 204 RELAY CAPACITOR BOTTOM DISCHARGE PRIMARY A OPTION N A m r 0 5 50W
34. N Green e GROUNDING STUD 53 y 4 1 75 81 OUTPUT TERMINALS SWITCH OPTIONAL MULTI PROCESS SWITCH 9WORK o L ELECTRODE 4 11 TOTERM TONEG TOPOS STRIP TERM TERM IDEALARC DC 400 LINCOLN LEAD NOT PRESENT WITH DIODE OPTION ELECTRICAL SYMBOLS PER E1537 T8 8 2 9 104 115 126 12 PIN J2 31 1 2 3 4 42 5 q 84 10 4PIN 6PIN 10PIN 5 CONNECTOR CAVITY NUMBERING SEQUENCE COMPONENT SIDE OF P C BOARD NOTES N A CIRCUITRY PRESENT ON CAPACITOR DISCHARGE ONLY N B TAPE UP SEPARATELY TO PROVIDE AT LEAST 600 V INSULATION 220V WINDING PLUG AND CIRCUIT BREAKER ARE PRESENT ONLY ON 50 60 HERTZ WELDER N D 31 AND 32 ARE NOT PRESENT ON EUROPEAN MODELS N E CIRCUITRY PRESENT ON DIODE OPTION ONLY O L9106 diagram for a particular code is pasted inside the It may not be accurate for all machines covered by this manual The speci If the diagram is illegible write to the Service Department for a replacement Give the equipment code number This diagram is for reference only NOTE machine on one of the enclosure panels F 3 DIAGRAMS WIRING DIAGRAM FOR CODES 10859 10880 11083 11084 FAN MOTOR 230 460 515V d H3 SHOWN CONNECTED FOR 230 V
35. S SWITCH ARC FORCE CONTROL DIAL 2 V Output Voltage Remote On Off Shielded Metal Arc Welding Gas Tungsten Arc Welding Arc Force Current Increase Decrease of Current Voltmeter Positive Electrode Negative Electrode EARTH GROUND CONNECTION Signifying the Earth Ground Connection RATING PLATE 3 Ay eee Three Phase Power QD _ Transformer m gt Rectifier gt Rectified DC Output Constant Voltage Characteristic MODE SWITCH zo Do not switch if e es output voltage or current is present QD TE Constant 092190 Voltage Submerged Arc Welding G Constant ove e e Voltage Flux _ cored arc weldin gas metal arc weld ing LE y z gt Constant e e 4 Current shield metal arc weld ing gas tung sten arc weld ing IDEALARC DC 400 LINCOLN B 3 RATING PLATE Continued NEMA EW 1 IEC 60974 1 OPERATION B 3 Designates welder complies with National Electrical Manufacturers Association requirements EW 1 Export Model only Designates welder complies with International Electrotechnical Commission requirements 60974 1 European model only Three Phase Power Transformer Rectifier Rectified DC Output Consiant Voltage Characteristic Constant Current Characteristic Line Connection Shielded Metal Arc Welding Flux Cored Arc Welding Submerged Arc Welding Designates
36. T 55 206 MIN IND 5 CV FCAW GMAW METERS n NOTES CV SUB ARC 15N 100W S4B at i eu N A CIRCUITRY PRESENT ON CAPACITOR ASSEMBLY Xo 31 000MFD 50V EACH i RECTIFIER 204 2 N 51 2 DISCHARGE ONLY NE a lt TAPE UP SEPARATELY TO PROVIDE eS om 204 208 2A AT LEAST 600 V INSULATION S4D 22 1 NO WACTUATED U ler SN NE Rb 10A 75 t 211 N C 230V WINDING RECEPTACLE AND ra 21 lo CIRCUIT 7 Ra CIRCUIT BREAKER ARE PRESENT ARC FORCE CONTROL BREAKER ONLY ON EUROPEAN WELDERS NO sac 214 p ACTUATED VOLTMETER 10K N 2W 204 ff IN CC ONLY SWITCH OUTPUT CONTROL N D 31 AND 32 ARE NOT PRESENT ON gt 2 r C6 0047MFD 1400V SWITCH EUROPEAN CE WELDERS CIRCUITRY PRESENT ON DIODE Screen if A OPTIONAL OPTION ONLY a pagari MULTI PROCESS ROUNDING Pr 1 L NJ FOR EUROPEAN AN
37. TROL switch in wrong position Faulty OUTPUT control switch Faulty OUTPUT control poten tiometer Leads or connections open in control circuit Faulty Control PC Board OUTPUT CONTROL switch in wrong position Faulty OUTPUT CONTROL switch Faulty remote control potentiome ter Leads or connections open in control circuit Faulty Control PC Board Check and clean all connections Check table in instruction manual Check procedures for recom mended settings Check and replace if defective Check and replace if defective If SAC or S4D actuator is found defective replace mode switch cam also Place switch in LOCAL Check and replace if found faulty Check and replace if found faulty Check lead continuity and con nections for an open and repair if necessary Replace See Procedure for Replacing PC Boards Place switch in REMOTE Check and replace if found faulty Check and replace if found faulty Check all leads and connections internal or remote for continuity Repair if necessary 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 L
38. Welder can be used in environments with increased hazard of electric shock IEC model only Degree of protection provided by the enclosure Designates welder complies with low voltage directive and with EMC directive Export Model only IDEALARC DC 400 LINCOLN OPERATION E GENERAL MACHINE DESCRIPTION The DC 400 is an SCR controlled three phase DC power source lt is designed with a single range potentiometer control RECOMMENDED PROCESSES amp EQUIPMENT The DC 400 model is designed for all open arc processes including Innershield and GMAW all solid wire and gas procedures within the capacity of the machine plus the capability of stick and TIG welding and air carbon arc gouging up to 5 16 8mm diame ter A mode switch selects CV FCAW GMAW CV Submerged Arc or CC Stick TIG Stick welding per formance is similar to that of the R3R 500 The DC 400 is designed to be used with the LN 7 LN 7 GMA LN 8 LN 9 LN 9 GMA LN 23P LN 25 or LN 742 semiautomatic wire feeders the NA 3 NA 5 and NA 5R automatics and the LT 56 and LT 7 trac tors within the 400 ampere capacity of the machine The DC 400 Diode Kit option is required to utilize the cold start and cold electrode sensing features of the NA 3 NA 5 and NA 5R OPERATIONAL FEATURES amp CONTROLS ARC CHARACTERISTICS Through the unique combination of the transformer three phase semiconverter rectifier capacitor bank arc control choke and the s
39. ain it is within applicable OSHA PEL and ACGIH TLV limits 5 c Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 5 d Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 5 e Read and understand the manufacturer s instructions for this 54 LINCOLN 8 equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY gt WELDING and CUTTING gt SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the ope
40. ansfer processes Defective R1 L1 S4C S4D actu ator or S5 Check and replace if found defec tive If SAC or S4D actuator is found defective replace mode switch cam also Reset circuit breaker Make sure load on does not exceed 15 rat ing of circuit breaker Replace Check all wiring going to recepta cle and circuit breaker for possible broken connection 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 LINCOLN 115VAC Receptacle not working Circuit Breaker Tripped Defective Circuit Breaker Broken connection in wiring ES TROUBLESHOOTING E 6 PROCEDURE FOR REPLACING PC BOARDS A WARNING e ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts When a PC Board is suspected to be defective the follow ing procedure must be followed 1 Visually inspect the PC Board If the board has fuses check to see if any are blown Are any of the compo nents damaged Is a conductor on the back side of the board damaged If electrical damage is visible on the PC Board inspect the machine wiring for grounds or shorts to avoid damaging a new P
41. arge Option When using a DC 400 power source with wire feeders which do not have an electrical trigger interlock or with wire feeders with the electrical trigger interlock in the OFF position there will be a small spark if the electrode contacts the work or ground within several seconds after releasing the trigger When used with some wire feeders with the electrical trigger interlock in the ON position the arc can restart if the electrode touches the work or ground during these several seconds A WARNING Be sure to select OUTPUT TERMINALS REMOTE ON OFF for operation with wire feeders that have leads numbered 2 and 4 MEANINGS OF GRAPHIC SYMBOLS The DC 400 nameplate has been redesigned to use international symbols in describing the function of the various components Below are the symbols used POWER ON OFF SWITCH Input Power OUTPUT CONTROL DIAL Output Control 2795 gt Increase Decrease of Output Voltage or Current OUTPUT CONTROL LOCAL REMOTE SWITCH Remote Output Voltage or Current Control Local Output Voltage or Current Control Circuit Breaker THERMAL PROTECTION LIGHT High Temperature ARC CONTROL SWITCH G gt Gas Metal Arc Ka Welding 245 ncrease Decrease of Inductance a Low Inductance a High Inductance IDEALARC DC 400 LINCOLN B 2 OPERATION B 2 OUTPUT TERMINAL
42. ate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be danger ous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone rd E WELDING SPARKS can cause fire or do Tx explosion Keep flammable material away Do not weld on closed containers ARC RAYS can burn eyes and skin Wear eye ear and body protection EZ See additional warning information at front of this operator s manual CORRECT OPERATIONAL USE The machine should be located in a clean dry place where there is free circulation of clean air such that air movement in through the front and out through the back will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum INSTALLATION A 2 Failure to observe these precautions can result in excessive operating temperatures and nuisance shut down of the machine LIMIT ON STACKING A WARNING FALLING EQUIPMENT can cause injury Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder e Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not stack more than three high Do not stack the DC 400 on top of any other machine The units may be stacked three high by observing the following safety precautions A Make sure the first or bottom unit is
43. ble de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas X3TYTTLASU9 UAUNRUS ETBRAL VY FE e HEMMER AHS Al alll abil e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas O IJI RULE TIME SERE EVE Ro ao Sel deje H nelle AREY cus 13 jall la Jad y e Ale Cut Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese BIR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR f amp 5fBovRHOx z o0idBmmEtEk BIZ 3880 CT SU LTRHOR MEI TED CF SU S AOL REI XE AE RC JE t A9 BA FE ER 8 FR dE BEGE BI 01 SEA HYR
44. d on the nose of the center bottom primary coil and a second thermostat is attached to the lead connection the secondaries Both thermostats are connected in series with 2 4 cir cuit If the machine is overloaded the primary ther mostat will open the output will be zero and the amber thermal protection light will be on The fan will continue to run The secondary thermo stat will open either with an excessive overload or insufficient cooling The output will be zero and the amber protection light will be off IDEALARC DC 400 LINCOLN B a OPERATION B 8 AUXILIARY POWER CONNECTIONS The power source is equipped to furnish nominally 110 115 volt AC and 40 42 volt AC auxiliary power for operating wire feeding equipment etc The auxiliary power is available at the 14 pin MS style connector receptacle on the control panel and or at a terminal strip behind the hinged control panel on the front of the power source 110 115V AC is available at recep tacle pins A and J Domestic and Export models only and terminals 31 and 32 all models 40 42V AC is available only at receptacle pins and K The 110 115V AC and the 40 42V AC are isolated circuits and each is protected by a 10 amp circuit breaker REMOTE CONTROL CONNECTIONS Remote control connections are available both at a 14 pin connector receptacle located on the control panel and on terminal strips with screw connections located behind the hinged control panel on the fron
45. d your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor pers
46. e arc This results in the control of spatter fluidity and bead shape The ARC CONTROL is set to provide optimum welding depend ing on the process being used position electrode etc The pinch effect is increased by turning the con trol clockwise and may be adjusted while the machine is in operation MODE SWITCH A MODE SWITCH selects between Constant Voltage FCAW GMAW Constant Voltage Submerged Arc and Constant Current Stick TIG STICK WELDING When the DC 400 is used for stick welding or air car bon arc the control leads and welding cables to any semiautomatic or automatic wire feeders must be dis connected from the DC 400 for maximum safety unless the Multiprocess switch option is installed PARALLELING There are no provisions on the DC 400 to permit par alleling B 9 DIODE OPTION The DC 400 Diode option is required to utilize the cold start and cold electrode sensing features of the NA 3 NA 5 or NA 5R When this option is not used with an NA 3 NA 5 or NA 5R see the DC 400 NA 3 DC 400 NA 5 or DC 400 NA 5R connection diagram for instructions on how to disable this circuit If the circuit is not disabled the wire cannot be inched down Machine amp Circuit Protection Thermal Protection Light The power source is thermostatically protected with proximity thermostats against overload or insufficient cooling One thermostat is located on the nose of the center bottom primary coil and a second thermo
47. e at receptacle pins A and J A 10 amp circuit breaker protects this circuit Note that the 40 42V AC and 110 115V AC circuits are electrically isolated from each other FRONT VIEW OF 14 PIN CONNECTOR RECEPTACLE LEAD NO FUNCTION B D M IDEALARC DC 400 LINCOLN B7 OPERATION Terminal Strip Connections Terminal strip TS2 located behind the hinged control panel on the front of the power source supplies 110 115V AC A 10 amp circuit breaker protects this circuit Note that this 110 115V AC is also available in the 14 pin connector on the Domestic and Export models To gain access to the terminal strips simply remote the six 10 sheet metal screws from the perimeter of the welder nameplate as shown below Tilt panel for ward so it rests in a horizontal position See Table showing Front View of 14 Pin Connector Receptacle for lead number functions 1 2 0 0 e 2 230V AC Auxiliary Power for Water Cooler European and Export models A Continental European receptacle is located on the rear panel for supplying 230V AC to a water cooler A 3 5 amps 2 amps below code 11277 circuit breaker which is also located on the rear panel protects this circuit from excessive overloads or short circuits Machine and Circuit Protection The power source is thermostatically protected with proximity thermostats against overload or insufficient cooling One thermostat is locate
48. e harm The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The Above For Diesel Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING The Above For Gasoline Engines Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS 1 h To avoid scalding do not remove the FOR ENGINE yh I us de hen the engine powered equipment E Wi 7 hot or pressure cap when the engine IS 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND SR MAGNETIC FIELDS 353 may be dangerous 2 a Electric current flo
49. edures 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 LINCOLN TROUBLESHOOTING EN REMOTE CONTROL CHECK Disconnect the remote output control and connect an ohmmeter across 75 to 76 and rotate the rheostat in the remote control The resistance reading should go from zero to 10K ohms Repeat with ohmmeter across 75 and 76 with same results Connect ohm meter across 75 and 77 The reading should be 10K ohms A lower reading will indicate a shorted or par tially shorted rheostat A very high reading will indi cate an open rheostat In either of the last two cases replace rheostat Check cable for any physical dam age POWER RECTIFIER BRIDGE ASSEMBLY CHECKING PROCEDURE WARNING T e ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts 1 Bridge and Device Isolation See the instruc tion manual parts list for the exact location Disconnect the following leads from the bridge shown in Diagram 1 a Unplug P3 G1 G2 G3 and 204 from the Control PC Board b Unplug P5 from the Snubber PC Board c Secondary leads X1 X2 and X3 from the anodes of the SCR s and cathodes of the diodes 2 Disconnect positive bridge lead f
50. either steel K817 or rubber tired K817R wheels or a platform undercarriage K841 with mountings for two gas cylinder at rear of welder Install per instructions provided with trailer IDEALARC DC 400 LINCOLN D MAINTENANCE SAFETY PRECAUTIONS A WARNING e ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves See additional warning information throughout this operator s manual and the Engine manual as well ROUTINE MAINTENANCE 1 The fan motor has sealed bearings which require no service 2 In extremely dusty locations dirt may clog the air channels causing the welder to run hot Blow out the machine at regular intervals 3 In extremely dusty locations dirt may accumulate on the remote control terminal strip TS1 Wipe or blow this terminal strip off at regular intervals This is particularly important in damp locations IDEALARC DC 400 LINCOLN D 1 E TROUBLESHOOTING ES HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your
51. er protects against accidental con tact with the output studs Cover hinges upward for access to the studs The individual case sides are removable for easy access for internal service or inspection These are removable even though the machines are stacked three high IDEALARC DC 400 LINCOLN 5 B 9 OPERATION The case rear top section is equipped with a remov able access panel This provides easy access to the input contactor easy connection and reconnection of input leads and easy access for service or inspection The total construction of the machine permits outdoor operation The enclosure is designed with air intake louvers that keep dripping water from being drawn into the unit The transformer SCR bridge assembly and choke are double dipped in a special corrosion resis tant coating A permanent lifting hook is located at the top of the machine and is positioned so that it acts as nearly as possible through the center of gravity This lift hook is so positioned that it fits without interference under the base of the second machine when stacking ARC FORCE SELECTOR Effective only on CC for Stick and TIG Processes An ARC FORCE selector is provided similar to that used on the R3R This control allows the user to select the ideal arc force for the procedure and elec trode being used ARC CONTROL Effective Only When Using CVI Mode The ARC CONTROL is a five position switch that changes the pinch effect of th
52. h With the switch in the left position the wire feed terminals are electrode negative In the center position the wire feeder terminals are electrode posi tive In both the left and center switch position the right side stick terminals are disconnected In the right switch position the wire feed terminals are dis connected from the DC 400 and the stick terminals connected The polarity of the stick terminals is marked on the end of the box To change polarity the electrode and work leads must be interchanged In the stick position the stick terminals are energized at all times CONNECTIONS For those applications where it is not necessary to have separate work cables for stick and semiautomat ic welding If both stick and semiautomatic welding is done on the same workpiece only one work lead is required To do this connect a 4 0 107 mm jumper from the work terminal on the semiautomatic side to the termi nal to be used for work on the stick side The work lead from the semiautomatic side then serves as the work lead for both semiautomatic and stick welding To stick electrode holder or air carbon semi O arc torch auto or ELECTRODE a User supplied 4 0 107 jumper MULTIPROCESS SWITCH To change stick polarity reverse the leads at the and terminals on the right side of the Multiprocess Switch NOTE When a DC 400 equipped with Multiprocess Switch is mounted on an undercarriage
53. hms 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 Check position of switch Check switch amp replace if faulty Check wiring and control PC Board wiring harness plugs Replace See Procedure for Replacing PC Boards Check and replace potentiometer if faulty Check wiring of lead 75 Check and replace if blown after checking for reason for blown fuse Check for open and repair Replace See Procedure for Replacing PC Boards Check and Replace if faulty Check and repair broken leads Check and replace if necessary Replace 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 LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Variable or sluggish welding arc OUTPUT control not functioning on the machine OUTPUT control not functioning on REMOTE control Poor work or electrode connec tion Welding leads too small Welding current or voltage too low Defective main SCR bridge Microswitch S4C or S4D actuator defective OUTPUT CON
54. ing chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage eA safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P I Precautions for Safe Handling of Compressed Gases in O
55. it and the power circuit are mounted on the control PC board located behind the front control panel The front control panel hinges down for easy access to the board The starting circuit board is located on the back of the control box MACHINE COOLING The fan pulls air in through the louvered front of the machine over the internal parts and exhausts out the louvered rear of the machine The fan motor is fully enclosed has sealed ball bearings requires no lubri cation and operates when the power switch is turned on CASE FEATURES The machine uses a 32 813mm long base The low profile case facilitates installation of the machine under a workbench and stacking the machines three high to conserve floor space The case front incorporates a recessed control panel where all the machine controls are mounted This recessed panel protects the controls and minimizes the possibilities of accidental contact This control panel can be easily opened to permit access to the enclosed control section which contains the terminal strips PC board etc The output lead terminals are also recessed to avoid any object or person accidentally coming in contact with an output terminal Strain relief is provided by holes in the front of the base The leads are routed up through these holes to the output terminals This pre vents any damage of the output studs or insulation of same in the event the cables are pulled excessively An output stud cov
56. left side of the box are for connection of wire feed electrode and work leads The two terminals on the right side of the box are for connection of work and electrode for stick or air carbon arc The output terminals are protected against accidental contact by hinged covers The switch mounts to the front of the DC 400 by means of a bracket that fastens to the case sides Two 4 0 107 mm leads connect the switch assem bly to each output stud CONNECTIONS 1 Connect wire feed unit electrode and work cables through the rectangular strain relief holes in the base of the DC 400 to the output studs on the left side of the box 2 Connect wire feeder control cable and make other terminal strip connections as specified on the con nection diagram for the Lincoln wire feeder being used Electrode and Work are connected to the left side of the Multiprocess Switch 3 Connect stick or air carbon arc electrode and work cables through the rectangular strain relief holes in the base of the DC 400 to the output studs on the right side of the box OPERATION IDEALARC DC 400 LINCOLN 8 INSTALLATION ae The operation of the switch is as follows A semiautomatic or automatic wire feed unit electrode and work cables are connected to the terminals on the left side of the box Stick or air carbon arc electrode and work leads are connected to the terminals on the right side of the box There are three positions on the switc
57. nect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as
58. ng other open arc processes including short arc MIG welding and air carbon arc Most submerged arc welding can also be done in this mode The CV Submerged Arc Mode also produces an essentially flat output characteristic that can be varied from approximately 12 to 42 volts The dynamic characteristics of the CV Submerged Arc Mode make possible improved submerged arc welding over that possible using the Constant Voltage Innershield Mode The improvement is most noticeable on high deposition slow travel speed welds There are no means provided to switch between any of the modes remotely Do not change the position of the MODE SWITCH if output voltage or current is pre sent as this may damage the switch The CC Mode permits the DC 400 to produce a con stant current output characteristic through the range of 60 500 amps with an open circuit voltage of approxi mately 57 volts 54V on 50 60 Hz Stick welding and TIG are done with this position of the Mode Switch ARC FORCE CONTROL DIAL Effective only in CC mode The ARC FORCE control is calibrated from one to ten For most welding the dial should be set at approxi mately midrange 5 6 Adjustments up or down can then be made depending on the electrode proce dures and operator preference Lower settings will provide less short circuit current and a softer arc A setting that is too low may cause the electrode to stick in the puddle Higher settings will provide a higher short ci
59. olid state control system outstanding arc characteristics are achieved on con stant voltage In addition an arc force control enables the DC 400 to stick weld as well as the R3R 500 OUTPUT CONTROL The OUTPUT control a small 2 watt potentiometer is calibrated from 1 to 10 The OUTPUT control serves as a voltage control in the CV position and a current control in the CC position MACHINE OUTPUT CONTROL SWITCH LOCAL OR REMOTE The machine output can be controlled by either the OUTPUT control on the machine control panel the output control on the wire feed unit or an optional remote control that is available This switch selects the mode of control either LOCAL or REMOTE OUTPUT TERMINALS ON OR OUTPUT TERMI NALS REMOTE This switch provides an alternative to the 2 to 4 jumpering function by energizing the machine s output regardless of whether 2 or 4 is jumpered or not POLARITY SELECTION Polarity selection is made by appropriately connecting the electrode and work welding cables to either the stud or to the stud Select VOLTMETER oo switch for or electrode for the remote 21 work sensing lead VOLTMETER SWITCH ELECTRODE OR ELECTRODE This switch selects electrode polarity for the remote 21 work sensing lead of automatic or semiautomat ic equipment 115 VOLT POWER SWITCH The power input contact
60. onal injury or damage to this equipment LINCOLN 5 vi TABLE OF CONTENTS Page PR Section A Technical Specifications A 1 Safety PrecautiOns lisi desi rte sen c Dag az Bl d A kaya na ara alaya add A 2 Correct Operational use si A 2 stacking Lifting tereti d kak indie aka kkin w ka W an na nada A 2 Input Power Connections A 2 Output COMMECHIONS piranya lk r d lan a a dinate iin nza b A 3 Installation of Field Installed Options A 3 K843 Amptrol Installation Instructions A 4 Installation of Equipment Requied for Recommended Processes A 5 Thru A 6 Section Safety Precautions ERES B 1 Meaning of Graphic Symbols kk kek kek B 1 thru B 3 General Machine Description B 4 Recommended Processes amp Equipment B 4 Operational Features and Control B 4 Power Source Operation and Controls B 5 thru B 7 Auxiliary Power Connections sess B 8 Solid State Output Control iii B 8 Case Features r r rrr r gg B 8 Stick Welding ER a DD rrr Dr B 9 gg nmn gi j 9 Machine amp Circuit Protection B 9 5 5
61. or operates from an auxiliary 115 volt transformer that is energized through the POWER toggle switch on the machine control panel 1 is on and 0 is off PILOT LIGHT A white light on the machine control panel indicates when the power source input contactor is closed This means the main power transformer and all auxiliary and control transformers are energized THERMAL PROTECTION LIGHT An amber light on the machine control panel indicates when either of the two protective thermostats have opened Output power will be removed but input power will still be applied to the machine INPUT CONTACTOR The power source is equipped with an input contactor IDEALARC DC 400 LINCOLN B 5 POWER SOURCE OPERATION AND CONTROLS WARNING e ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts Duty Cycle and Time Period The DC 400 is rated at the following duty cycles DUTY CYCLE AMPS VOLTS 100 Based upon 10 minute time period i e for 60 duty cycle it is 6 minutes on and 4 minutes off Overloading the DC 400 may result in opening of an internal protective thermostat as indicated by the amber thermal protection light turning on STARTING THE MACHINE The POWER toggle switch at the extreme right side of the control panel in the position energize
62. rating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lift
63. rcuit current and a more forceful arc Excessive spatter may result if the control setting is too high For most TIG welding applications adjust this control to a minimum for best operating character istics ARC CONTROL SWITCH Effective only in CV FCAW GMAW mode The ARC CONTROL is a tapped switch numbered from 1 to 5 and changes the pinch effect of the arc This control is most useful in processes that utilize a shorting metal transfer and controls the spatter fluid ity and bead shape The pinch effect is increased by turning the control clockwise For all applications a good starting point for the ARC CONTROL is a midrange dial setting of 3 The control can be increased or decreased as desired B 6 OUTPUT TERMINALS SWITCH The OUTPUT TERMINALS toggle switch on the con trol panel labeled REMOTE ON allows the welder output to be activated remotely or to be always on For remote operation the toggle switch is set in REMOTE position and the welder output will be acti vated when 2 and 4 are closed when using a wire feeder For welder output to always be activated set the switch to the ON position 110 115V AC and 40 42V AC Auxiliary Power and Control Connections 14 PIN CONNECTOR The 14 pin connector receptacle supplies auxiliary power 40 42V AC is available at receptacle pins and K A 10 amp circuit breaker protects this circuit On the Domestic and Export models 110 115V AC is availabl
64. rom shunt and positive capacitor bank lead and from lug with triple 204 leads Perform the following steps 2 and 3 If diodes and SCR s are not shorted bridge test is com pleted If any device appears shorted discon nect the cathode lead of each diode 4 total and repeat Steps 2 and 3 a b O 2 Power Diode Test Establish the polarity of the ohmmeter leads and set to X10 scale Connect the ohmmeter positive lead to anode and negative lead to cathode Reverse the leads of the ohmmeter from Step b A shorted diode will indicate zero or an equally low resistance in both directions An open diode will have an infinite or high resistance in both directions and a good diode will have a low resistance in Step b and Step a much high er resistance in Step c Power Silicon Controlled Rectifier Test a e O 2 Connect the ohmmeter set to m X10 scale leads to the anode and cathode Reverse the leads of the ohmmeter from Step a A shorted SCR will indicate zero or an equally low resistance in one or both directions Establish the polarity of the ohmmeter Connect the positive lead to the gate and the negative lead to the cathode An open gate circuit will have an infinite or high resistance A good gate circuit will read a low resistance but not zero ohms If gate circuit reads zero ohms check gate harness for shorts between gate leads and 204 before replacing SCR CAUTIO
65. s and clos es the three phase input contactor from a 115 volt auxiliary transformer This in turn energizes the main power transformer The machine is de energized when the POWER switch is in the 0 position The white light below the POWER switch indicates when the input contactor is energized OUTPUT CONTROL DIAL The OUTPUT control to the right of the center of the control panel is a continuous control of the machine output The control may be rotated from minimum to maximum while under load to adjust the machine out put The machine is equipped with line voltage compensa tion as a standard feature This will hold the output constant except at maximum output of the machine through a fluctuation of 10 input line voltage OPERATION B 5 OUTPUT CONTROL LOCAL REMOTE SWITCH The OUTPUT CONTROL toggle switch on the control panel labeled LOCAL REMOTE gives the operator the option of controlling the output at the machine control panel or at a remote station For remote con trol the toggle switch is set in the REMOTE position and controlled at the wire feed unit control or by con necting a K775 control to terminals 75 76 and 77 on the terminal strip at the front of the machine or by connecting a K857 control to the 14 pin connector on the front of the machine For control at the machine control panel the toggle switch is set in the LOCAL Exception When used with an LN 9 LN 9 GMA or NA 5 wire
66. s applied to the machine Refer to the Machine and Circuit Protection section CHECKING SNUBBER CIRCUIT In case of an SCR malfunction or failure the snubber assembly should be checked Turn the machine off and remove the sides of the machine See the instruction man ual parts list for the exact location 1 Visually inspect the snubber assembly for overheated components or damaged components CHECKING OUTPUT CONTROL RHEOSTAT ON MACHINE Turn machine off O position Remove the control panel screws and open the control panel see the section on Terminal Strip Connections for Screw locations Turn the OUTPUT CONTROL switch to REMOTE Disconnect the harness plug from the Control PC Board With an ohmmeter on X1K connect it to lead 210 and 75 on R4 Exercise caution to avoid damaging POT taps POWER 1 0 SWITCH CHECK 1 Turn off the machine power input 0 position S1 has 115V across it when the input power is connected 2 Isolate the switch to be tested by removing all connecting leads 3 Check to make sure the switch is making connections with an ohmmeter The meter should read zero resis tance 4 Put the ohmmeter on X1K scale and measure the resis tance between the terminal and the case of the machine touch a self tapping screw Reading should be infinite 5 If either step 3 or step 4 fails replace the switch CAUTION If for any reason you do not understand the test proc
67. ses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please recor
68. setting on a level well supported surface B The units must be stacked with their fronts flush making sure the two holes in the base rails of the unit being stacked on top are over the two pins located on the top front corners of the unit it is being stacked on Input Power Connections By removing the rear access panel the three phase input power is connected to the three line terminals on the input contactor and the earth grounding lead to the grounding terminal on the input box floor marked with the symbol Install and reconnect panel for the proper input voltage per the diagram pasted inside the access panel cover See Technical Specification Page IDEALARC DC 400 LINCOLN 5 A 3 CAUTION Failure to follow these instructions can cause immediate failure of com ponents within the machine When powering welder from a gener ator be sure to turn off the welder first before generator is shut down in order to prevent damage to welder Output Cable Connections The output leads are connected to the output termi nals marked and They are located at the lower right and lower left corners of the front panel Output Cables CABLE SIZES FOR COMBINED LENGTH OF ELECTRODE AND WORK CABLE MACHINE LOAD 400A 500A 100 DUTY 50 DUTY CABLE LENGTHS CY D UP TO 50 ft 15m n dum Des s 50 to 100 ft 15 30 m N m E s 100 150 ft 30 46 m bi INSTALLATION OF FIELD INSTALLED OPTIONS 15
69. sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 E ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards
70. stat is attached to the lead connecting the secondaries Both thermostats are connected in a series with the 2 4 circuit If the machine is overloaded the primary thermostat will be open the output will be zero and the amber thermal protection light will be on The fan will continue to run The secondary thermostat will open either with an excessive overload or insufficient cooling The output will be zero and the amber pro tection light will be on When the thermostats reset the protection light will be off The power source is also protected against overloads on the SCR bridge assembly through an electronic protection circuit This circuit senses an overload on the power source and limits the output to 550 amps by phasing back the SCR s Protection is provided to protect the circuitry from accidental grounds If the customer accidentally grounds 75 76 or 77 to the positive output lead the DC 400 will be reduced to a low value thus prevent ing any damage to the machine If the ground occurs between 75 76 77 and the negative output lead one of the PC board self restoring fuses will blow pre venting any machine damage IDEALARC DC 400 LINCOLN e ACCESSORIES C 1 TIG OPTIONS TIG MODULE K930 2 Docking Kit Control Cable Extension 45 Water valve Kit AMPTROL ADAPTER FOR K799 HI FREQUENCY KIT K915 1 REQUIRES K864 ADAPTER A V cable to connect a K799 Hi Freq Kit 5 pin con nector with either
71. t Ihrem K rper oder feuchter Kleidung e solieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e electro dos com a pele ou roupa molhada sole se da pe a e terra e d E rh O E NAHE 72 e MLMPT APSSAPEBRE B BA ER 7 ERE RAE CRA CRM NI HER ATAH 2452 Je 84 mc BSS uu YRA e 2x9 AAS ASA OAR Mi gma gi l gl sit outils aul DE dus ule Y jo Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos e Hav v6008 EA e 18 tJ Z PA Ya SRE LFB ects 248 YZ AIX nig Aa ALI al gll a e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo e SU e ARR HRAEBSHRRAR ez 119 0A save AIS dil s due le Lily jules cil sai T 3 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA
72. t of the power source OUTPUT CONNECTIONS The output terminals are recessed on the case front and labeled and INPUT CONNECTIONS The three input lines are brought in through the rear panel of the power source and attached to the input contactor Removal of the removable access panel makes the contactor accessible for the input cable connections INPUT LINE VOLTAGE COMPENSATION The power source is equipped with input line voltage compensation as standard For a line voltage fluctua tion of 10 the output will remain essentially con stant This is accomplished through the feedback net work in the control circuit SOLID STATE OUTPUT CONTROL The output of the welder is electronically controlled by SCR s instead of mechanical contactors providing extra long life for highly repetitive welding applica tions SOLID STATE CONTROL SYSTEM The control circuitry consists of six basic circuits 1 the SCR snubber network 2 the SCR firing circuit 3 the control fault protection circuit 4 the starting circuit 5 the power up delay circuit and 6 the power circuit The SCR snubber board consists of a capacitor and resistor connected across each SCR and across the entire bridge and MOV s to protect the control circuitry and SCR s from transient voltages The snubber board is mounted on the back of the case front The SCR firing circuit the control fault protection cir cuit the power up delay circu
73. the undercarriage handle in the resting position can hit the case of the Multiprocess Switch This does no harm but if the user desires a 1 4 or 3 8 bolt and nut may be placed in the hole in the undercarriage tow bar to limit the travel of the undercarriage handle STICK TIG OR AIR CARBON ARC a Turn off all power b Disconnect all wire feed unit control electrode and work leads c Place MODE SWITCH in the CONSTANT CUR RENT STICK TIG for air carbon arc For stick TIG or air carbon arc place OUTPUT TERMINALS switch into the ON position With the DC 400 connected for stick TIG or air carbon arc welding the output terminals will be energized at all times NOTE If stick welding TIG welding or air carbon arc cutting is to be done on the DC 400 along with semi automatic automatic welding then a K804 1 Multiprocess Switch is required the Multiprocess Switch is not used then all control electrode and work leads to wire feed equipment must be disconnected from the DC 400 before connecting the DC 400 for Stick or air carbon arc cutting IDEALARC DC 400 LINCOLN B OPERATION E SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts This next section applies to DC 400 s without the Capacitor Disch
74. troubleshooting assistance before you proceed IDEALARC DC 400 LINCOLN B TROUBLESHOOTING EN Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Input contactor CR1 chatters 1 Faulty input contactor CR1 Repair or Replace 2 Low line voltage Check input power Machine input contactor does not Supply line fuse blown Replace if blown look for reason operate first Contactor power circuit dead Check control transformer T2 and associated leads Broken power lead Check input voltage at contactor Wrong input voltage Check voltage against instruc tions Open input contactor coil Replace coil POWER 1 0 switch 51 closing Replace switch Machine input contactor operates 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 Electrode or work lead loose or Repair Connection broken Open main transformer T1 pri Repair mary or secondary circuit Defective Control PC Board Replace See Procedure for Replacing PC Boards Primary or secondary thermostats 5 Amber thermal protection light is on Check for overheating make sure fan is operating and there is no obstruction to free air flow Machine has minimum output and 1 Terminals 75 76 or 77 grounded 1 Check 75 76 or
75. wing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor idler by pushing on the throttle control rods while the engine is running N 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work discon
76. ylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact

Lincoln Electric IDEALARC DC-400 User's Manual

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