Lincoln IDEALARC DC-400 Operating Manual Download Page 1

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IMA 474A

June 1999

OPERATING MANUAL

IDEALARC

DC-400

(For Codes 1386 to 1462)

SAFETY DEPENDS ON YOU

Lincoln welders are designed and built with safety in mind. However, your overall safety can be increased

by proper installation . . . and thoughtful operation on your part. Read and observe the general safety

precautions on page 2 and follow specific installation and operating instructions included in this manual.

Most importantly, think before you act and be careful.

THE LINCOLN ELECTRIC COMPANY

(AUSTRALIA) PTY. LTD.

A.B.N. 36 000 040 308

SYDNEY. AUSTRALIA

A Subsidiary of

THE LINCOLN ELECTRIC CO. U.S.A.

Associated Subsidiaries in Australasia, Asia, Canada, Europe, North and South America.

THE WORLD’S LEADER IN WELDING AND CUTTING PRODUCTS

ARC WELDING SUPPLIES - 07 847 7870

Summary of Contents for IDEALARC DC-400

Page 1: ...eral safety precautions on page 2 and follow specific installation and operating instructions included in this manual Most importantly think before you act and be careful THE LINCOLN ELECTRIC COMPANY AUSTRALIA PTY LTD A B N 36 000 040 308 SYDNEY AUSTRALIA A Subsidiary of THE LINCOLN ELECTRIC CO U S A Associated Subsidiaries in Australasia Asia Canada Europe North and South America THE WORLD S LEAD...

Page 2: ...or this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices e Also see Item 7b 3 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 AS 1674 2 2003 AS1337 1992 and AS1338 19...

Page 3: ...ired 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 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running g To prevent accidentally starting petrol engines whil...

Page 4: ...kers function Generally the interference does not permanently damage the pacemaker Once the wearer leaves the arc welding environment or stops welding the pacemaker returns to normal functioning The welding arc has little or no effect on the operation of some pacemakers especially designs that are bi polar or designed to filter out such interference For a welder or anyone working around electrical...

Page 5: ...cture of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering the mains supply Conside...

Page 6: ...Increase Decrease of Output OUTPUT CONTROL DIAL POWER ON OFF SWITCH Remote Output Voltage Local Output Voltage OUTPUT CONTROL LOCAL REMOTE SWITCH Circuit Breaker CIRCUIT BREAKER High Temperature THERMAL PROTECTION LIGHT Gas Metal Arc Welding ARC CONTROL SWITCH Increase Decrease of Inductance Low Inductance High Inductance Voltage or Current or Current Control or Current Control A R C W E L D I N G...

Page 7: ...RCE CONTROL DIAL Gas Tungsten Arc Welding Arc Force Current Increase Decrease of Current 10 Voltmeter VOLTMETER SWITCH Three Phase Power RATING PLATE Transformer Rectifier Rectified DC Output Constant Voltage Characteristic Positive Electrode Negative Electrode A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 8: ...merged Arc Welding Three Phase Power Transformer Rectifier Rectified DC Output Constant Voltage Characteristic Line Connection Shielded Metal Arc Welding Flux Cored Arc Welding Degree of protection provided by the enclosure IP21 A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 9: ...ification WARNING IDENTIFICATION Signifying the Earth Connection EARTH CONNECTION Constant Voltage Submerged Arc Welding Constant Voltage Flux cored arc welding gas metal arc welding Constant Current shield metal arc welding gas tungsten arc welding A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 10: ... connecting the electrode and work welding cables to either the stud or to the stud Select VOLTMETER 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 semiautomatic equipment POWER SWITCH The power input contactor operates from an auxiliary 115 volt transform...

Page 11: ...the event the cables are pulled excessively An output stud cover protects against accidental contact 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 The case rear top section is equipped with a removable access panel This p...

Page 12: ...x with 8 5m of four conductor cable This connects to terminals 75 76 and 77 on the terminal strip and the case grounding screw so marked with the symbol on the 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 AMPTROL ADAPTER CABLE K843 A five wire cable 300mm long is available ...

Page 13: ...ine has a 6 pin connector which requires either a K864 adapter to connect with the 14 pin connector on the machine or a K843 adapter to connect to terminals 75 76 77 and the case grounding screw on the machine UNDERCARRIAGES KA1236 Basic Undercarriage KA1237 Basic undercarriage with gas bottle support For easy moving of the machine optional undercarriages are available Install per instructions pro...

Page 14: ...ad to the earthing terminal on the input box floor marked with the symbol Output Cable Connections The output leads are connected to the output terminals marked and They are located at the lower right and lower left corners of the front panel Strain relief for the electrode and work cables is provided by routing the leads through the elliptical holes in the base before connecting them to the outpu...

Page 15: ... a K799 or K930 2 Hi Frequency Kit See Amptrol Adapter Installation Instructions on next page K930 2 TIG Module Kit supplies the high frequency plus shielding gas valve for DC GTAW TIG welding applications High frequency bypass is built in and the DC 400 is shipped with the proper R F bypass circuitry installed to protect the control circuit while welding with a Hi Frequency unit A control cable K...

Page 16: ...ate connection diagram for the exact instructions for the wire feeder being used 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 position c Connect the electrode cable to the output terminal of polarity required by electrode Connect the work lead to the other terminal d ...

Page 17: ...he 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 STICK TIG OR AIR CARBON ARC a Turn off all power b Disconnect all wire feed u...

Page 18: ...e stud Select VOLTMETER 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 21 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 output power will be disab...

Page 19: ... at receptacle pins I and K A10 amp circuit breaker protects this circuit 110 115V AC is available 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 Terminal Strip Connections Terminal strip TS2 located behind the hinged control panel on the f...

Page 20: ...p off at regular intervals This is particularly important in damp locations TROUBLESHOOTING Page 20 DC 400 IMA 474 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 WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input...

Page 21: ...ion to free air flow D Machine has minimum output 1 Terminals 75 76 or 77 1 Check 75 76 or 77 for ground to and no control grounded to positive output positive output circuit Nearly zero ohms to ground indicates a grounded circuit A value greater than a few thousand ohms is normal Self restoring fuses on PC Board automatically reset within a few seconds after ground is cleared E Machine has high o...

Page 22: ...oswitch S4C or S4D 5 Check and replace if defective actuator defective If S4C or S4D actuator is found defective replace mode switch cam also J OUTPUT CONTROL not 1 OUTPUT CONTROL switch in 1 Place switch in LOCAL functioning on the machine wrong position 2 Faulty OUTPUT CONTROL 2 Check and replace if found faulty switch 3 Faulty OUTPUT CONTROL 3 Check and replace if found faulty potentiometer 4 L...

Page 23: ... problem disappears replace Start PC Board 3 Defective Control PC Board 3 Replace See Procedure for Replacing PC Boards 4 Capacitor s in output circuit 4 Replace entire bank of capacitors failed A failure is indicated if Do not replace individual the small vent plug on top of a capacitors capacitor is raised or blown out WARNING The liquid electrolyte in these capacitors is toxic Avoid contact wit...

Page 24: ...move the sides of the machine See the instruction manual parts list for the exact location Visually inspect the snubber assembly for overheated components or damaged components CHECKING OUTPUT CONTROL RHEOSTAT ON MACHINE Turn machine off 0 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 sw...

Page 25: ...Step b d 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 higher resistance in Step c 3 Power Silicon Controlled Rectifier Test a Connect the ohmmeter set to m X10 scale leads to the anode and cathode b Reverse the leads o...

Page 26: ...est Connect one lead of the MEGA tester to the frame of the machine and the other to the input contactor jumper Apply the test Min resistance 1MΩ 10 Input Circuit to Welding Circuit Tests Connect one lead of the MEGA tester to the input contactor jumper and the other lead to the positive output stud Apply the test Min resistance 10MΩ 11 Input Circuit to Auxiliary CircuitTests Connect one lead of t...

Page 27: ...IMA 474 DC 400 Page 27 AP 234 Operative 1 4 99 Supersedes New Parts List for DC 400 A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 28: ...Page 28 DC 400 IMA 474 7 6 3 2 4 1 5 AP 234 A Operative 1 4 99 Supersedes New Illustration of Sub Assemblies A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 29: ...Contact an authorised Lincoln LiquidArc Field Service Shop for any code numbers not listed Use the Illustration of Sub Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine DC 400 For Codes 1386 To 1462 Optional Equipment Miscellaneous Items Illustraction of Sub Assemblies Case Front Assembly Fan Baffle R...

Page 30: ...code number is not listed Contact an authorised Lincoln LiquidArc Field Service Shop for any code numbers not listed Use the Illustration of Sub Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine DC 400 For Codes 1386 To 1462 Diode Option Multi Process Switch Power Rectifier Bridge Wiring Diagram Wirin...

Page 31: ...ith gas KA1237 Undercarriage without gas KA1236 Amptrol Adapter K843 Water Valve Option K844 Remote Output Control K857 Amptrol Adapter K915 1 Remote Control Adapter K864 TIG Module K930 2 Miscellaneous Items These items are not illustrated Description Part No Qty 1 Earth Decal T13259 1 X Earth Decal T13260 4 1 X Identification Sticker 1CR T14798 1 1 X Warranty Decal Domestic Export S19633 2 1 X C...

Page 32: ...DC400 2 1 10A 10B Part of Wiring Harness 28 27B 27A 26A 26B 3 13 30B 14B 4A 29 14A 14C 18A 30A 17B 17A 31A 31B 18B 18C 18D 17C 17D 17E 25A 25C 25B 9 22 21 24A 24B 24D 24E 23 19 20 5 11 15B 12A Part of 12A 8 16 15A 12B Part of 15A 7 6 4B A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 33: ... 3 8 18 Hex Nut 1 X 18A Lead Mode Switch to Negative Terminal M13607 10 1 X 18B Plain Washer not shown 1 X 18C Lock Washer 1 X 18D 5 16 18 Hex Nut 1 X 19 Reed Switch Plate S11797 14 1 X 20 Reed Switch Assembly S12334 50 1 X 21 Clamp T8970 17 2 X 22 Self Tapping Screw S8025 76 2 X 23 Marker CR3 T14798 3 1 X 24A Lead Shunt to positive terminal M16549 1 X with Multi Process Switch 24B 3 8 16 x 1 00 H...

Page 34: ...persedes New Fan Baffle Reconnect Panel LINC DC400 5 1G Part of 1G 1C 1F 1E 1E 1F 1D 1H 9C 10C 9A 9C 9B 10B 10C 10A 1A 1B 1B 8 11A 6B 7B 7A Part of 3A Part of 3A 6A 11B 11C 10D 10E 10F 5A 5B 4A 4B 12 A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 35: ...anel AS4278 1 X 4B Self Tapping Screw 12 X 5A Input Access Door AM3257 1 X 5B Self Tapping Screw 3 X 6A Contactor M12161 80 1 X 6B Self Tapping Screw 3 X 7A Control Transformer codes 1386 AM2681 2 1 X 7A Control Transformer codes 1415 AM2681 1 1 X 7B Self Tapping Screw 3 X 8 Bushing T12380 2 1 X 9A Resistor R2 S10404 95 1 X 9B 10 24 x 7 50 Round Head Screw 1 X 9C Insulating Washer T7562 2 X 9D Loc...

Page 36: ...sembly 15A 15B 15C 20A 20B 20C 20A 20B 20C 11B 11D 14 4B 4A 15C 15B 15A 13A 13B 13C 14 12 1 13A 13B 13C 13A 13B 13C 11A 10 4C 11A 9D 9C 9B 8D 8C 3 6E 6A 19 8A 8B 7 16A 16B 17B 17A 16A 5B 5C 2 5A 5C 5D 5E 6C 6B 6D 18 4E 4D 4B 9A 9B A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 37: ...asher 3 X 8C Lock Washer 3 X 8D 5 16 18 Hex Nut 3 X 9A 5 16 18 x 1 25 Hex Head Cap Screw 1 X 9B Plain Washer 2 X 9C Lock Washer 1 X 9D 5 16 18 Hex Nut 1 X 10 E1159 B 625 3 25 sleeving 1 X 11A Rectifier Diode M9661 31 4 X 11B Plain Washer 3 X 11C Springer Washer not shown 4 X 11D 5 16 18 x 1 50 Hex Head Cap Screw 3 X 12 Lead Bridge negative to Mode Switch S16954 10 1 X 13A Plain Washer 3 X 13B Lock...

Page 38: ...P 234 F Operative 1 4 99 Supersedes New Transformer Lift Bale Assembly 2 1 3C 3B 3C 6A 6B 11B 11A 7B 7E 7C 7C 7A 12A 12B 12C 14 11B 11A 9 10A 10B 13A 13B 4 9 5A 8 7F 7D 5B A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 39: ... 50 Round Head Screw 1 X 7C Insulating Washer 2 X 7D Lock Washer 1 X 7E Plain Washer 1 X 7F 10 24 Hex Nut 1 X 8 Lift Bale Assembly L6485 1 X 9 Thread Forming Screw 4 X 10A Capacitor Mounting Bracket S17354 1 X 10B Thread Forming Screw 1 X 11A Insulating Baffle T11472 24 2 X 11B Thread Forming Screw 2 X 12A 3 8 16 X 75 Hex Head Cap Screw 4 X 12B Lock Washer 4 X 12C Plain Washer 4 X 13A Capacitor Br...

Page 40: ...sembly LINC DC400 3 10 Part of 10 12 11 5A 5B 4C 4B 2 3 1 4A 6A 6B 7A 7B 8 9A 9B 12B 12A 13B 13C 13D 13A 13E 22A Part of 22A 18A 22B 22C 23 31B 31A 33 19A 25 26 21 14 16 15 24 18B 28 29 Part of Meter 28 29 17 37A 32 17 27 20 37B 36 A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 41: ... C Voltmeter M10486 3 1 X 18B Plain Washer 4 X 19A D C Ammeter M10485 8 1 X 19B Plain Washer not shown 4 X 20 Circuit Breaker T12287 20 2 X 21 Thermal Protection Light T13534 11 1 X 22A Knob T10491 1 2 X 22B Felt Washer T14034 2 X 22C Insulation Tube T12792 1 2 X 23 Knob M15796 1 X 24A Arc Control Switch S5 M15750 1 1 X 24B Self Tapping Screw not shown 1 X 25 Box Connector T9639 1 1 X 26 Plug Butt...

Page 42: ...Page 42 DC 400 IMA 474 AP 234 H Operative 1 4 99 Supersedes New Coil Assemblies 6 TOP 7D 7C 7B 1 LEFT 5 4 2 RIGHT 3 6 7A 7B 7C 7D BOTTOM A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 43: ...1 X 2 Primary Coil Top Centre Code 1415 9852 53 1 X 3 Primary Coil Top Right Codes 1386 1449 1462 9857 54 1 X 3 Primary Coil Top Right Code 1415 9852 54 1 X 4 Primary Coil Bottom Codes 1386 1449 1462 9857 51 3 X 4 Primary Coil Bottom Codes 1415 9852 51 3 X 5 Secondary Coil Assembly AM3362 3 X 6 Lamination Assembly L6268 4 2 X 7A Stud AS4324 6 4 X 7B Plain Washer 4 X 7C Lock Washer 4 X 7D 3 8 16 He...

Page 44: ... 1 1 Roof Code 1462 uses 10U AM2805 10 1 X 2A Side Panel Code 1462 uses 1U AM2804 1 2 X 2B Self Tapping Screw AS1733 3Z 18 X 3 Cover Seal S12934 1 X 5 Warning Decal T13086 20 1 X 5 Warning Decal Europe L8064 1 1 X 6 Caution Decal Back side of panel not shown S13504 1 X A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 45: ...her 4 X Lock Washer 2 X 5 16 18 Hex Nut 4 X 6 Connection Lead S20945 1 X 7 Mounting Bracket S20946 2 X 8 1 4 20 x 1 50 Hex Head Cap Screw 2 X Plain Washer 8 X Insulator T11267 B 8 X Insulator T14605 4 X Lock Washer 4 X 1 4 20 Hex Nut 4 X 9 Lock Washer 2 X Thread Forming Screw 2 X 10 Flat Aluminium Lead M13607 13 1 X 5 16 18 x 1 00 Hex Head Cap Screw 2 X 11 Plain Washer 2 X Lock Washer 1 X 5 16 18 ...

Page 46: ...04 204 204 204 220 D1 D2 D3 SCR1 SCR2 SCR3 G1 G2 G3 D4 ANODE CATHODE ANODE CATHODE P3 Gate leads plug to control P C board To T1 main transformer To plug P1 To mode switch To side of capacitor bank _ X1 X2 X3 GATE _ AP 234 L Operative 1 4 99 Supersedes New A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 47: ...red by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Customer Service Department for a replacement Give the equipment code no and serial no Ref AL2460 A26 6 96 A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 48: ...terminal and hex bolt push the link completely forward Securely tighten all hex bolts Do not remove hex bolts at any time 2 Connect L1 L2 L3 input supply lines H1 H2 control transformer leads to input side of ICR starter as shown 3 Insulate the unused H3 H4 H5 lead terminals with adequate tape to provide at least 600V insulation 4 Connect terminal marked to ground per national electrical code CAUT...

Page 49: ... if its code number is not listed Contact the Customer Service Department for any code numbers not listed Use the Illustration of Sub Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine Multi Process Switch K804 1 General Assembly A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 50: ...Page 50 DC 400 IMA 474 AP 239 C Operative 1 4 99 Supersedes New Multi Process Switch 2 4 11 12 5 10 13 8 9 14 17 3 1 16 6 L6203 1 A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 51: ... 6 Micro Switch Assembly S16658 1 X 1 4 20 Hex Head Cap Screw 2 X Lock Washer 2 X 1 4 20 Hex Nut 2 X 8 Output Terminal S16656 4 X Thread Forming Screw 8 X Output Stud Nut T3960 4 X 9 Control Handle Assembly S16664 7 1 X 10 Box AL2461 1 1 X 11 Jumper S16673 1 X Plain Washer 1 X Lock Washer 1 X 12 Jumper S16674 1 X Plain Washer 1 X Lock Washer 1 X 13 Marker to work T3962 1 1 X Fastener Button T14659...

Page 52: ...unction of any such battery CONDITION OF WARRANTY TO OBTAIN WARRANTY COVERAGE The purchaser must contact Lincoln or Lincoln s Authorised Service Facility about any defect claimed under Lincoln s warranty Determination of warranty on welding and cutting equipment will be made by Lincoln or Lincoln s Authorised Service Facility WARRANTY REPAIR If Lincoln or Lincoln s Authorised Service Facility conf...

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