Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines; OPERATOR’S MANUAL
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii; Refer to
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - PRÉCAUTIONS DE SÛRETÉ; iv
PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique:...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TAbLE OF CONTENTS
vi vi TAbLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions ............
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS – DC-400
A-1 INSTALLATION IDEALARC® DC-400 A-1 TECHNICAL SPECIFICATIONS – DC-400 INPUT-THREE PHASE ONLY RATED OUTPUT HEIGHT WIDTH DEPTH WEIGHT 27.50 in. 22.25 in. 32.0 in. 473 lbs. 699 mm 565 mm 988 mm 215 kg. OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIzES FOR MAXIMUM RATED OUTPUT. IN ADDITION, FOLLOW LATEST N...
Page 9 - SAFETY PRECAUTIONS; Input Power Connections; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n a t; FALLING EQUIPMENT
A-2 INSTALLATION IDEALARC® DC-400 A-2 SAFETY PRECAUTIONS CORRECT OPERATIONAL USE The machine should be located in a clean dry placewhere there is free circulation of clean air such that airmovement in through the front and out through theback will not be restricted. Dirt and dust that can bedrawn in...
Page 10 - Output Cable Connections; Output Cables; CAUTION
A-3 INSTALLATION IDEALARC® DC-400 A-3 * 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 welderfirst, before generator is shut down inorder to prevent damage to welder. Output Cable C...
Page 11 - IO
A-4 INSTALLATION A-4 K 84 3 A M P TR O L™ A D A P TE R IN S TA LL A TI O N IN S TR U C TI O N S Fo r u se w ith : D C -2 50 , D C -4 00 , R 3R o r W el da np ow er 2 50 (D -1 0 an d P ro ) w ith re m ot e co nt ro l p ow er s ou rc es . W A R N IN G : T U R N T H E P O W E R S O U R C E O FF B E FO ...
Page 12 - WIRE FEEDER CONTROL CAbLE CONNECTIONS
A-5 INSTALLATION IDEALARC® DC-400 A-5 I N S TA L L AT I O N O F E Q U I P M E N T R E Q U I R E D F O R R E C O M M E N D E D PROCESSES WIRE FEEDER CONTROL CAbLE CONNECTIONS For control cable with 14-pin connector: Connect control cable to 14-pin connector on the frontpanel of the machine. See the a...
Page 13 - CONNECTIONS; MULTIPROCESS SWITCH
A-6 INSTALLATION IDEALARC® DC-400 A-6 The operation of the switch is as follows: A semiautomatic or automatic wire feed unit electrodeand work cables are connected to the terminals on theleft side of the box. Stick or air carbon arc electrodeand work leads are connected to the terminals on theright ...
Page 14 - OPERATION; ELECTRIC SHOCK
b-1 OPERATION IDEALARC® DC-400 b-1 SAFETY PRECAUTIONS When using a DC-400 power source with wire feederswhich do not have an electrical trigger interlock (orwith wire feeders with the electrical trigger interlock inthe OFF position), there will be a small spark if theelectrode contacts the work or g...
Page 16 - NEMA EW 1
b-3 OPERATION b-3 IDEALARC® DC-400 RATING PLATE (Continued) Constant Current Characteristic Submerged Arc Welding Designates welder complies with National Electrical ManufacturersAssociation requirements EW 1. (Export Model only) Designates welder complies with low voltage directive and withEMC dire...
Page 17 - GENERAL MACHINE DESCRIPTION
b-4 OPERATION b-4 IDEALARC® DC-400 GENERAL MACHINE DESCRIPTION The DC-400 is an SCR controlled three phase DCpower source. It is designed with a single rangepotentiometer control. RECOMMENDED PROCESSES& EQUIPMENT T h e D C - 4 0 0 m o d e l i s d e s i g n e d f o r a l l o p e n a r cprocesses ...
Page 18 - Duty Cycle and Time Period
b-5 OPERATION b-5 IDEALARC® DC-400 POWER SOURCE OPERATION ANDCONTROLS Duty Cycle and Time Period The DC-400 is rated at the following duty cycles: * 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 anin...
Page 19 - OUTPUT TERMINALS SWITCH
b-6 OPERATION b-6 IDEALARC® DC-400 In this position, the dynamic characteristics of themachine under welding conditions provide optimumwelding characteristics for Innershield ® welding, other open arc processes including short arc MIG welding,and air carbon arc. Most submerged arc welding canalso be...
Page 20 - Terminal Strip Connections
b-7 OPERATION b-7 IDEALARC® DC-400 Terminal Strip Connections Terminal strip TS2 located behind the hinged controlp a n e l o n t h e f r o n t o f t h e p o w e r s o u r c e s u p p l i e s110-115V AC. A 10 amp circuit breaker protects thiscircuit. Note that this 110-115V AC is also available inth...
Page 22 - MODE SWITCH
b-9 OPERATION b-9 IDEALARC® DC-400 The case rear, top section, is equipped with a remov-able access panel. This provides easy access to theinput contactor, easy connection and reconnection ofinput leads, and easy access for service or inspection. The total construction of the machine permits outdoor...
Page 23 - ACCESSORIES; TIG OPTIONS; OPTIONAL EQUIPMENT; Factory Installed Options; DIODE OPTION; Field Installed Options
C-1 ACCESSORIES C-1 TIG OPTIONS TIG MODULE (K930-2) Docking KitControl Cable Extension-45’Water valve Kit AMPTROL ADAPTER FOR K799 HI-FREQUENCYKIT (K915-1, REQUIRES K864 ADAPTER) A “V” cable to connect a K799 Hi-Freq Kit (5-pin con-nector) with either a K963 Hand Amptrol or a K870Foot Amptrol (6-pin...
Page 25 - MAINTENANCE; • Turn the input power off at the fuse; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n
D-1 MAINTENANCE D-1 IDEALARC® DC-400 SAFETY PRECAUTIONS ----------------------------------------------------------------------- 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 e...
Page 26 - TROUbLESHOOTING; Local Lincoln Authorized Field Service Facility; HOW TO USE TROUbLESHOOTING GUIDE
E-1 TROUbLESHOOTING E-1 IDEALARC® DC-400 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. CAUTION This Troubleshooti...
Page 27 - Observe all Safety Guidelines detailed throughout this manual; PRObLEMS
E-2 TROUbLESHOOTING E-2 IDEALARC® DC-400 Observe all Safety Guidelines detailed throughout this manual 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 troubleshoo...
Page 32 - REMOTE CONTROL CHECK
E-7 TROUbLESHOOTING E-7 IDEALARC® DC-400 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. CAUTION REMOTE CONTROL CHE...
Page 33 - DIAGRAMS
Page 38 - NOTES