Lincoln Idealarc 400 Manual

IM474-E
IDEALARC ® DC-400 February, 2011
For use with machines having Code Numbers: 9847 thru 9852, 9854, 9855, 9857, 10008,
10275, 10276, 10859, 10880, 11083, 11084,
This manual covers equipment which is no 11277, 11278, 11279 11348, 11349, 11350,
longer in production by The Lincoln Electric Co. 11351, 11352, 11353, 11567
Specifications and availability of optional
features may have changed.
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
... and thoughtful operation on
your part. DO NOT INSTALL,
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.
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
• 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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline 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.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & 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.
FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. 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 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. 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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
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 sitting,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and within applicable OSHA PEL and
should be as close as possible to the area being welded. ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
3.e. Ground the work or metal to be welded to a good electrical stances, outdoors, a respirator may be required.
(earth) ground. Additional precautions are also required when welding
on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace 5. b. The operation of welding fume control equipment is affected
damaged insulation. by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
3.g. Never dip the electrode in water for cooling. cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.h. Never simultaneously touch electrically “hot” parts of periodically thereafter to be certain it is within applicable
electrode holders connected to two welders because voltage OSHA PEL and ACGIH TLV limits.
between the two can be the total of the open circuit voltage
of both welders. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
3.i. When working above floor level, use a safety belt to protect The heat and rays of the arc can react with solvent vapors to
yourself from a fall should you get a shock. form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.j. Also see Items 6.c. and 8.
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

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.
5.f. Also see item 1.b.

iii iii
SAFETY
WELDING and CUTTING CYLINDER may explode
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. 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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing 8.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate cir- Electrical Code, all local codes and the manufacturer’s
cuits. This can create fire hazards or overheat lifting chains recommendations.
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturer’s recommendations.
6.I. 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.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instructions zones où lʼon pique le laitier.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 6. Eloigner les matériaux inflammables ou les recouvrir afin de
antes: prévenir tout risque dʼincendie dû aux étincelles.
Sûreté Pour Soudage A LʼArc 7. Quand on ne soude pas, poser la pince à une endroit isolé de
1. Protegez-vous contre la secousse électrique: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours 8. Sʼassurer que la masse est connectée le plus prés possible
tout contact entre les parties sous tension et la peau nue de la zone de travail quʼil est pratique de le faire. Si on place
ou les vétements mouillés. Porter des gants secs et sans la masse sur la charpente de la construction ou dʼautres
trous pour isoler les mains. endroits éloignés de la zone de travail, on augmente le risque
b. Faire trés attention de bien sʼisoler de la masse quand on de voir passer le courant de soudage par les chaines de lev-
soude dans des endroits humides, ou sur un plancher age, câbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques dʼincendie ou dʼechauffement des chaines et des
les positions assis ou couché pour lesquelles une grande câbles jusquʼà ce quʼils se rompent.
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble 9. Assurer une ventilation suffisante dans la zone de soudage.
de soudage et la machine à souder en bon et sûr état Ceci est particuliérement important pour le soudage de tôles
defonctionnement. galvanisées plombées, ou cadmiées ou tout autre métal qui
d.Ne jamais plonger le porte-électrode dans lʼeau pour le produit des fumeés toxiques.
refroidir.
e. Ne jamais toucher simultanément les parties sous tension 10. Ne pas souder en présence de vapeurs de chlore provenant
des porte-électrodes connectés à deux machines à souder dʼopérations de dégraissage, nettoyage ou pistolage. La
parce que la tension entre les deux pinces peut être le chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
total de la tension à vide des deux machines. du solvant pour produire du phosgéne (gas fortement toxique)
f. Si on utilise la machine à souder comme une source de ou autres produits irritants.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de 11. Pour obtenir de plus amples renseignements sur la sûreté,
soudage. voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, LES MACHINES À SOUDER À
donc:
TRANSFORMATEUR ET À
a. Utiliser un bon masque avec un verre filtrant approprié REDRESSEUR
ainsi quʼun verre blanc afin de se protéger les yeux du ray-
onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc. 1. Relier à la terre le chassis du poste conformement au code de
b. Porter des vêtements convenables afin de protéger la lʼélectricité et aux recommendations du fabricant. Le dispositif
peau de soudeur et des aides contre le rayonnement de de montage ou la piece à souder doit être branché à une
lʻarc. bonne mise à la terre.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables. 2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres 3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan- er à lʼinterrupteur à la boite de fusibles.
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
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!
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 posses-
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 customerʼs 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 record 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.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
vi TABLE OF CONTENTS vi
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions ..........................................................................................A-2
Correct Operational use ..................................................................................A-2
Stacking and Lifting.........................................................................................A-2
Input Power Connections ................................................................................A-2
Output Connections ........................................................................................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
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Operational ......................................................................................................Section B
Safety Precautions.................................................................................................B-1
Meaning of Graphic Symbols...................................................................B-1 thru B-3
General Machine Description ................................................................................B-4
Recommended Processes & Equipment ...............................................................B-4
Operational Features and Control .........................................................................B-4
Power Source Operation and Controls ....................................................B-5 thru B-7
Auxiliary Power Connections ..........................................................................B-8
Solid State Output Control ..............................................................................B-8
Case Features.................................................................................................B-8
Stick Welding ..................................................................................................B-9
Paralleling .......................................................................................................B-9
Machine & Circuit Protection...........................................................................B-9
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Accessories .....................................................................................................Section C
TIG Welding Options / Accessories.......................................................................C-1
Optional Equipment .............................................................................................C-1 thru C-2
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-5
Procedure for Replacing P.C. Boards ............................................................E-6, E-7
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Wiring Diagrams ..............................................................................................Section F
________________________________________________________________________
Parts Pages .................................................................................................P-234, P-239
A-1 INSTALLATION A-1
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 78/39/31Amps 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
Duty Cycle (1) Amps Volts at Rated Amps
100% 400 36
60% 450 38
50% 500 40
OUTPUT
OUTPUT MAXIMUM OPEN CIRCUIT VOLTAGE AUXILIARY POWER
Min.----60A 12V CV(22V CC) 57V. (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 (mm2) (IEC) SIZES (mm2)
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 81 3(25) 8(10) 100 REN-100

230/50/60Hz 77 3(25) 8(10) 100 REN-100
380/50/60Hz 47 6(16) 10(6) 60 RES-60
400/50/60Hz 45 6(16) 10(6) 60 RES-60
415/50/60Hz 43 8(10) 10(6) 60 RES-60
440/50/60Hz 41 8(10) 10(6) 50 RES-50
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
Failure to observe these precautions can result in

excessive operating temperatures and nuisance shut-
SAFETY PRECAUTIONS down of the machine.
WARNING
LIMIT ON STACKING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or WARNING
electrode with skin or wet clothing.
• Insulate yourself from work and FALLING EQUIPMENT can cause
ground. injury.
• Always wear dry insulating gloves. • Do not lift this machine using lift
------------------------------------------------------------------------ bale if it is equipped with a heavy
FUMES AND GASES can be danger- accessory such as trailer or gas
ous. cylinder.
• Keep your head out of fumes. • Lift only with equipment of adequate lifting
• Use ventilation or exhaust to remove capacity.
fumes from breathing zone. • Be sure machine is stable when lifting.
------------------------------------------------------------------------ • Do not stack more than three high.
WELDING SPARKS can cause fire or • Do not stack the DC-400 on top of any other
explosion. machine.
• Keep flammable material away.
• Do not weld on closed containers. The units may be stacked three high by observing the
following safety precautions:
------------------------------------------------------------------------ A. Make sure the first or bottom unit is setting on a
ARC RAYS can burn eyes and skin. level, well supported surface.
• Wear eye, ear and body
protection. 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
See additional warning information at being stacked on.
front of this operatorʼs manual.
Input Power Connections
----------------------------------------------------------- By removing the rear access panel the three phase
CORRECT OPERATIONAL USE input power is connected to the three line terminals on
the input contactor, and the earth grounding lead to
The machine should be located in a clean dry place the grounding terminal on the input box floor marked
where there is free circulation of clean air such that air with the symbol. Install and reconnect panel for
movement in through the front and out through the the proper input voltage per the diagram pasted inside
back will not be restricted. Dirt and dust that can be the access panel cover.
drawn into the machine should be kept to a minimum.
See Technical Specification Page:
IDEALARC® DC-400
REMOTE CONTROL ADAPTER CABLE (K864)
CAUTION
STRAIGHT PLUG (14 PIN) CABLE RECEPTACLE (6 SOCKET)
* Failure to follow these instructions TO POWER SOURCE
TO: 1) K857 REMOTE CONTROL
can cause immediate failure of com- 2) K963 HAND AMPTROL

3) K870 FOOT AMPTROL
ponents within the machine.

• When powering welder from a gener- CABLE RECEPTACLE (14 SOCKET)
ator be sure to turn off the welder TO LN-7 WIRE FEEDER
first, before generator is shut down in

order to prevent damage to welder.
A “V” cable 12” (.30m) long to connect a K857
Remote Control (6 pin connector) with a wire-feeder
Output Cable Connections (14-pin connector) and the machine (14-pin connec-
The output leads are connected to the output termi- tor). If a remote control is used alone the wire-feeder
nals marked “+” and “-”. They are located at the lower connection is then not used.
right and lower left corners of the front panel.
Output Cables WARNING
CABLE SIZES FOR COMBINED LENGTH OF
ELECTRODE AND WORK CABLE ELECTRIC SHOCK can kill.
MACHINE LOAD • Turn the power switch of the
400A 500A welding power source “OFF”
(100% DUTY (50% DUTY before installing plugs on
CABLE LENGTHS CYCLE) CYCLE)
cables or when connecting or
UP TO 50 ft 3/0 2/0 disconnecting plugs to weld-
(15m) 85 mm2 67 mm2
ing power source.
50 to 100 ft 3/0 2/0
(15-30 m) 85 mm2 67 mm2
AMPTROL ADAPTER CABLE (843)
100-150 ft 3/0 3/0
(30-46 m) 85 mm2 85 mm2 A five wire cable, 12” (.30m ) long, used for easy
connection of standard K963 Hand Amptrol or K870
150-200 ft 3/0 3/0 Foot amptrol. The cable has a 6-pin MS-style
(46-61 m) 85 mm2 85 mm2 connector which connects to the Amptrol and termi-
nals which connect to 75, 76, and 77 on the machine
200-250 ft 4/0 4/0 terminal strip and to the case grounding screw. the
(67-76 m) 107 mm2 107 mm2 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
INSTALLATION OF FIELD INSTALLED may be used in conjunction with the Amptrol Adapter
OPTIONS Cable Kit.) The Amptrol arc start switch is nonfunc-
tional unless used with a K799 Hi-Frequency Kit.
Remote Output Control (K857 or K857-1
with K864 Adapter)
See Amptrol Adapter installation Instructions on next
An optional “remote out control” is available. The
page.
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.
IDEALARC® DC-400
FIG. 4 FIG. 3 FIG. 2 FIG. 1
A-4
white lead to white.

K843 lead to black and K799
lead to white. and insulate.
connect black lead to black and white not used. Tape
SWITCH and SWITCH and connect black insulate.
K775 Tape and Black and white leads
ARC START ARC START
CUT OFF CUT OFF leads not used.
Black and white
76 { {
77
76 77 and tape. 75
77 76 75 77 76 75
insulate
connection. with K799)
(included K799) 76
Bolt and nut
Arc start cable (included with 77
K843 Adapter Arc start cable
K843 Adapter 77 76 75 strip
and tape. terminal Adapter
Insulate Power source K843
connection. Adapter
Bolt and nut K843
Amptrol™
INSTALLATION
or K870 Amptrol™
K963*,K813* SOURCE Kit Hi-Freq™ Kit Limit Control
POWER Hi-Freq™ or K870
K963*,K813* SOURCE K799 K775 Remote
K799 POWER
Limit Control
K775 Remote K870 Amptrol™
the remote limit control. SOURCE K963*, K813* or SOURCE
power source to a maximum set by K870 Amptrol™ POWER POWER
current from the minimum of the the full range of the power source. K963*, K813* or
welding. The Amptrol™ controls Amptrol™ controls current through by the remote limit control.
frequency starting for DC TIG starting for DC TIG welding. The the power source to a maximum set of the power source.
Hi-Freq™ kit to turn on gas and high kit to turn on gas and high frequency current control from the minimum of current control through the full range
The Amptrol™ switch will start the The Amptrol™ will start the Hi-Freq™ The Amptrol™ provides remote The Amptrol™ provides remote
PLUS REMOTE LIMIT CONTROL HI-FREQ.™ KIT REMOTE LIMIT CONTROL
AMPTROL™ PLUS AMPTROL™ ONLY
AMPTROL™ AND HI-FREQ.™ KIT AMPTROL™ AND
(D-10 and Pro) with remote control power sources.
and connected in four different ways, as shown below. accessories to DC-250, DC-400, R3R or Weldanpower 250
for Amptrol™ to control current. Accessories may be combined K813* or K870), remote control (K775), and HI-FREQ™ (K799)
The power source "machine/remote" switch must be in "remote" This K843 adapter is used to connect AMPTROL™ (K963*,
WARNING: TURN THE POWER SOURCE OFF BEFORE INSTALLATION
with remote control power sources.
For use with: DC-250, DC-400, R3R or Weldanpower 250 (D-10 and Pro)
A-4
K843 AMPTROL™ ADAPTER INSTALLATION INSTRUCTIONS

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INSTALLATION OF EQUIPMENT MULTIPROCESS SWITCH CONNECTION AND
REQUIRED FOR RECOMMENDED OPERATION
PROCESSES
PURPOSE
WIRE FEEDER CONTROL CABLE CONNECTIONS A Multiprocess Switch has been designed for use with
the DC-400 or DC-600. With this switch installed on
For control cable with 14-pin connector: the DC-400, it permits easy changing of the polarity of
the wire feed unit connected and also provides sepa-
Connect control cable to 14-pin connector on the front rate terminals for connection of stick or air carbon arc.
panel of the machine. See the appropriate connection The Multiprocess Switch is available as either a facto-
diagram for the exact instructions for the wire feeder ry installed or field installed option.
being used. Refer to Section 2.4.1 for connector pin
functions. NOTE: IF THE DC-400 IS TO BE USED FOR BOTH
SEMIAUTOMATIC/AUTOMATIC AND STICK/
AIR CARBON ARC, THEN A MULTI-
For control cable with terminal strip connectors: PROCESS SWITCH IS REQUIRED.
The control cable from the wire feeding equipment is

connected to the terminal strips behind the control DESIGN
panel*. A strain relief box connector is provided for
access into the terminal strip section. A chassis The Multiprocess Switch consists of a 3-position
ground screw is also provided below the terminal strip switch assembly that is mounted in a sheet metal
marked with the symbol for connecting the auto- enclosure that has two output terminals on each end
matic equipment grounding wire. See the appropriate of the box. The two terminals on the left side of the
connection diagram for the exact instructions for the box are for connection of wire feed electrode and work
wire feeder being used. leads. The two terminals on the right side of the box
are for connection of work and electrode for stick or
A cover (Lincoln Electric Part Number S17062-3) is air carbon arc. The output terminals are protected
available for the unused 14-pin connector to protect it against accidental contact by hinged covers.
against dirt and moisture.
The switch mounts to the front of the DC-400 by
* See Terminal Strip Connections section for access means of a bracket that fastens to the case sides.
to the terminal strips. Two 4/0 (107 mm2) leads connect the switch assem-
bly to each output stud.
CONNECTION OF DC-400 TO LN-22 OR LN-25
a) Turn off all power. CONNECTIONS
b) Place output terminals switch into the “ON” posi- 1. Connect wire feed unit electrode and work cables
tion. through the rectangular strain relief holes in the
base of the DC-400 to the output studs on the left
c) Connect the electrode cable to the output terminal side of the box.
of polarity required by electrode. Connect the work
lead to the other terminal. 2. Connect wire feeder control cable and make other
terminal strip connections as specified on the con-
d) Place the OUTPUT CONTROL Switch at “LOCAL” nection diagram for the Lincoln wire feeder being
position unless a Remote Control is connected to used. “Electrode” and “Work” are connected to the
the DC-400. left side of the Multiprocess Switch.
e) Place MODE SWITCH in “CONSTANT VOLTAGE 3. Connect stick or air carbon arc electrode and work
(FCAW, GMAW)”. cables through the rectangular strain relief holes in
the base of the DC-400 to the output studs on the
NOTE: The output terminals are energized at all right side of the box.
times.
OPERATION
IDEALARC® DC-400
The operation of the switch is as follows: WORK + To stick

electrode
A semiautomatic or automatic wire feed unit electrode holder or
air carbon
and work cables are connected to the terminals on the To semi- arc torch
left side of the box. Stick or air carbon arc electrode auto or ELECTRODE
and work leads are connected to the terminals on the auto User supplied
right side of the box. There are three positions on the uipment 4/0 (107 mm 2 )
switch. With the switch in the left position, the wire jumper
feed terminals are electrode negative. In the center
position, the wire feeder terminals are electrode posi- MULTIPROCESS SWITCH
tive. In both the left and center switch position, the
right side stick terminals are disconnected. In the
To change stick polarity, reverse the leads at the (+)
right switch position, the wire feed terminals are dis-
and (-) terminals on the right side of the Multiprocess
connected from the DC-400 and the stick terminals
Switch.
connected. The polarity of the stick terminals is
marked on the end of the box. To change polarity, the
NOTE: When a DC-400 equipped with Multiprocess
electrode and work leads must be interchanged. In
Switch is mounted on an undercarriage, the
the stick position, the stick terminals are energized at
undercarriage handle in the resting position
all times.
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
CONNECTIONS
hole in the undercarriage tow bar to limit the
travel of the undercarriage handle.
(For those applications where it is not necessary to
have separate work cables for stick and semiautomat-
ic welding.)
STICK, TIG OR AIR/CARBON ARC *
If both stick and semiautomatic welding is done on the
a) Turn off all power.
same workpiece, only one work lead is required. To
do this, connect a 4/0 (107 mm2) jumper from the
b) Disconnect all wire feed unit control, electrode, and
work terminal on the semiautomatic side to the termi-
work leads.
nal to be used for work on the stick side. The work
lead from the semiautomatic side then serves as the
c) Place MODE SWITCH in the “CONSTANT CUR-
work lead for both semiautomatic and stick welding.
RENT (STICK/TIG)” for air carbon arc.
d) 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. If
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
B-1 OPERATION B-1
SAFETY PRECAUTIONS OUTPUT CONTROL DIAL
WARNING
ELECTRIC SHOCK can kill. Output (Control)
• Have an electrician install and ser-
vice this equipment.
• Turn the input power off at the fuse
box before working on equipment. Increase/Decrease of
• Do not touch electrically hot parts. Output (Voltage or
• This next section applies to DC-400ʼs without Current)
the Capacitor Discharge Option:
OUTPUT CONTROL “LOCAL-REMOTE” SWITCH

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 Remote Output Voltage
electrode contacts the work or ground within several or Current Control
seconds after releasing the trigger.
When used with some wire feeders with the electrical Local Output Voltage or
trigger interlock in the ON position, the arc can restart Current Control
if the electrode touches the work or ground during
these several seconds.
CIRCUIT BREAKER
WARNING
• Be sure to select OUTPUT TERMINALS “REMOTE
ON/OFF” for operation with wire feeders that have Circuit Breaker
leads numbered 2 and 4.
THERMAL PROTECTION LIGHT

MEANINGS OF GRAPHIC SYMBOLS
High Temperature
The DC-400 nameplate has been redesigned to use
international symbols in describing the function of the
various components. Below are the symbols used.
ARC CONTROL SWITCH
POWER ON-OFF SWITCH

Gas Metal Arc
Input (Power) Welding
Increase/Decrease
On of Inductance
Low Inductance
Off
High Inductance
IDEALARC® DC-400
B-2 OPERATION B-2
OUTPUT TERMINALS SWITCH RATING PLATE
Output (Voltage) Three Phase Power
On Transformer
Remote On/Off Rectifier
ARC FORCE CONTROL DIAL

Rectified DC Output
Shielded Metal Arc

Welding
Constant Voltage
Characteristic
Gas Tungsten Arc
Welding MODE SWITCH
Do not switch if
Arc Force Current output voltage
or current is
present.
Increase/Decrease
of Current
VOLTMETER SWITCH Constant

Voltage
(Submerged Arc
Voltmeter Welding)
Positive Electrode
Constant
Voltage (Flux
cored arc
weldin,gas
Negative Electrode metal arc weld-
ing).
EARTH GROUND CONNECTION C o n s t a n t

Current (shield
metal arc weld-
Signifying the Earth
ing, gas tung-
(Ground) Connection
sten arc weld-
ing).
IDEALARC® DC-400
B-3 OPERATION B-3
RATING PLATE (Continued)
Designates welder complies with National Electrical Manufacturers

NEMA EW 1 Association requirements EW 1. (Export Model only)
Designates welder complies with International Electrotechnical

IEC 60974-1 Commission requirements 60974-1. (European model only)
Three Phase Power
Transformer
Rectifier
Rectified DC Output
Constant Voltage Characteristic
Constant Current Characteristic
Line Connection
Shielded Metal Arc Welding
Flux Cored Arc Welding
Submerged Arc Welding
Designates Welder can be used in environments with

S increased hazard of electric shock. (IEC model only)
IP21 Degree of protection provided by the enclosure
Designates welder complies with low voltage directive and with

CE EMC directive. (Export Model only)
IDEALARC® DC-400
B-4 OPERATION B-4
GENERAL MACHINE DESCRIPTION OUTPUT TERMINALS “ON” OR OUTPUT TERMI-
NALS “REMOTE”
The DC-400 is an SCR controlled three phase DC This switch provides an alternative to the “2 to 4”
power source. It is designed with a single range jumpering function by energizing the machineʼs output
potentiometer control. regardless of whether “2 or 4” is jumpered or not.
RECOMMENDED PROCESSES POLARITY SELECTION

& EQUIPMENT
Polarity selection is made by appropriately connecting
the electrode and work welding cables to either the
The DC-400 model is designed for all open arc
processes including Innershield® and GMAW all solid “ + “ stud or to the “- ” stud. Select “VOLTMETER”
wire and gas procedures within the capacity of the switch for “+” or “-” electrode, for the remote (#21)
machine, plus the capability of stick and TIG welding work sensing lead.
and air carbon arc gouging up to 5/16” (8mm) diame-
VOLTMETER SWITCH “+” ELECTRODE OR “-”
ter. A mode switch selects CV (FCAW, GMAW), CV
ELECTRODE
Submerged Arc, or CC (Stick/TIG). Stick welding per-
formance is similar to that of the R3R-500.
This switch selects electrode polarity for the remote
(#21) work sensing lead of automatic or semiautomat-
The DC-400 is designed to be used with the LN-7, LN-
ic equipment.
7 GMA, LN-8, LN-9, LN-9 GMA, LN-23P, LN-25, or
LN-742 semiautomatic wire feeders, the NA-3, NA-5 115 VOLT POWER SWITCH
and NA-5R automatics, and the LT-56 and LT-7 trac-
tors, within the 400 ampere capacity of the machine. The power input contactor operates from an auxiliary
The DC-400 Diode Kit option is required to utilize the 115 volt transformer that is energized through the
cold start and cold electrode sensing features of the POWER toggle switch on the machine control panel.
NA-3, NA-5 and NA-5R. “ I “ is on and “0” is off.
OPERATIONAL FEATURES & PILOT LIGHT
CONTROLS A white light on the machine control panel indicates

when the power source input contactor is closed. This
ARC CHARACTERISTICS means the main power transformer and all auxiliary
and control transformers are energized.
Through the unique combination of the transformer,
three phase semiconverter rectifier, capacitor bank, THERMAL PROTECTION LIGHT
arc control choke, and the solid state control system,
outstanding arc characteristics are achieved on con- An amber light on the machine control panel indicates
stant voltage. when either of the two protective thermostats have
opened. Output power will be removed but input
In addition, an arc force control enables the DC-400 to power will still be applied to the machine.
stick weld as well as the R3R-500.
INPUT CONTACTOR
OUTPUT CONTROL
The power source is equipped with an input contactor.
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”.
IDEALARC® DC-400
B-5 OPERATION B-5
POWER SOURCE OPERATION AND OUTPUT CONTROL “LOCAL-REMOTE” SWITCH©

CONTROLS The OUTPUT CONTROL toggle switch on the control
panel labeled “LOCAL-REMOTE” gives the operator
WARNING the option of controlling the output at the machine
ELECTRIC SHOCK can kill. control panel or at a remote station. For remote con-
• Have an electrician install and ser- trol, the toggle switch is set in the “REMOTE” position
vice this equipment. and controlled at the wire feed unit control, or by con-
• Turn the input power off at the fuse necting a K775 control to terminals 75, 76, and 77 on
box before working on equipment. the terminal strip at the front of the machine, or by
• Do not touch electrically hot parts. 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”.
Duty Cycle and Time Period (Exception: When used with an LN-9, LN-9 GMA or
The DC-400 is rated at the following duty cycles: NA-5 wire feeder, the OUTPUT CONTROL switch
DUTY CYCLE * AMPS VOLTS must be in the “REMOTE” position or automatic shut-
down of the LN-9 or NA-5 may occur.)
100% 400 36
60% 450 38 POLARITY SELECTION
50% 500 40
Polarity selection is made by appropriately connecting
* Based upon 10 minute time period (i.e., for 60% duty the electrode and work welding cables to either the
cycle, it is 6 minutes on and 4 minutes off). “ + ” stud or to the “- ” stud. Select “VOLTMETER”
Overloading the DC-400 may result in opening of an switch for “+” or “-” electrode for the remote (#21)
internal protective thermostat as indicated by the work sensing lead.
amber thermal protection light turning on.
VOLTMETER SWITCH
STARTING THE MACHINE
Select “+” for positive electrode or “-” for negative
The POWER toggle switch at the extreme right side of electrode polarity for the remote (#21) work sensing
the control panel in the “I“ position energizes and clos- lead of automatic or semiautomatic equipment.
es the three phase input contactor from a 115 volt
auxiliary transformer. This in turn energizes the main THERMAL PROTECTION LIGHT
power transformer.
The amber thermal protection light will be lit if either of
The machine is de-energized when the POWER the two protective thermostats have opened. The out-
switch is in the “0” position. put power will be disabled but input power will still be
applied to the welder. (Refer to Machine and Circuit
The white light below the POWER switch indicates Protection section).
when the input contactor is energized.
MODE SWITCH
OUTPUT CONTROL DIAL
The large MODE SWITCH on the left side of the
The OUTPUT control to the right of the center of the machine, labeled “Constant Voltage (Submerged Arc),
control panel is a continuous control of the machine Constant Voltage (FCAW/GMAW) and Constant
output. The control may be rotated from minimum to Current (Stick/TIG)”, is used to select the proper
maximum while under load to adjust the machine out- welder characteristics for the process being used.
put.
The CV (FCAW/GMAW) Mode permits the DC-400 to
The machine is equipped with line voltage compensa- produce essentially a flat output characteristic that can
tion as a standard feature. This will hold the output be varied from approx. 12 to 42 volts.
constant except at maximum output of the machine,
through a fluctuation of ±10% input line voltage.
IDEALARC® DC-400
B-6 OPERATION B-6
In this position, the dynamic characteristics of the OUTPUT TERMINALS SWITCH
machine under welding conditions provide optimum
welding characteristics for Innershield® welding, other The OUTPUT TERMINALS toggle switch on the con-
open arc processes including short arc MIG welding, trol panel labeled “REMOTE - ON” allows the welder
and air carbon arc. Most submerged arc welding can output to be activated remotely or to be always on.
also be done in this mode. For remote operation, the toggle switch is set in
“REMOTE” position and the welder output will be acti-
The CV (Submerged Arc) Mode also produces an vated when 2 and 4 are closed when using a wire-
essentially flat output characteristic that can be varied feeder. For welder output to always be activated, set
from approximately 12 to 42 volts. The dynamic the switch to the “ON” position.
characteristics of the CV Submerged Arc Mode make
possible improved submerged arc welding over that 110-115V AC and 40-42V AC Auxiliary
possible using the Constant Voltage Innershield Power and Control Connections
Mode. The improvement is most noticeable on high
deposition, slow travel speed welds.
14-PIN CONNECTOR
There are no means provided to switch between any
The 14-pin connector receptacle supplies auxiliary
of the modes remotely. Do not change the position of
power.
the MODE SWITCH if output voltage or current is pre-
sent as this may damage the switch.
40-42V AC is available at receptacle pins I and K. A
10 amp circuit breaker protects this circuit.
The CC Mode permits the DC-400 to produce a con-
stant current output characteristic through the range of
On the Domestic and Export models 110-115V AC is
60-500 amps with an open circuit voltage of approxi-
available at receptacle pins A and J. A 10 amp circuit
mately 57 volts (54V on 50/60 Hz). Stick welding and
breaker protects this circuit. Note that the 40-42V AC
TIG are done with this position of the Mode Switch.
and 110-115V AC circuits are electrically isolated from
each other.
ARC FORCE CONTROL DIAL (Effective only in CC
mode)
FRONT VIEW OF 14-PIN
CONNECTOR RECEPTACLE
The ARC FORCE control is calibrated from one to ten.
For most welding, the dial should be set at approxi- D = 4E
C =2
L =S P A R E
B= GN D
=7 7
A =3 2
M =S P A R E
K =4 2
F =7 6G=7
J= 31
5
H =2 1
N = S P A RE
I= 4 1
mately midrange, 5-6. Adjustments up or down can K=42

A=32 J=31
then be made depending on the electrode, proce-
dures, and operator preference. Lower settings will B=GND I=41
provide less short circuit current and a softer arc. A
setting that is too low may cause the electrode to stick L=SPARE N=SPARE
in the puddle. Higher settings will provide a higher
short circuit current and a more forceful arc. C=2
H=21
Excessive spatter may result if the control setting is
D=4
too high. For most TIG welding applications adjust G=75
this control to a minimum for best operating character-
E=77 F=76
istics.
M =SPARE
ARC CONTROL SWITCH (Effective only in CV

FCAW/GMAW mode)
PIN LEAD NO. FUNCTION
The ARC CONTROL is a tapped switch numbered
from 1 to 5 and changes the pinch effect of the arc. A 32 110 - 115V AC (Domestic & Export)
B GND CHASSIS CONNECTION
This control is most useful in processes that utilize a C 2 TRIGGER CIRCUIT
“shorting” metal transfer and controls the spatter, fluid- D 4 TRIGGER CIRCUIT
E 77 OUTPUT CONTROL
ity, and bead shape. The pinch effect is increased by F 76 OUTPUT CONTROL
turning the control clockwise. G 75 OUTPUT CONTROL
H 21 WORK CONNECTION
I 41 40-42V AC
For all applications, a good starting point for the ARC J 31 110-115V AC (Domestic & Export)
CONTROL is a midrange dial setting of 3. The control K 42 40-42V AC
L --- ---
can be increased or decreased as desired. M --- ---
N --- ---
IDEALARC® DC-400
B-7 OPERATION B-7
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.
5 4 3
1 2
1 2
5 4 3
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 located 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
B-8 OPERATION B-8
AUXILIARY POWER CONNECTIONS
The SCR snubber board consists of a capacitor and
The power source is equipped to furnish nominally resistor connected across each SCR and across the
110-115 volt AC and 40-42 volt AC auxiliary power for entire bridge and MOVʼs to protect the control circuitry
operating wire feeding equipment, etc. The auxiliary and SCRʼs from transient voltages. The snubber
power is available at the 14-pin MS-style connector board is mounted on the back of the case front.
receptacle on the control panel and/or at a terminal
strip behind the hinged control panel on the front of The SCR firing circuit, the control fault protection cir-
the power source. 110-115V AC is available at recep- cuit, the power-up delay circuit, and the power circuit
tacle pins A and J (Domestic and Export models only), are mounted on the control PC board located behind
and terminals 31 and 32 (all models). 40-42V AC is the front control panel. (The front control panel hinges
available only at receptacle pins I and K. The 110- down for easy access to the board.)
115V AC and the 40-42V AC are isolated circuits and The starting circuit board is located on the back of the
each is protected by a 10 amp circuit breaker. control box.
REMOTE CONTROL CONNECTIONS MACHINE COOLING
Remote control connections are available both at a The fan pulls air in through the louvered front of the
14-pin connector receptacle located on the control machine over the internal parts and exhausts out the
panel, and on terminal strips with screw connections louvered rear of the machine. The fan motor is fully
located behind the hinged control panel on the front of enclosed, has sealed ball bearings, requires no lubri-
the power source. cation, and operates when the power switch is turned
on.
OUTPUT CONNECTIONS
CASE FEATURES
The output terminals are recessed on the case front
and labeled “+” and “-”. The machine uses a 32” (813mm) long base. The low
profile case facilitates installation of the machine
INPUT CONNECTIONS under a workbench and stacking the machines three
high to conserve floor space.
The three input lines are brought in through the rear
panel of the power source and attached to the input The case front incorporates a recessed control panel
contactor. Removal of the removable access panel where all the machine controls are mounted. This
makes the contactor accessible for the input cable recessed panel protects the controls and minimizes
connections. the possibilities of accidental contact. This control
panel can be easily opened to permit access to the
INPUT LINE VOLTAGE COMPENSATION enclosed control section which contains the terminal
strips, PC board, etc.
The power source is equipped with input line voltage
compensation as standard. For a line voltage fluctua- The output lead terminals are also recessed to avoid
tion of ±10% the output will remain essentially con- any object or person accidentally coming in contact
stant. This is accomplished through the feedback net- with an output terminal. Strain relief is provided by
work in the control circuit. holes in the front of the base. The leads are routed up
through these holes to the output terminals. This pre-
SOLID STATE OUTPUT CONTROL vents any damage of the output studs or insulation of
same in the event the cables are pulled excessively.
The output of the welder is electronically controlled by An output stud cover protects against accidental con-
SCRʼs instead of mechanical contactors, providing tact with the output studs. Cover hinges upward for
extra long life for highly repetitive welding applica- access to the studs.
tions.
The individual case sides are removable for easy
SOLID STATE CONTROL SYSTEM access for internal service or inspection. These are
removable even though the machines are stacked
The control circuitry consists of six basic circuits: (1) three high.
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.
IDEALARC® DC-400
B-9 OPERATION B-9
The case rear, top section, is equipped with a remov- DIODE OPTION
able access panel. This provides easy access to the
input contactor, easy connection and reconnection of The DC-400 Diode option is required to utilize the cold
input leads, and easy access for service or inspection. start and cold electrode sensing features of the NA-3,
NA-5 or NA-5R. When this option is not used with an
The total construction of the machine permits outdoor NA-3, NA-5 or NA-5R, see the DC-400/NA-3, DC-
operation. The enclosure is designed with air intake 400/NA-5 or DC-400/NA-5R connection diagram for
louvers that keep dripping water from being drawn into instructions on how to disable this circuit. If the circuit
the unit. The transformer, SCR bridge assembly, and is not disabled, the wire cannot be inched down.
choke are double-dipped in a special corrosion resis-
tant coating.
Machine & Circuit Protection
A permanent lifting hook is located at the top of the (Thermal Protection Light)
machine and is positioned so that it acts as nearly as
possible through the center of gravity. This lift hook is The power source is thermostatically protected with
so positioned that it fits without interference under the proximity thermostats against overload or insufficient
base of the second machine when stacking. cooling. One thermostat is located on the nose of the
center bottom primary coil and a second thermostat is
ARC FORCE SELECTOR attached to the lead connecting the secondaries.
(Effective only on CC for Stick and TIG Processes) Both thermostats are connected in a series with the 2-
4 circuit. If the machine is overloaded, the primary
An ARC FORCE selector is provided similar to that thermostat will be open, the output will be zero, and
used on the R3R. This control allows the user to the amber thermal protection light will be on. The fan
select the ideal arc force for the procedure and elec- will continue to run. The secondary thermostat will
trode being used. open either with an excessive overload or insufficient
cooling. The output will be zero and the amber pro-
ARC CONTROL
tection light will be on. When the thermostats reset
(Effective Only When Using CVI Mode)
the protection light will be off.
The ARC CONTROL is a five-position switch that
The power source is also protected against overloads
changes the pinch effect of the arc. This results in the
on the SCR bridge assembly through an electronic
control of spatter, fluidity, and bead shape. The ARC
protection circuit. This circuit senses an overload on
CONTROL is set to provide optimum welding depend-
the power source and limits the output to 550 amps by
ing on the process being used, position, electrode,
phasing back the SCRʼs.
etc. The pinch effect is increased by turning the con-
trol clockwise and may be adjusted while the machine
Protection is provided to protect the circuitry from
is in operation.
accidental grounds. If the customer accidentally
MODE SWITCH “grounds” 75, 76, or 77 to the positive output lead, the
DC-400 will be reduced to a low value, thus prevent-
A MODE SWITCH selects between Constant Voltage ing any damage to the machine. If the ground occurs
(FCAW/GMAW), Constant Voltage (Submerged Arc), between 75, 76, 77 and the negative output lead, one
and Constant Current (Stick/TIG). of the PC board “self-restoring” fuses will blow, pre-
venting any machine damage.
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.
IDEALARC® DC-400
C-1 ACCESSORIES C-1
TIG OPTIONS UNDERCARRIAGES (K817, K817R, K841)
TIG MODULE (K930-2) For easy moving of the machine, optional undercar-
riages are available with either steel (K817) or rubber
Docking Kit tired (K817R) wheels or a platform undercarriage
Control Cable Extension-45ʼ (K841) with mountings for two gas cylinder at rear of
Water valve Kit welder.
AMPTROL ADAPTER FOR K799 HI-FREQUENCY Install per instructions provided with trailer.
KIT (K915-1, REQUIRES K864 ADAPTER)
OPTIONAL EQUIPMENT
A “V” cable to connect a K799 Hi-Freq Kit (5-pin con- Factory Installed Options
nector) with either 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 DIODE OPTION
which requires a K864 adapter to connect with the 14-
pin connector on the DC-400. Refer to S20909 This internally installed option allows the use of the
instructions for connection information. cold start and cold electrode sensing features of the
NA-3, NA-5 or NA-5R.
MULTIPROCESS SWITCH (K804-1)
MULTIPROCESS SWITCH
Kit that mounts on the front of the DC-400, and
includes hinged covers over its output studs. The Factory or field installed kit that mounts on the front of
switch has three positions: Positive the DC-400, and includes hinged covers over its out-
semiautomatic/automatic, negative semiautomatic/ put studs. The switch has three positions: Positive
automatic, and stick/air carbon arc. Required when semiautomatic / automatic, negative semiautomatic /
using the DC-400 for both semiautomatic/automatic automatic, and stick / air carbon arc. Required when
and stick/air carbon arc. using the DC-400 for both semiautomatic/automatic
and stick/air carbon arc. The field installed kit equiva-
Install per M17137 instructions included with the field lent is identified as K804-1. For details on the
installed kit. Multiprocess Switch, see the Installation of Equipment
section.
CAPACITOR DISCHARGE CIRCUIT (K828-1)
Field Installed Options
Circuit that mounts inside the DC-400.
Recommended when: REMOTE OUTPUT CONTROL
(K857 WITH K864 ADAPTER OR K775 )
1) DC-400 is used in conjunction with any LN-23P or
older LN-8 or LN-9 semiautomatic wire-feeder. The K857 has a 6-pin MS-style connector. The K857
Eliminates possible arc flash re-start of weld when requires a K864 adapter cable which connects to the
trigger interlock is used. Not required with current 14-pin connector on the machine.
LN-8 (above Code 8700), or LN-9ʼs with serial num-
bers above 115187 (manufactured after 12/83), or An optional “remote output control” is available. This is
any LN-9 having an L6043-1 Power PC Board. the same remote control that is used on the Lincoln
R3R, and DC-600 power sources (K775). The K775
2) DC-400 is used with an LN-22 equipped with an consists of a control box with 28 ft (8.5m) of four con-
older K279 Contactor-Voltage Control Option. ductor cable. This connects to terminals 75, 76, and
Eliminates electrode overrun when gun trigger is 77 on the terminal strip and the case grounding screw
released. Not required when later K279 (above so marked with the symbol on the machine. These
Code 8800) is used. terminals are located behind the control panel on the
front of the power source. This control will give the
3) DC-400 is used with any semiautomatic wire-feeder same control as the output control on the machine.
and possible small spark, if electrode touches work
just after gun trigger is released, is objectionable.
Install per M17060 instructions included with the
Kit.
IDEALARC® DC-400
C-2 ACCESSORIES C-2
AMPTROL™ ADAPTER CABLE (K843)

For easy moving of the machine, optional undercar-
A five wire cable, 12” (.30m) long, is available for easy riages are available with either steel (K817) or rubber
connection of standard K963 Hand Amptrol or K870 tired (K817R) wheels or a platform undercarriage
Foot Amptrol. The cable has a 6-pin MS-style connec- (K841) with mountings for two gas cylinder at rear of
tor which connects to the Amptrol and terminals which welder.
connect to 75, 76 and 77 on the machine terminal
strip and to the case grounding screw. The Amptrol Install per instructions provided with trailer.
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. 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) CABLE RECEPTACLE (6 SOCKET)

TO POWER SOURCE
TO: 1) K857 REMOTE CONTROL
2) K963 HAND AMPTROL
3) K870 FOOT AMPTROL
CABLE RECEPTACLE (14 SOCKET)
TO 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). If a
remote control or amptrol is used alone the wire-feed-
er connection is then not used.
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)

IDEALARC® DC-400
D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS
WARNING
-----------------------------------------------------------------------
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 operatorʼs 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
E-1 TROUBLESHOOTING E-1
HOW TO USE TROUBLESHOOTING GUIDE
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 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 Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
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.
WARNING
• Have an electrician install and service
this 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 troubleshooting assistance before you proceed.
IDEALARC® DC-400
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). 1. Repair or Replace.
2. Low line voltage. 2. Check input power.
Machine input contactor does not 1. Supply line fuse blown. 1. Replace if blown - look for reason
operate. first.
2. Contactor power circuit dead. 2. Check control transformer T2 and

associated leads.
3. Broken power lead. 3. Check input voltage at contactor.
4. Wrong input voltage. 4. Check voltage against instruc-

tions.
5. Open input contactor coil.
5. Replace coil.
6. POWER “I/0” switch (S1) not
closing. 6. Replace switch.
Machine input contactor operates, 1. 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.
2. Electrode or work lead loose or 2. Repair Connection.

broken.
3. Open main transformer (T1) pri- 3. Repair.

mary or secondary circuit.
4. Defective Control PC Board. 4. Replace. See Procedure for

Replacing PC Boards.
5. Primary or secondary thermostats 5. Amber thermal protection light is

open. on: Check for overheating; make
sure fan is operating and there is
no obstruction to free air flow.
Machine has minimum output and no 1. Terminals 75, 76 or 77 grounded 1. Check 75, 76, or 77 for ground to
control. 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
IDEALARC® DC-400
Machine has high output or pulsing 1. Terminals 75, 76, or 77 grounded 1. Check 75, 76, or 77 for ground to
output and no control. to negative output. negative output circuit. Nearly
zero ohms 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.
Machine has low output and no 1. OUTPUT CONTROL “LOCAL- 1. Check position of switch.
control. REMOTE” switch (S2) in wrong
position.
2. OUTPUT CONTROL switch 2. Check switch & replace if faulty.

faulty.
3. Open in feedback circuitry. 3. Check wiring and control PC

Board wiring harness plugs.
4. Faulty Control PC Board. 4. Replace. See Procedure for

5. OUTPUT control potentiometer 5. Check and replace potentiometer

circuit open (lead 75). if faulty. Check wiring of lead
#75.
Machine does not have maximum 1. One input fuse blows. 1. Check and replace if blown after
output. checking for reason for blown
fuse.
2. One phase of main transformer 2. Check for open and repair.

open.

4. OUTPUT control potentiometer. 4. Check and Replace if faulty.
5. OUTPUT control potentiometer 5. Check and repair broken leads.

leads 210, 211 or 75 open.
Machine will not shut off. 1. Input contactor contacts frozen. 1. Check and replace if necessary.
2. Defective POWER “1/0” switch, 2. Replace.

(S1).
CAUTION
IDEALARC® DC-400
Variable or sluggish welding arc. 1. Poor work or electrode connec- 1. Check and clean all connections.
tion.
2. Check table in instruction manual.
2. Welding leads too small.
3. Check procedures for recom-
mended settings.
3. Welding current or voltage too
low. 4. Check and replace if defective.
4. Defective main SCR bridge. 5. Check and replace if defective.

(If S4C or S4D actuator is found
5. Microswitch S4C or S4D actuator defective, replace mode switch
defective. cam also.)
OUTPUT control not functioning on 1. OUTPUT CONTROL switch in 1. Place switch in “LOCAL”.
the machine. wrong position.
2. Faulty OUTPUT control switch. 2. Check and replace if found faulty.
3. Faulty OUTPUT control poten- 3. Check and replace if found faulty.

tiometer.
4. Leads or connections open in 4. Check lead continuity and con-

control circuit. nections for an open and repair if
necessary.

OUTPUT control not functioning on 1. OUTPUT CONTROL switch in 1. Place switch in “REMOTE”.
“REMOTE” control. wrong position.
2. Faulty OUTPUT CONTROL 2. Check and replace if found faulty.

switch.
3. Check and replace if found faulty.
3. Faulty remote control potentiome-
ter. 4. Check all leads and connections,
internal or remote, for continuity.
4. Leads or connections open in Repair if necessary.
control circuit.

CAUTION
IDEALARC® DC-400
Poor arc striking with semiautomatic 1. Defective start circuit. 1. Check Start PC Board and reed
or automatic wire feeders. switch CR3.
2. Poor work connection. 2. Work connection must be ade-

quate for application.
3. Improper procedures. 3. Adjust procedures for improved

starting.

Poor arc characteristics. 1. Start circuit energized at all times 1. Short reed switch CR3 leads
(read switch CR3 not closing). together. If welding improves,
replace reed switch.
2. Defective Start PC Board.
2. If problem is still present with
reed switch shorted, unplug Start
PC Board. If problem disap-
pears, replace Start PC Board.

4. Capacitor(s) in output circuit 4. Replace entire bank of capaci-

failed. A failure is indicated if the tors. Do not replace individual
small vent plug on top of a capac- 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 1. Defective R1, L1, S4C, S4D actu- 1. Check and replace if found defec-
(FCAW/GMAW) mode with short cir- ator or S5. tive. (If S4C or S4D actuator is
cuit transfer processes. found defective, replace mode
switch cam also.)
115VAC Receptacle not working. 1. Circuit Breaker Tripped. 1. Reset circuit breaker. Make sure
2. Defective Circuit Breaker. load on does not exceed 15A rat-
3. Broken connection in wiring. ing of circuit breaker.
2. Replace
3. Check all wiring going to recepta-
cle and circuit breaker for possible
broken connection.
CAUTION
IDEALARC® DC-400
PROCEDURE FOR REPLACING PC BOARDS FAULT PROTECTION OPERATION
WARNING The overload protection circuit, in the Control PC Board will

limit the welding current (heat) to 550 amps if a short or
ELECTRIC SHOCK can kill. overload is applied to the machine. (Refer to the Machine
and Circuit Protection section).
CHECKING SNUBBER CIRCUIT
• Do not touch electrically hot parts.
In case of an SCR malfunction or failure the snubber
----------------------------------------------------------------------
assembly should be checked. Turn the machine off and
When a PC Board is suspected to be defective, the follow- remove the sides of the machine. (See the instruction man-
ing procedure must be followed: ual parts list for the exact location.)
1. Visually inspect the PC Board. If the board has fuses, 1. Visually inspect the snubber assembly for overheated
check to see if any are blown. Are any of the compo- components or damaged components.
nents damaged? Is a conductor on the back side of the
board damaged? If electrical damage is visible on the CHECKING OUTPUT CONTROL RHEOSTAT ON
PC Board, inspect the machine wiring for grounds or MACHINE
shorts to avoid damaging a new PC Board, Install a new
PC Board only after a visual inspection of the PC Board Turn machine off (“0” position).
and machine wiring is satisfactory.
2. If the problem is remedied by a new PC Board, install the Remove the control panel screws and open the control
old PC Board and see if the problem still exists. If the panel (see the section on Terminal Strip Connections for
problem does not return with the old board: screw locations).
a) Check the PC Board harness plug and PC Board plug
for contamination, corrosion or oversize. Turn the OUTPUT CONTROL switch to “REMOTE”.
b) Check leads in the harness for loose connections.
Disconnect the harness plug from the Control PC Board.
CONNECTING THE REMOTE CONTROL TO THE
MACHINE With an ohmmeter on X1K, connect it to lead 210 and 75 on
R4.
Extreme caution must be observed when installing or
extending the wiring of a remote control. Improper connec- Exercise caution to avoid damaging POT taps.
tion of this unit can lead to failure of the output control rheo-
stat or the control circuit. Only the green lead can and POWER “I/0” SWITCH CHECK
should be grounded to the machine case. When extending
the standard remote control, make sure the leads are the 1. Turn off the machine power input (“0” position). S1 has
same and the splice is waterproof. Be very careful not to 115V across it when the input power is connected.
ground the cable when in use and donʼt let the lugs touch
against the case. 2. Isolate the switch to be tested by removing all connecting
leads.
OUTPUT VOLTAGE
3. Check to make sure the switch is making connections
The output circuit voltage of the machine should be with an ohmmeter. The meter should read zero resis-
adjustable from 10 to 46 volts in CV. In the CC mode, the tance.
open circuit voltage should be approximately 57 volts (54
volts on 50/60 Hz) except at near minimum settings of the 4. Put the ohmmeter on X1K scale and measure the resis-
output control where it may be lower. If any other condition tance between the terminal and the case of the machine
exists, refer to the Troubleshooting Guide. (touch a self-tapping screw). Reading should be infinite.
5. If either step (3) or step (4) fails, replace the switch.
CAUTION
IDEALARC® DC-400
REMOTE CONTROL CHECK 2. Power Diode Test
Disconnect the remote output control and connect an a) Establish the polarity of the ohmmeter leads
ohmmeter across 75 to 76 and rotate the rheostat in and set to X10 scale.
the remote control. The resistance reading should go
from zero to 10K ohms. Repeat with ohmmeter b) Connect the ohmmeter positive lead to anode
across 75 and 76 with same results. Connect ohm- and negative lead to cathode.
meter across 75 and 77. The reading should be 10K
ohms. A lower reading will indicate a shorted or par- c) Reverse the leads of the ohmmeter from
tially shorted rheostat. A very high reading will indi- Step b.
cate an open rheostat. In either of the last two cases,
replace rheostat. Check cable for any physical dam- d) A shorted diode will indicate zero or an equally
age. 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
POWER RECTIFIER BRIDGE ASSEMBLY low resistance in Step b and Step a much high-
CHECKING PROCEDURE er resistance in Step c.
WARNING 3. Power Silicon Controlled Rectifier Test

• Have an electrician install and ser- a) Connect the ohmmeter (set to m X10 scale)
vice this equipment. leads to the anode and cathode.
box before working on equipment. b) Reverse the leads of the ohmmeter from Step
• Do not touch electrically hot parts. a.
---------------------------------------------------------------------
c) A shorted SCR will indicate zero or an equally
1. Bridge and Device Isolation (See the instruc- low resistance in one or both directions.
tion manual parts list for the exact location.)
d) Establish the polarity of the ohmmeter.
Disconnect the following leads from the bridge, Connect the positive lead to the gate and the
shown in Diagram 1: negative lead to the cathode.
a) Unplug P3 (G1, G2, G3 and 204) from the e) An open gate circuit will have an infinite or high
Control PC Board. resistance. A good gate circuit will read a low
resistance, but not zero ohms. If gate circuit
b) Unplug P5 from the Snubber PC Board. reads zero ohms, check gate harness for
shorts between gate leads and 204 before
c) Secondary leads X1, X2, and X3 from the replacing SCR.
anodes of the SCRʼs and cathodes of the
diodes.
d) Disconnect positive bridge lead from shunt and

positive capacitor bank lead and from lug with
triple 204 leads.
e) Perform the following steps 2 and 3. If diodes

and SCRʼs 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.
CAUTION
IDEALARC® DC-400
F-1 DIAGRAMS F-1
IDEALARC® DC-400
F-2
DIAGRAMS
IDEALARC® DC-400
WIRING DIAGRAM FOR CODES 9847 THRU 9852, 9854, 9855, 9857, 10008, 10275, 11350, 11351
NOTE: This diagram is for reference only. It may not be accurate for all machines covered 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 Service Department for a replacement. Give the equipment code number.
F-2
F-3
WIRING DIAGRAM FOR CODES 10859, 10880,11083, 11084
DIAGRAMS
IDEALARC® DC-400
A
L9107
F-3
F-4
WIRING DIAGRAM FOR CODE 9847, 11349
DIAGRAMS
IDEALARC® DC-400
F-4
F-5
DIAGRAMS
IDEALARC® DC-400
WIRING DIAGRAM FOR CODES 11277, 11278 AND 11279, 11348, 11352, 11353 and 11567
F-5
NOTES
IDEALARC® DC-400
NOTES
IDEALARC® DC-400
• Do not touch electrically live parts or • Keep flammable materials away. • Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.

• Insulate yourself from work and
ground.
Spanish
• No toque las partes o los electrodos • Mantenga el material combustible • Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.
PRECAUCION • Aislese del trabajo y de la tierra.
French • Ne laissez ni la peau ni des vête- • Gardez à l’écart de tout matériel • Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
• Isolez-vous du travail et de la terre.
German • Berühren Sie keine stromführenden • Entfernen Sie brennbarres Material! • Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
• Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
• Não toque partes elétricas e electro- • Mantenha inflamáveis bem guarda- • Use proteção para a vista, ouvido e
dos com a pele ou roupa molhada. dos. corpo.
ATENÇÃO • Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
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 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.
• Keep your head out of fumes. • Turn power off before servicing. • Do not operate with panel open or
• Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
• Los humos fuera de la zona de res- Spanish
• Desconectar el cable de ali- • No operar con panel abierto o
piración.
• Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
• Gardez la tête à l’écart des fumées. • Débranchez le courant avant l’entre- • N’opérez pas avec les panneaux French
• Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
• Vermeiden Sie das Einatmen von • Strom vor Wartungsarbeiten • Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öffnen; oder Innenschutzverkleidung in
• Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Maschine anhalten!) Betrieb setzen! WARNUNG
• Não opere com as tampas removidas. Portuguese
• Mantenha seu rosto da fumaça. • Mantenha-se afastado das partes
• Use ventilação e exhaustão para • Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço.
• Não toque as partes elétricas nuas.
• Não opere com os paineis abertos ATENÇÃO
ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES

DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• 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

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IM474-E

IDEALARC ® DC-400 February, 2011

Safety Depends on You

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

FOR ENGINE 1.h. To avoid scalding, do not remove the

2.d.4. Connect the work cable to the workpiece as close as

5.e. Read and understand the manufacturer’s instructions for this

5.f. Also see item 1.b.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

On-Line Product Registration

400Amps/36V 450Amps/38V 500Amps/40V

400Amps/36V 450Amps/38V 500Amps/40V

220/50/60Hz 81 3(25) 8(10) 100 REN-100

27.50 in. 22.25 in. 32.0 in. 473 lbs.

Failure to observe these precautions can result in

can cause immediate failure of com- 2) K963 HAND AMPTROL

ponents within the machine.

ator be sure to turn off the welder TO LN-7 WIRE FEEDER

first, before generator is shut down in

The K857 and K857-1 have a 6-pin connector and

white lead to white.

K843 AMPTROL™ ADAPTER INSTALLATION INSTRUCTIONS

The control cable from the wire feeding equipment is

a) Turn off all power. CONNECTIONS

The operation of the switch is as follows: WORK + To stick

d) For stick, TIG or air carbon arc, place OUTPUT

*NOTE: If stick welding, TIG welding or air carbon arc

SAFETY PRECAUTIONS OUTPUT CONTROL DIAL

OUTPUT CONTROL “LOCAL-REMOTE” SWITCH

THERMAL PROTECTION LIGHT

POWER ON-OFF SWITCH

Output (Voltage) Three Phase Power

Remote On/Off Rectifier

ARC FORCE CONTROL DIAL

Shielded Metal Arc

VOLTMETER SWITCH Constant

EARTH GROUND CONNECTION C o n s t a n t

Designates welder complies with National Electrical Manufacturers

Designates welder complies with International Electrotechnical

Three Phase Power

Constant Voltage Characteristic

Constant Current Characteristic

Shielded Metal Arc Welding

Flux Cored Arc Welding

Submerged Arc Welding

Designates Welder can be used in environments with

IP21 Degree of protection provided by the enclosure

Designates welder complies with low voltage directive and with

RECOMMENDED PROCESSES POLARITY SELECTION

OPERATIONAL FEATURES & PILOT LIGHT

CONTROLS A white light on the machine control panel indicates

MACHINE OUTPUT CONTROL SWITCH “LOCAL”

The machine output can be controlled by either the

POWER SOURCE OPERATION AND OUTPUT CONTROL “LOCAL-REMOTE” SWITCH©

mately midrange, 5-6. Adjustments up or down can K=42