Lincoln Electric DC-400 manual

RED-D-ARC DC-400 IM655-B November, 2006 Red-D-Ar c Spec-Built W elding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on Y ou This welder is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful ope[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

Thank You for selecting a QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions [...]

vi vi T ABLE OF CONTENTS Page Installation .. .......................................................................................................Section A Technical Specifications ............................................................................................. A-1 Safety Precautions .................................................[...]

vii T ABLE OF CONTENTS Page Maintenance ... ....................................................................................................Section D Safety Precautions .......................................................................................................D-1 Routine Maintenance ..................................................[...]

A-1 INST ALLA TION DC-400 A-1 TECHNICAL SPECIFICA TIONS – DC-400 Standard Input Current at Rated Output (CVI) Voltage 100 % Duty Cycle 60 % Duty Cycle (4) 50 % Duty Cycle Frequency 230/460/575V/60Hz 400Amps/36V 450Amps/38V 500Amps/40V 78/39/31Amps 83/42/33Amps 84/42/34Amps INPUT -THREE PHASE ONL Y RA TED OUTPUT HEIGHT WIDTH DEPTH WEIGHT 27.50 in.[...]

A-2 INST ALLA TION DC-400 A-2 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. ---------------------[...]

A-3 INST ALLA TION DC-400 A-3 REMOTE CONTROL ADAPTER CABLE (K864) 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[...]

A-4 INST ALLA TION DC-400 A-4 HI-FREQUENCY KIT (K799 CODES 8634 AND ABOVE ONL Y) 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[...]

A-5 INST ALLA TION DC-400 A-5 CONNECTION OF DC-400 TO LN-22 OR LN-25 a) Turn off all power. b) Place output terminals switch into the “ ON ” posi- tion. c) Connect the electrode cable to the output terminal of polarity required by electrode. Connect the work lead to the other terminal. d) Place the OUTPUT CONTROL Switch at “ LOCAL ” positio[...]

A-6 INST ALLA TION DC-400 A-6 AUXILIARY POWER CONNECTIONS The power source is equipped to furnish nominally 110-115 volt AC and 40-42 volt AC auxiliary power for operating wire feeding equipment, etc. The auxiliary power is available at the 14-pin MS-style connector receptacle on the control panel and/or at a terminal strip behind the hinged contro[...]

A-7 INST ALLA TION DC-400 A-7 The individual case sides are removable for easy access for internal service or inspection. The case rear, top section, is equipped with a remov- able access panel. This provides easy access to the input contactor, easy connection and reconnection of input leads, and easy access for service or inspection. The total con[...]

A-8 INST ALLA TION DC-400 A-8 To change stick polarity, reverse the leads at the (+) and (-) terminals on the right side of the Multiprocess Switch. NOTE: When a DC-400 equipped with Multiprocess Switch is mounted on an undercarriage, the undercarriage handle in the resting position can hit the case of the Multiprocess Switch. This does no harm, bu[...]

B-1 OPERA TION DC-400 B-1 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill. • Have an electrician install and ser- vice this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. • This next section [...]

DC-400 B-2 OPERA TION B-2 Gas Metal Arc Welding ARC CONTROL SWITCH Increase/Decrease of Inductance Low Inductance High Inductance Output (Voltage) OUTPUT TERMINALS SWITCH On Remote On/Off Shielded Metal Arc Welding ARC FORCE CONTROL DIAL Gas Tungsten Arc Welding Arc Force Current Increase/Decrease of Current Voltmeter VOLTMETER SWITCH Positive Elec[...]

DC-400 B-3 OPERA TION B-3 RATING PLATE (Continued) Transformer Constant Current Characteristic Submerged Arc Welding Rectifier Rectified DC Output Constant Voltage Characteristic Line Connection Shielded Metal Arc Welding Designates Welder can be used in environments with increased hazard of electric shock. (IEC model only) Flux Cored Arc Welding D[...]

DC-400 B-4 OPERA TION B-4 Do not switch if output voltage or current is present. MODE SWITCH Warning Identification WARNING IDENTIFICATION Signifying the Earth (Ground) Connection EARTH GROUND CONNECTION Constant Voltage (Submerged Arc Welding) Constant Voltage (Flux cored arc welding, gas metal arc welding). Constant Current (shield metal arc weld[...]

B-5 OPERA TION B-5 GENERAL MACHINE DESCRIPTION The DC-400 is an SCR controlled three phase DC power source. It is designed with a single range potentiometer control. 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), t[...]

B-6 OPERA TION B-6 POWER SOURCE OPERA TION Duty Cycle and Time Period The DC-400 is rated at the following duty cycles: * Based upon 10 minute time period (i.e., for 60% duty cycle, it is 6 minutes on and 4 minutes off). Overloading the DC-400 may result in opening of an internal protective thermostat as indicated by the amber thermal protection li[...]

B-7 OPERA TION B-7 In this position, the dynamic characteristics of the machine under welding conditions provide optimum welding characteristics for Innershield ® welding, other open arc processes including short arc MIG welding, and air carbon arc. Most submerged arc welding can also be done in this mode. The CV (Submerged Arc) Mode also produces[...]

B-8 OPERA TION B-8 T erminal Strip Connections Terminal strip TS2 located behind the hinged control panel on the front of the power source supplies 110-115V AC. A 15 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[...]

C-1 ACCESSORIES C-1 Factory Installed Options DIODE OPTION This internally installed option allows the use of the cold start and cold electrode sensing features of the NA-3, NA-5 or NA-5R. MULTIPROCESS SWITCH Factory or field installed kit that mounts on the front of the DC-400, and includes hinged covers over its out- put studs. The switch has thr[...]

C-2 ACCESSORIES C-2 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 cool[...]

DC-400 D-1 MAINTENANCE D-1 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[...]

DC-400 E-1 TROUBLESHOOTING E-1 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair possible machine [...]

E-2 TROUBLESHOOTING E-2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Input contactor (CR1) chatters. Machine input contactor does not operate. Machine input contactor operates, but no output when trying to weld. Machine has minimum output and no control. 1. Faulty inpu[...]

E-3 TROUBLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSIBLE CA[...]

E-4 TROUBLESHOOTING E-4 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSIBLE CA[...]

DC-400 E-5 TROUBLESHOOTING E-5 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. PROCEDURE FOR REPLACING PC BOARDS When a PC Board is suspected to be defective, the following [...]

DC-400 E-6 TROUBLESHOOTING E-6 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. REMOTE CONTROL CHECK Disconnect the remote output control and connect an ohmmeter across 75 to[...]

F-1 DIAGRAMS F-1 DC-400 L9107 13 14 15 16 17 18 H2 H3 H4 ELECTRICAL SYMBOLS PER E1537 CONNECTOR CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P.C. BOARD) NOTES N.A. CIRCUITRY PRESENT ON CAPACITOR DISCHARGE ONLY. TO PROVIDE AT LEAST 600 V INSULATION. CONTROL BOARD P6 206 205 225 VM AM 206 231 + + - - 232 PILOT LIGHT SWITCH POWER S1 225 225 P2 209 214[...]

F-2 DIAGRAMS F-2 DC-400 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.. WIR[...]

F-3 DIAGRAMS F-3 DC-400 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.. WIR[...]

F-4 DIAGRAMS F-4 DC-400 POWER RECTIFIER BRIDGE DIAGRAM 1 PLUG TO SNUBBER BOARD SHUNT P5 221 222 223 204 220 204 204 204 204 220 D1 D2 D3 SCR1 SCR2 SCR3 G1 G2 G3 D4 ANODE CATHODE ANODE CATHODE P3 Gate leads plug to control P.C. board To T1 main transformer To plug P1 To mode switch To (+) side of capacitor bank _ + X 1 X 2 X 3 GATE _ +[...]

F-5 DIMENSION PRINT F-5 DC-400 Part No. Type ABCD F G H M12244-7 DC-400 32.00 15.39 30.92 1.44 30.02 + .11 30.02 + .11 .94[...]

DC-400 NOTES[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA E[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

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