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IM474-D
IDEALARC DC-400 October, 2007
For Machines Having Code Numbers 9847 thru 9852, 9854, 9855, 9857, 10008,
10275, 10276, 10859, 10880, 11083, 11084,
11277, 11278, 11279
11348, 11349, 11350, 11351, 11352, 11353
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 READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR鈥橲 MANUAL
Copyright 漏 2007 Lincoln Global Inc.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
i i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause
cancer, birth defects, or other reproductive harm.
cancer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of 鈥淪afety in Welding & Cutting - ANSI Standard Z49.1鈥? from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of 鈥淎rc Welding Safety鈥? 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
powered equipment. radiator pressure cap when the engine is
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
may be dangerous
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from localized Electric and Magnetic Fields (EMF). Welding
vaporizing on contact with hot engine parts current creates EMF fields around welding cables and
and igniting. Do not spill fuel when filling tank. welding machines
If 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.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
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.
SAFETY
ii ii
ARC RAYS can burn.
ELECTRIC SHOCK can
kill. 4.a. Use a shield with the proper filter and cover
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 鈥渉ot鈥? when the welder is on. open arc welding. Headshield and filter lens
Do not touch these 鈥渉ot鈥? 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
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
4.c. Protect other nearby personnel with suitable, non-flammable
area of physical contact with work and ground.
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
can be dangerous.
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
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
鈥? Semiautomatic DC Constant Voltage (Wire) Welder.
fumes and gases. When welding, keep
鈥? DC Manual (Stick) Welder. your head out of the fume. Use enough
鈥? 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 鈥渉ot鈥?. 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 below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and 5. b. The operation of welding fume control equipment is affected
welding machine in good, safe operating condition. Replace by various factors including proper use and positioning of
damaged insulation. the equipment, maintenance of the equipment and the
specific welding procedure and application involved.
3.g. Never dip the electrode in water for cooling. Worker exposure level should be checked upon installation
and periodically thereafter to be certain it is within
3.h. Never simultaneously touch electrically 鈥渉ot鈥? parts of applicable OSHA PEL and ACGIH TLV limits.
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
of both welders. coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.i. When working above floor level, use a safety belt to protect form phosgene, a highly toxic gas, and other irritating
yourself from a fall should you get a shock. products.
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始s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer始s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
SAFETY
iii iii
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 鈥淪afety in Welding and Cutting鈥? (ANSI 鈥? 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.
鈥? 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 鈥渉ot鈥? 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 鈥渃leaned鈥?. For information, purchase 鈥淩ecommended 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鈥?, 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 鈥淧recautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,鈥? 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
FOR ELECTRICALLY
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
powered equipment.
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
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
8.b. Install equipment in accordance with the U.S. National
increase the possibility of the welding current passing
Electrical Code, all local codes and the manufacturer始s
through lifting chains, crane cables or other alternate
recommendations.
circuits. This can create fire hazards or overheat lifting
chains or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer始s recommendations.
6.h. Also see item 1.c.
Jan, 07
6.I. Read and follow NFPA 51B 鈥? Standard for Fire Prevention
During Welding, Cutting and Other Hot Work鈥?, 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.
SAFETY
iv iv
PR脡CAUTIONS DE S脹RET脡 6. Eloigner les mat茅riaux inflammables ou les recouvrir afin de
pr茅venir tout risque d始incendie d没 aux 茅tincelles.
Pour votre propre protection lire et observer toutes les instructions
et les pr茅cautions de s没ret茅 specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince 脿 une endroit isol茅 de
manuel aussi bien que les pr茅cautions de s没ret茅 g茅n茅rales
la masse. Un court-circuit accidental peut provoquer un
suivantes:
茅chauffement et un risque d始incendie.
S没ret茅 Pour Soudage A L始Arc
8. S始assurer que la masse est connect茅e le plus pr茅s possible
1. Protegez-vous contre la secousse 茅lectrique:
de la zone de travail qu始il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d始autres
a. Les circuits 脿 l始茅lectrode et 脿 la pi茅ce sont sous tension
endroits 茅loign茅s de la zone de travail, on augmente le risque
quand la machine 脿 souder est en marche. Eviter toujours
de voir passer le courant de soudage par les chaines de
tout contact entre les parties sous tension et la peau nue
levage, c芒bles de grue, ou autres circuits. Cela peut
ou les v茅tements mouill茅s. Porter des gants secs et sans
provoquer des risques d始incendie ou d始echauffement des
trous pour isoler les mains.
chaines et des c芒bles jusqu始脿 ce qu始ils se rompent.
b. Faire tr茅s attention de bien s始isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
9. Assurer une ventilation suffisante dans la zone de soudage.
metallique ou des grilles metalliques, principalement dans
Ceci est particuli茅rement important pour le soudage de t么les
les positions assis ou couch茅 pour lesquelles une grande
galvanis茅es plomb茅es, ou cadmi茅es ou tout autre m茅tal qui
partie du corps peut 锚tre en contact avec la masse.
produit des fume茅s toxiques.
c. Maintenir le porte-茅lectrode, la pince de masse, le c芒ble
de soudage et la machine 脿 souder en bon et s没r 茅tat
10. Ne pas souder en pr茅sence de vapeurs de chlore provenant
defonctionnement.
d始op茅rations de d茅graissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-茅lectrode dans l始eau pour le
chaleur ou les rayons de l始arc peuvent r茅agir avec les vapeurs
refroidir.
du solvant pour produire du phosg茅ne (gas fortement toxique)
e. Ne jamais toucher simultan茅ment les parties sous tension
ou autres produits irritants.
des porte-茅lectrodes connect茅s 脿 deux machines 脿 souder
parce que la tension entre les deux pinces peut 锚tre le
11. Pour obtenir de plus amples renseignements sur la s没ret茅,
total de la tension 脿 vide des deux machines.
voir le code 鈥淐ode for safety in welding and cutting鈥? CSA
f. Si on utilise la machine 脿 souder comme une source de
Standard W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-茅lectrode s始applicuent aussi au pistolet de
soudage.
PR脡CAUTIONS DE S脹RET脡 POUR
2. Dans le cas de travail au dessus du niveau du sol, se prot茅ger
LES MACHINES 脌 SOUDER 脌
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le c芒ble-茅lectrode autour de n始importe quelle partie
TRANSFORMATEUR ET 脌
du corps.
REDRESSEUR
3. Un coup d始arc peut 锚tre plus s茅v猫re qu始un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant appropri茅 1. Relier 脿 la terre le chassis du poste conformement au code de
ainsi qu始un verre blanc afin de se prot茅ger les yeux du l始茅lectricit茅 et aux recommendations du fabricant. Le dispositif
rayonnement de l始arc et des projections quand on soude de montage ou la piece 脿 souder doit 锚tre branch茅 脿 une
ou quand on regarde l始arc. bonne mise 脿 la terre.
b. Porter des v锚tements convenables afin de prot茅ger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, I始installation et l始entretien du poste seront
l驶arc. effectu茅s par un 茅lectricien qualifi茅.
c. Prot茅ger l始autre personnel travaillant 脿 proximit茅 au
soudage 脿 l始aide d始茅crans appropri茅s et non-inflammables. 3. Avant de faires des travaux 脿 l始interieur de poste, la
debrancher 脿 l始interrupteur 脿 la boite de fusibles.
4. Des gouttes de laitier en fusion sont 茅mises de l始arc de
soudage. Se prot茅ger avec des v锚tements de protection libres 4. Garder tous les couvercles et dispositifs de s没ret茅 脿 leur
de l始huile, tels que les gants en cuir, chemise 茅paisse, place.
pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de s茅curit茅 dans la zone de
soudage. Utiliser des lunettes avec 茅crans lateraux dans les
zones o霉 l始on pique le laitier.
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
Thank You 鈥⑩?⑩?? 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
equipment. 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
possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to
such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer始s particular
purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for
updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand
or alter any warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change 鈥? 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.
鈥? 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.
鈥? For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose 鈥淨uick Links鈥? and then
鈥淧roduct Registration鈥?. 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.
鈥?6鈥?
TABLE OF CONTENTS
Page
Safety Precautions..............................................................................................................i-iv
Introductory Information .......................................................................................................6
Meaning of Graphic Symbols ............................................................................................8-13
General Machine Description..............................................................................................14
Recommended Processes & Equipment ............................................................................14
Operational Features and Control ....................................................................................14-16
Operational Equipment.................................................................................................17
Technical Specification .......................................................................................................18
Installation ........................................................................................................................19-24
Safety Precautions .......................................................................................................19
Location ........................................................................................................................19
Stacking........................................................................................................................19
Input Wiring ..................................................................................................................19
Output Connections......................................................................................................20
Installation of Field Installed Options .........................................................................20-22
Installation of Equipment Required for Recommended Processes............................22-24
Operating Instructions.........................................................................................................24
Safety Precautions .......................................................................................................24
Power Source Operation and Controls.............................................................................25-27
Duty Cycle ....................................................................................................................25
To Set Polarity ..............................................................................................................25
Control Descriptions...................................................................................................25-27
Maintenance .......................................................................................................................27
Routine Maintenance....................................................................................................27
Troubleshooting................................................................................................................28-32
Procedure for Replacing P.C. Boards.................................................................................33
Miscellaneous System Checks ...........................................................................................34
Power Rectifier Bridge ........................................................................................................35
Wiring Diagram............................................................................................................36,37,38,39
Parts Lists ....................................................................................................................P234,P239
鈥?7鈥?
MEANINGS OF GRAPHIC SYMBOLS
The DC-400 nameplate has been redesigned to use international symbols in describing the function of the various
components. Below are the symbols used.
POWER ON-OFF SWITCH
Input (Power)
On
Off
OUTPUT CONTROL DIAL
Output (Control)
Increase/Decrease of Output (Voltage or Current)
OUTPUT CONTROL 鈥淟OCAL-REMOTE鈥? SWITCH
Remote Output Voltage or Current Control
Local Output Voltage or Current Control
鈥?8鈥?
CIRCUIT BREAKER
Circuit Breaker
THERMAL PROTECTION LIGHT
High Temperature
ARC CONTROL SWITCH
Gas Metal Arc Welding
Increase/Decrease of Inductance
Low Inductance
High Inductance
鈥?9鈥?
OUTPUT TERMINALS SWITCH
Output (Voltage)
On
Remote On/Off
ARC FORCE CONTROL DIAL
Shielded Metal Arc Welding
Gas Tungsten Arc Welding
Arc Force Current
Increase/Decrease of Current
鈥? 10 鈥?
VOLTMETER SWITCH
Voltmeter
Positive Electrode
Negative Electrode
RATING PLATE
Three Phase Power
Transformer
Rectifier
Rectified DC Output
Constant Voltage Characteristic
鈥? 11 鈥?
RATING PLATE (Continued)
NEMA EW 1 Designates welder complies with National Electrical Manufacturers
Association requirements EW 1. (Export Model only)
IEC 60974-1
Designates welder complies with International Electrotechnical
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
S
Designates Welder can be used in environments with
increased hazard of electric shock. (IEC model only)
IP21
CE
Degree of protection provided by the enclosure
Designates welder complies with low voltage directive and with
EMC directive. (Export Model only)
鈥? 12 鈥?
MODE SWITCH
Do not switch if output voltage or current is present.
Constant Voltage (Submerged Arc Welding)
Constant Voltage (Flux cored arc welding, gas
metal arc welding).
Constant Current (shield metal arc welding, gas
tungsten arc welding).
WARNING IDENTIFICATION
Warning Identification
EARTH GROUND CONNECTION
Signifying the Earth (Ground) Connection
鈥? 13 鈥?
GENERAL MACHINE DESCRIPTION MACHINE OUTPUT CONTROL SWITCH 鈥淟OCAL鈥?
OR 鈥淩EMOTE鈥?
The DC-400 is an SCR controlled three phase DC The machine output can be controlled by either the
power source. It is designed with a single range OUTPUT control on the machine control panel, the
potentiometer control. output control on the wire feed unit, or an optional
鈥渞emote control鈥? that is available. This switch selects
the mode of control, either 鈥淟OCAL鈥? or 鈥淩EMOTE鈥?.
RECOMMENDED PROCESSES
& EQUIPMENT
OUTPUT TERMINALS 鈥淥N鈥? OR OUTPUT
TERMINALS 鈥淩EMOTE鈥?
This switch provides an alternative to the 鈥?2 to 4鈥?
The DC-400 model is designed for all open arc
jumpering function by energizing the machine始s output
processes including Innershield庐 and GMAW all solid
regardless of whether 鈥?2 or 4鈥? is jumpered or not.
wire and gas procedures within the capacity of the
machine, plus the capability of stick and TIG welding
POLARITY SELECTION
and air carbon arc gouging up to 5/16鈥? (8mm)
diameter. A mode switch selects CV (FCAW,
Polarity selection is made by appropriately connecting
GMAW), CV Submerged Arc, or CC (Stick/TIG). Stick
the electrode and work welding cables to either the
welding performance is similar to that of the R3R-500.
鈥?+鈥? stud or to the 鈥?-鈥? stud. Select 鈥淰OLTMETER鈥?
The DC-400 is designed to be used with the LN-7, switch for 鈥?+鈥? or 鈥?-鈥? electrode, for the remote (#21)
LN-7 GMA, LN-8, LN-9, LN-9 GMA, LN-23P, LN-25, work sensing lead.
or LN-742 semiautomatic wire feeders, the NA-3,
NA-5 and NA-5R automatics, and the LT-56 and LT-7
VOLTMETER SWITCH 鈥?+鈥? ELECTRODE OR 鈥?-鈥?
tractors, within the 400 ampere capacity of the
ELECTRODE
machine. The DC-400 Diode Kit option is required to
utilize the cold start and cold electrode sensing
This switch selects electrode polarity for the remote
features of the NA-3, NA-5 and NA-5R.
(#21) work sensing lead of automatic or
semiautomatic equipment.
OPERATIONAL FEATURES &
CONTROLS 115 VOLT POWER SWITCH
The power input contactor operates from an auxiliary
ARC CHARACTERISTICS 115 volt transformer that is energized through the
POWER toggle switch on the machine control panel.
鈥? I 鈥? is on and 鈥?0鈥? is off.
Through the unique combination of the transformer,
three phase semiconverter rectifier, capacitor bank,
arc control choke, and the solid state control system, PILOT LIGHT
outstanding arc characteristics are achieved on
constant voltage. A white light on the machine control panel indicates
when the power source input contactor is closed. This
In addition, an arc force control enables the DC-400 to means the main power transformer and all auxiliary
stick weld as well as the R3R-500. and control transformers are energized.
THERMAL PROTECTION LIGHT
OUTPUT CONTROL
An amber light on the machine control panel indicates
The OUTPUT control, a small 2 watt potentiometer, is
when either of the two protective thermostats have
calibrated from 1 to 10. The OUTPUT control serves
opened. Output power will be removed but input
as a voltage control in the CV position and a current
power will still be applied to the machine.
control in the CC position.
INPUT CONTACTOR
The power source is equipped with an input contactor.
鈥? 14 鈥?
AUXILIARY POWER CONNECTIONS SOLID STATE CONTROL SYSTEM
The power source is equipped to furnish nominally The control circuitry consists of six basic circuits: (1)
110-115 volt AC and 40-42 volt AC auxiliary power for the SCR snubber network, (2) the SCR firing circuit,
operating wire feeding equipment, etc. The auxiliary (3) the control/fault protection circuit, (4) the starting
power is available at the 14-pin MS-style connector circuit, (5) the power-up delay circuit, and (6) the
receptacle on the control panel and/or at a terminal power circuit.
strip behind the hinged control panel on the front of
the power source. 110-115V AC is available at The SCR snubber board consists of a capacitor and
receptacle pins A and J (Domestic and Export models resistor connected across each SCR and across the
only), and terminals 31 and 32 (all models). 40-42V entire bridge and MOV始s to protect the control circuitry
AC is available only at receptacle pins I and K. The and SCR始s from transient voltages. The snubber
110-115V AC and the 40-42V AC are isolated circuits board is mounted on the back of the case front.
and each is protected by a 10 amp circuit breaker.
The SCR firing circuit, the control fault protection
circuit, the power-up delay circuit, and the power
REMOTE CONTROL CONNECTIONS circuit are mounted on the control PC board located
behind the front control panel. (The front control
Remote control connections are available both at a panel hinges down for easy access to the board.)
14-pin connector receptacle located on the control The starting circuit board is located on the back of the
panel, and on terminal strips with screw connections control box.
located behind the hinged control panel on the front of
the power source.
MACHINE COOLING
OUTPUT CONNECTIONS The fan pulls air in through the louvered front of the
machine over the internal parts and exhausts out the
The output terminals are recessed on the case front louvered rear of the machine. The fan motor is fully
and labeled 鈥?+鈥? and 鈥?-鈥?. enclosed, has sealed ball bearings, requires no
lubrication, and operates when the power switch is
turned on.
INPUT CONNECTIONS
CASE FEATURES
The three input lines are brought in through the rear
panel of the power source and attached to the input
contactor. Removal of the removable access panel The machine uses a 32鈥? (813mm) long base. The low
makes the contactor accessible for the input cable profile case facilitates installation of the machine
connections. under a workbench and stacking the machines three
high to conserve floor space.
INPUT LINE VOLTAGE COMPENSATION The case front incorporates a recessed control panel
where all the machine controls are mounted. This
The power source is equipped with input line voltage recessed panel protects the controls and minimizes
compensation as standard. For a line voltage the possibilities of accidental contact. This control
fluctuation of 卤10% the output will remain essentially panel can be easily opened to permit access to the
constant. This is accomplished through the feedback enclosed control section which contains the terminal
network in the control circuit. strips, PC board, etc.
The output lead terminals are also recessed to avoid
SOLID STATE OUTPUT CONTROL any object or person accidentally coming in contact
with an output terminal. Strain relief is provided by
The output of the welder is electronically controlled by holes in the front of the base. The leads are routed up
SCR始s instead of mechanical contactors, providing through these holes to the output terminals. This
extra long life for highly repetitive welding prevents any damage of the output studs or insulation
applications. of same in the event the cables are pulled
excessively. An output stud cover protects against
accidental contact with the output studs. Cover
hinges upward for access to the studs.
鈥? 15 鈥?
The individual case sides are removable for easy PARALLELING
access for internal service or inspection. These are
removable even though the machines are stacked There are no provisions on the DC-400 to permit
three high. paralleling.
The case rear, top section, is equipped with a
removable access panel. This provides easy access DIODE OPTION
to the input contactor, easy connection and
reconnection of input leads, and easy access for The DC-400 Diode option is required to utilize the cold
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
resistant coating.
Machine & Circuit Protection
(Thermal Protection Light)
A permanent lifting hook is located at the top of the
machine and is positioned so that it acts as nearly as
possible through the center of gravity. This lift hook is
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 will continue to run. The secondary thermostat will
electrode being used. open either with an excessive overload or insufficient
cooling. The output will be zero and the amber
protection light will be on. When the thermostats reset
ARC CONTROL
the protection light will be off.
(Effective Only When Using CVI Mode)
The power source is also protected against overloads
The ARC CONTROL is a five-position switch that
on the SCR bridge assembly through an electronic
changes the pinch effect of the arc. This results in the
protection circuit. This circuit senses an overload on
control of spatter, fluidity, and bead shape. The ARC
the power source and limits the output to 550 amps by
CONTROL is set to provide optimum welding
phasing back the SCR始s.
depending on the process being used, position,
electrode, etc. The pinch effect is increased by
Protection is provided to protect the circuitry from
turning the control clockwise and may be adjusted
accidental grounds. If the customer accidentally
while the machine is in operation.
鈥済rounds鈥? 75, 76, or 77 to the positive output lead, the
DC-400 will be reduced to a low value, thus
MODE SWITCH
preventing any damage to the machine. If the ground
occurs between 75, 76, 77 and the negative output
A MODE SWITCH selects between Constant Voltage
lead, one of the PC board 鈥渟elf-restoring鈥? fuses will
(FCAW/GMAW), Constant Voltage (Submerged Arc),
blow, preventing any machine damage.
and Constant Current (Stick/TIG).
STICK WELDING
When the DC-400 is used for stick welding or air
carbon arc, the control leads and welding cables to
any semiautomatic or automatic wire feeders must be
disconnected from the DC-400 for maximum safety
(unless the Multiprocess switch option is installed).
鈥? 16 鈥?
OPTIONAL EQUIPMENT REMOTE CONTROL ADAPTER CABLE (K864)
Factory Installed Options CABLE RECEPTACLE (6 SOCKET)
STRAIGHT PLUG (14 PIN)
DIODE OPTION
TO POWER SOURCE
TO: 1) K857 REMOTE CONTROL
2) K963 HAND AMPTROL
3) K870 FOOT AMPTROL
This internally installed option allows the use of the
cold start and cold electrode sensing features of the
CABLE RECEPTACLE (14 SOCKET)
NA-3, NA-5 or NA-5R.
TO LN-7 WIRE FEEDER
A 鈥淰鈥? cable 12鈥? (.30m) long to connect a K857
Remote Control, K963 Hand Amptrol or K870 Foot
MULTIPROCESS SWITCH Amptrol (6-pin connector) with a wire-feeder (14-pin
connector) and the machine (14-pin connector). If a
Factory or field installed kit that mounts on the front of remote control or amptrol is used alone the wire-
the DC-400, and includes hinged covers over its feeder connection is then not used.
output studs. The switch has three positions: Positive
semiautomatic / automatic, negative semiautomatic /
MULTIPROCESS SWITCH (K804-1)
automatic, and stick / air carbon arc. Required when
using the DC-400 for both semiautomatic/automatic
Field installed kit that mounts on the front of the DC-
and stick/air carbon arc. The field installed kit
400, and includes hinged covers over its output studs.
equivalent is identified as K804-1. For details on the
The switch has three positions: Positive
Multiprocess Switch, see the Installation of Equipment
semiautomatic / automatic, negative semiautomatic /
section.
automatic, and stick / air carbon arc. Required when
Field Installed Options 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
REMOTE OUTPUT CONTROL on the Multiprocess Switch, see the section for
(K857 WITH K864 ADAPTER OR K775 ) Installation of Equipment Required for Recommended
Processes.
The K857 has a 6-pin MS-style connector. The K857
requires a K864 adapter cable which connects to the HI-FREQUENCY KIT
14-pin connector on the machine. (K799 CODES 8634 AND ABOVE ONLY)
An optional 鈥渞emote output control鈥? is available. This is Kit supplies the high frequency plus gas valve for DC
the same remote control that is used on the Lincoln TIG welding. The DC-400 is shipped with proper R.F.
R3R, and DC-600 power sources (K775). The K775 bypass circuitry installed to protect the control circuit
consists of a control box with 28 ft (8.5m) of four when welding with a HI-FREQ unit. K844 Water Valve
conductor cable. This connects to terminals 75, 76, Option Kit can be used with K799 when TIG welding
and 77 on the terminal strip and the case grounding with water cooled torches.
screw so marked with the symbol on the machine.
These terminals are located behind the control panel UNDERCARRIAGES (K817P, K841)
on the front of the power source. This control will give
the same control as the output control on the For easy moving of the machine, optional
machine. undercarriages are available with polyolefin wheels
(K817P) or a platform undercarriage (K841) with
AMPTROL鈩? ADAPTER CABLE (K843) mountings for two gas cylinders at rear of welder.
A five wire cable, 12鈥? (.30m) long, is available for easy Install per instructions provided with undercarriage.
connection of standard K963 Hand Amptrol or K870
Foot Amptrol. The cable has a 6-pin MS-style
connector which connects to the Amptrol and
terminals which connect to 75, 76 and 77 on the
machine terminal strip and to the case grounding
screw. The Amptrol will control the same range of
output as the current control on the welder. (If a
smaller range of control is desired for finer
adjustment, 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.
鈥? 17 鈥?
TECHNICAL SPECIFICATIONS 鈥? DC-400
INPUT-THREE PHASE ONLY
Input Current at Rated Output (CVI)
Standard
Voltage
Frequency 50% Duty Cycle
100% Duty Cycle 60% Duty Cycle
500Amps/40V
400Amps/36V 450Amps/38V
230/460/575V/60Hz 84/42/34Amps
78/39/31Amps 83/41/33Amps
500Amps/40V
400Amps/36V 450Amps/38V
220/230/380/400/440V/50/60Hz 81/77/47/45/41Amps 85/81/49/47/42Amps 86/82/50/48/43Amps
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
TYPE 75掳C TYPE 75掳C
INPUT TYPE 75掳C
INPUT AMPERE
GROUND WIRE IN SUPER LAG
VOLTAGE / COPPER WIRE IN
RATING ON
CONDUIT AWG (IEC) OR BREAKER
FREQUENCY CONDUIT AWG (IEC)
NAMEPLATE
SIZE(AMPS)
@100% SIZES (mm2)
SIZES (mm2)
Duty Cycle 40掳C(104掳F)
125
230/60Hz 78 6(16)
3(25)
60
460/60Hz 39 10(6)
8(10)
50
575/60Hz 31 10(6)
10(6)
220/50/60Hz 81 3(25) 125
6(16)
230/50/60Hz 77 3(25) 125
6(16)
380/50/60Hz 47 6(16) 70
8(10)
400/50/60Hz 45 6(16) 70
8(10)
440/50/60Hz 41 8(10) 60
10(6)
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掳F to 104掳F(-30掳C +40掳C) -40掳F to 140掳F(-40掳C+60掳C)
(1) Based upon 10 minute time period (i.e., for 60% duty cycle, it is 6 minutes on an 4 minutes off).
Insulation class 155(F)
DC-400
鈥? 18 鈥?
INSTALLATION Failure to observe these precautions can result in
excessive operating temperatures and nuisance
Safety Precautions shutdown of the machine.
WARNING
LIMIT ON STACKING
ELECTRIC SHOCK can kill.
WARNING
鈥? Do not touch electrically live parts or
electrode with skin or wet clothing.
FALLING EQUIPMENT can cause
鈥? Insulate yourself from work and
injury.
ground.
鈥? Do not lift this machine using lift
鈥? Always wear dry insulating gloves.
bale if it is equipped with a heavy
------------------------------------------------------------------------
accessory such as trailer or gas
FUMES AND GASES can be
cylinder.
dangerous.
鈥? Lift only with equipment of adequate lifting
鈥? Keep your head out of fumes.
capacity.
鈥? Use ventilation or exhaust to remove
鈥? Be sure machine is stable when lifting.
fumes from breathing zone.
鈥? Do not stack more than three high.
------------------------------------------------------------------------
鈥? Do not stack the DC-400 on top of any other
WELDING SPARKS can cause fire or
machine.
explosion.
---------------------------------------------------------------------
鈥? Keep flammable material away.
鈥? 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.
鈥? 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 operator始s manual.
Input Power Connections
----------------------------------------------------------- By removing the rear access panel the three phase
input power is connected to the three line terminals on
CORRECT OPERATIONAL USE
the input contactor, and the earth grounding lead to
the grounding terminal on the input box floor marked
The machine should be located in a clean dry place
with the symbol. Install and reconnect panel for
where there is free circulation of clean air such that air
the proper input voltage per the diagram pasted inside
movement in through the front and out through the
the access panel cover.
back will not be restricted. Dirt and dust that can be
drawn into the machine should be kept to a minimum.
See Technical Specification Page:
鈥? 19 鈥?
REMOTE CONTROL ADAPTER CABLE (K864)
CAUTION
Failure to follow these instructions can cause
immediate failure of components within the machine.
CABLE RECEPTACLE (6 SOCKET)
STRAIGHT PLUG (14 PIN)
When powering welder from a generator be sure to
TO POWER SOURCE
TO: 1) K857 REMOTE CONTROL
2) K963 HAND AMPTROL
turn off the welder first, before generator is shut down
3) K870 FOOT AMPTROL
in order to prevent damage to welder.
CABLE RECEPTACLE (14 SOCKET)
Output Cable Connections
TO LN-7 WIRE FEEDER
A 鈥淰鈥? cable 12鈥? (.30m) long to connect a K857
The output leads are connected to the output
Remote Control (6 pin connector) with a wire-feeder
terminals marked 鈥?+鈥? and 鈥?-鈥?. They are located at the (14-pin connector) and the machine (14-pin
lower right and lower left corners of the front panel. connector). If a remote control is used alone the wire-
feeder connection is then not used.
Output Cables
WARNING
CABLE SIZES FOR COMBINED LENGTH OF
ELECTRODE AND WORK CABLE
ELECTRIC SHOCK can kill.
MACHINE LOAD
鈥? Turn the power switch of the
400A 500A
welding power source 鈥淥FF鈥?
(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
(15m) 85 mm2 67 mm2
welding 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鈥? (.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
terminals which connect to 75, 76, and 77 on the
200-250 ft 4/0 4/0
machine terminal strip and to the case grounding
(67-76 m) 107 mm2 107 mm2
screw. the Amptrol will control the same range of
INSTALLATION OF FIELD INSTALLED output as the current control on the welder. (if a
smaller range of control is desired for finer
OPTIONS adjustment, a K775 Remote may be used in
conjunction with the Amptrol Adapter Cable Kit.) The
Remote Output Control (K857 or K857-1 Amptrol arc start switch is nonfunctional unless used
with K864 Adapter) with a K799 Hi-Frequency Kit.
An optional 鈥渞emote out control鈥? is available. The
K857 or K857-1 are the same remote control options
See Amptrol Adapter installation Instructions on next
that are used on other Lincoln power sources. The
page.
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.
鈥? 20 鈥?
K843 AMPTROL鈩? ADAPTER INSTALLATION INSTRUCTIONS
For use with: DC-250, DC-400, R3R or Weldanpower 250 (D-10 and Pro)
with remote control power sources.
WARNING: TURN THE POWER SOURCE OFF BEFORE INSTALLATION
This K843 adapter is used to connect AMPTROL鈩? (K963*, source "machine/remote" switch must be in "remote" for
K813* or K870), remote control (K775), and HI-FREQ鈩? (K799) Amptrol鈩? to control current. Accessories may be combined and
accessories to DC-250, DC-400, R3R or Weldanpower 250 connected in four different ways, as shown below.
(D-10 and Pro) with remote control power sources. The power
AMPTROL鈩? AND AMPTROL鈩? AND HI-FREQ.鈩? KIT
AMPTROL鈩? PLUS
AMPTROL鈩? ONLY
HI-FREQ.鈩? KIT PLUS REMOTE LIMIT CONTROL
REMOTE LIMIT CONTROL
The Amptrol鈩? provides remote The Amptrol鈩? provides remote The Amptrol鈩? will start the Hi-Freq鈩? The Amptrol鈩? switch will start the
current control through the full range current control from the minimum of kit to turn on gas and high frequency Hi-Freq鈩? kit to turn on gas and high
of the power source. the power source to a maximum set starting for DC TIG welding. The frequency starting for DC TIG
by the remote limit control. Amptrol鈩? controls current through welding. The Amptrol鈩? controls
the full range of the power source. current from the minimum of the
K963*, K813* or power source to a maximum set by
POWER POWER K870 Amptrol鈩?
the remote limit control.
SOURCE SOURCE
K963*, K813* or
鈥? 21 鈥?
K775 Remote
K870 Amptrol鈩?
Limit Control
POWER K799
K963*,K813*
SOURCE
K775 Remote K799 Hi-Freq鈩? POWER
or K870
Limit Control Hi-Freq鈩? Kit K963*,K813*
Kit SOURCE
Amptrol鈩? or K870
Amptrol鈩?
K843 Bolt and nut
Adapter connection.
K843 Insulate
Power source
Adapter and tape.
terminal
strip 75 76 77 K843 Adapter
Arc start cable K843 Adapter
77 Arc start cable
(included with
Bolt and nut
(included
K799)
76 connection.
with K799)
insulate
75 76 77
75 76 77 and tape.
75 76 77
77
76
{ {
Black and white
CUT OFF CUT OFF
leads not used.
ARC START ARC START
Tape and K775
Black and white leads SWITCH and connect black SWITCH and
insulate.
not used. Tape lead to black and white connect black
and insulate. lead to white. K843
lead to black and K799
white lead to white.
FIG. 1 FIG. 2 FIG. 3 FIG. 4
TIG OPTIONS UNDERCARRIAGES (K817, K817R, K841)
For easy moving of the machine, optional
TIG MODULE (K930-2)
undercarriages are available with either steel (K817)
or rubber tired (K817R) wheels or a platform
Docking Kit
undercarriage (K841) with mountings for two gas
Control Cable Extension-45始
cylinder at rear of welder.
Water valve Kit
Install per instructions provided with trailer.
AMPTROL ADAPTER FOR K799 HI-FREQUENCY
KIT (K915-1, REQUIRES K864 ADAPTER)
Installation of Equipment Required for
A 鈥淰鈥? cable to connect a K799 Hi-Freq Kit (5-pin
Recommended Processes
connector) 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 WIRE FEEDER CONTROL CABLE CONNECTIONS
which requires a K864 adapter to connect with the 14-
pin connector on the DC-400. Refer to S20909 For control cable with 14-pin connector:
instructions for connection information.
Connect control cable to 14-pin connector on the front
MULTIPROCESS SWITCH (K804-1) panel of the machine. See the appropriate connection
diagram for the exact instructions for the wire feeder
Kit that mounts on the front of the DC-400, and being used. Refer to Section 2.4.1 for connector pin
includes hinged covers over its output studs. The functions.
switch has three positions: Positive
semiautomatic/automatic, negative semiautomatic/
automatic, and stick/air carbon arc. Required when For control cable with terminal strip connectors:
using the DC-400 for both semiautomatic/automatic
and stick/air carbon arc. The control cable from the wire feeding equipment is
connected to the terminal strips behind the control
Install per M17137 instructions included with the field panel*. A strain relief box connector is provided for
installed kit. access into the terminal strip section. A chassis
ground screw is also provided below the terminal strip
CAPACITOR DISCHARGE CIRCUIT (K828-1) marked with the symbol for connecting the
automatic equipment grounding wire. See the
Circuit that mounts inside the DC-400. appropriate connection diagram for the exact
Recommended when: instructions for the wire feeder being used.
1) DC-400 is used in conjunction with any LN-23P or A cover (Lincoln Electric Part Number S17062-3) is
older LN-8 or LN-9 semiautomatic wire-feeder. available for the unused 14-pin connector to protect it
Eliminates possible arc flash re-start of weld when against dirt and moisture.
trigger interlock is used. Not required with current
LN-8 (above Code 8700), or LN-9始s with serial * See Terminal Strip Connections section for access
numbers above 115187 (manufactured after 12/83), to the terminal strips.
or any LN-9 having an L6043-1 Power PC Board.
2) DC-400 is used with an LN-22 equipped with an
older K279 Contactor-Voltage Control Option.
Eliminates electrode overrun when gun trigger is
released. Not required when later K279 (above
Code 8800) is used.
3) DC-400 is used with any semiautomatic wire-feeder
and possible small spark, if electrode touches work
just after gun trigger is released, is objectionable.
Install per M17060 instructions included with the
Kit.
鈥? 22 鈥?
CONNECTION OF DC-400 TO LN-22 OR LN-25 CONNECTIONS
a) Turn off all power. 1. Connect wire feed unit electrode and work cables
through the rectangular strain relief holes in the
b) Place output terminals switch into the 鈥淥N鈥? base of the DC-400 to the output studs on the left
position. side of the box.
c) Connect the electrode cable to the output terminal 2. Connect wire feeder control cable and make other
of polarity required by electrode. Connect the work terminal strip connections as specified on the
lead to the other terminal. connection diagram for the Lincoln wire feeder
being used. 鈥淓lectrode鈥? and 鈥淲ork鈥? are connected
d) Place the OUTPUT CONTROL Switch at 鈥淟OCAL鈥? to the left side of the Multiprocess Switch.
position unless a Remote Control is connected to
the DC-400. 3. Connect stick or air carbon arc electrode and work
cables through the rectangular strain relief holes in
e) Place MODE SWITCH in 鈥淐ONSTANT VOLTAGE the base of the DC-400 to the output studs on the
(FCAW, GMAW)鈥?. right side of the box.
NOTE: The output terminals are energized at all
OPERATION
times.
The operation of the switch is as follows:
MULTIPROCESS SWITCH CONNECTION AND A semiautomatic or automatic wire feed unit electrode
OPERATION and work cables are connected to the terminals on the
left side of the box. Stick or air carbon arc electrode
PURPOSE and work leads are connected to the terminals on the
right side of the box. There are three positions on the
A Multiprocess Switch has been designed for use with switch. With the switch in the left position, the wire
the DC-400 or DC-600. With this switch installed on feed terminals are electrode negative. In the center
the DC-400, it permits easy changing of the polarity of position, the wire feeder terminals are electrode
the wire feed unit connected and also provides positive. In both the left and center switch position,
separate terminals for connection of stick or air carbon the right side stick terminals are disconnected. In the
arc. The Multiprocess Switch is available as either a right switch position, the wire feed terminals are
factory installed or field installed option. disconnected from the DC-400 and the stick terminals
connected. The polarity of the stick terminals is
NOTE: IF THE DC-400 IS TO BE USED FOR BOTH marked on the end of the box. To change polarity, the
SEMIAUTOMATIC/AUTOMATIC AND STICK/ electrode and work leads must be interchanged. In
AIR CARBON ARC, THEN A MULTI- the stick position, the stick terminals are energized at
PROCESS SWITCH IS REQUIRED. all times.
DESIGN CONNECTIONS
The Multiprocess Switch consists of a 3-position (For those applications where it is not necessary to
switch assembly that is mounted in a sheet metal have separate work cables for stick and
enclosure that has two output terminals on each end semiautomatic welding.)
of the box. The two terminals on the left side of the
box are for connection of wire feed electrode and work If both stick and semiautomatic welding is done on the
leads. The two terminals on the right side of the box same workpiece, only one work lead is required. To
are for connection of work and electrode for stick or do this, connect a 4/0 (107 mm2) jumper from the
air carbon arc. The output terminals are protected work terminal on the semiautomatic side to the
against accidental contact by hinged covers. terminal to be used for work on the stick side. The
work lead from the semiautomatic side then serves as
The switch mounts to the front of the DC-400 by the work lead for both semiautomatic and stick
means of a bracket that fastens to the case sides. welding.
Two 4/0 (107 mm 2 ) leads connect the switch
assembly to each output stud.
鈥? 23 鈥?
OPERATING INSTRUCTIONS
Safety Precautions
+ WARNING
To stick
WORK
electrode
ELECTRIC SHOCK can kill.
holder or
air carbon
鈥? Have an electrician install and
To semi- arc torch
ELECTRODE
auto or service this equipment.
auto
鈥? Turn the input power off at the fuse
User supplied
equipment 4/0 (107 mm 2 ) box before working on equipment.
jumper
鈥? Do not touch electrically hot parts.
鈥? This next section applies to DC-400始s without
MULTIPROCESS SWITCH the Capacitor Discharge Option:
---------------------------------------------------------------------
When using a DC-400 power source with wire feeders
which do not have an electrical trigger interlock (or
To change stick polarity, reverse the leads at the (+)
with wire feeders with the electrical trigger interlock in
and (-) terminals on the right side of the Multiprocess
the OFF position), there will be a small spark if the
Switch.
electrode contacts the work or ground within several
seconds after releasing the trigger.
NOTE: When a DC-400 equipped with Multiprocess
Switch is mounted on an undercarriage, the
When used with some wire feeders with the electrical
undercarriage handle in the resting position
trigger interlock in the ON position, the arc can restart
can hit the case of the Multiprocess Switch.
if the electrode touches the work or ground during
This does no harm, but if the user desires, a
these several seconds.
1/4鈥? or 3/8鈥? bolt and nut may be placed in the
WARNING
hole in the undercarriage tow bar to limit the
travel of the undercarriage handle.
鈥? Be sure to select OUTPUT TERMINALS 鈥淩EMOTE
ON/OFF鈥? for operation with wire feeders that have
STICK, TIG OR AIR/CARBON ARC *
leads numbered 2 and 4.
------------------------------------------------------------------------
a) Turn off all power.
b) Disconnect all wire feed unit control, electrode, and
work leads.
c) Place MODE SWITCH in the 鈥淐ONSTANT
CURRENT (STICK/TIG)鈥? for air carbon arc.
d) For stick, TIG or air carbon arc, place OUTPUT
TERMINALS switch into the 鈥淥N鈥? 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.
鈥? 24 鈥?
POWER SOURCE OPERATION AND OUTPUT CONTROL 鈥淟OCAL-REMOTE鈥? SWITCH漏
CONTROLS The OUTPUT CONTROL toggle switch on the control
WARNING
panel labeled 鈥淟OCAL-REMOTE鈥? gives the operator
the option of controlling the output at the machine
ELECTRIC SHOCK can kill. control panel or at a remote station. For remote
control, the toggle switch is set in the 鈥淩EMOTE鈥?
鈥? Have an electrician install and service
position and controlled at the wire feed unit control, or
this equipment.
by connecting a K775 control to terminals 75, 76, and
鈥? Turn the input power off at the fuse
77 on the terminal strip at the front of the machine, or
box before working on equipment.
by connecting a K857 control to the 14-pin connector
鈥? Do not touch electrically hot parts.
on the front of the machine. For control at the
---------------------------------------------------------------------
machine control panel, the toggle switch is set in the
鈥淟OCAL鈥?.
Duty Cycle and Time Period
The DC-400 is rated at the following duty cycles: (Exception: When used with an LN-9, LN-9 GMA or
NA-5 wire feeder, the OUTPUT CONTROL switch
DUTY CYCLE * AMPS VOLTS
must be in the 鈥淩EMOTE鈥? position or automatic
100% 400 36 shutdown of the LN-9 or NA-5 may occur.)
60% 450 38
50% 500 40
* Based upon 10 minute time period (i.e., for 60% duty POLARITY SELECTION
cycle, it is 6 minutes on and 4 minutes off).
Polarity selection is made by appropriately connecting
the electrode and work welding cables to either the
Overloading the DC-400 may result in opening of an 鈥?+鈥? stud or to the 鈥?-鈥? stud. Select 鈥淰OLTMETER鈥?
internal protective thermostat as indicated by the
switch for 鈥?+鈥? or 鈥?-鈥? electrode for the remote (#21)
amber thermal protection light turning on.
work sensing lead.
STARTING THE MACHINE
VOLTMETER SWITCH
The POWER toggle switch at the extreme right side of
the control panel in the 鈥淚鈥? position energizes and
Select 鈥?+鈥? for positive electrode or 鈥?-鈥? for negative
closes the three phase input contactor from a 115 volt
electrode polarity for the remote (#21) work sensing
auxiliary transformer. This in turn energizes the main
lead of automatic or semiautomatic equipment.
power transformer.
The machine is de-energized when the POWER
switch is in the 鈥?0鈥? position.
THERMAL PROTECTION LIGHT
The white light below the POWER switch indicates
The amber thermal protection light will be lit if either of
when the input contactor is energized.
the two protective thermostats have opened. The
output power will be disabled but input power will still
be applied to the welder. (Refer to Machine and
OUTPUT CONTROL DIAL
Circuit Protection section).
The OUTPUT control to the right of the center of the
control panel is a continuous control of the machine
MODE SWITCH
output. The control may be rotated from minimum to
maximum while under load to adjust the machine
The large MODE SWITCH on the left side of the
output.
machine, labeled 鈥淐onstant Voltage (Submerged Arc),
Constant Voltage (FCAW/GMAW) and Constant
The machine is equipped with line voltage
Current (Stick/TIG)鈥?, is used to select the proper
compensation as a standard feature. This will hold
welder characteristics for the process being used.
the output constant except at maximum output of the
machine, through a fluctuation of 卤10% input line
The CV (FCAW/GMAW) Mode permits the DC-400 to
voltage.
produce essentially a flat output characteristic that can
be varied from approx. 12 to 42 volts.
鈥? 25 鈥?
OUTPUT TERMINALS SWITCH
In this position, the dynamic characteristics of the
machine under welding conditions provide optimum
The OUTPUT TERMINALS toggle switch on the
welding characteristics for Innershield庐 welding, other
control panel labeled 鈥淩EMOTE - ON鈥? allows the
open arc processes including short arc MIG welding,
welder output to be activated remotely or to be always
and air carbon arc. Most submerged arc welding can
on. For remote operation, the toggle switch is set in
also be done in this mode.
鈥淩EMOTE鈥? position and the welder output will be
activated when 2 and 4 are closed when using a wire-
The CV (Submerged Arc) Mode also produces an
feeder. For welder output to always be activated, set
essentially flat output characteristic that can be varied
the switch to the 鈥淥N鈥? position.
from approximately 12 to 42 volts. The dynamic
characteristics of the CV Submerged Arc Mode make
possible improved submerged arc welding over that
possible using the Constant Voltage Innershield
110-115V AC and 40-42V AC Auxiliary
Mode. The improvement is most noticeable on high
Power and Control Connections
deposition, slow travel speed welds.
There are no means provided to switch between any
14-PIN CONNECTOR
of the modes remotely. Do not change the position of
the MODE SWITCH if output voltage or current is
The 14-pin connector receptacle supplies auxiliary
present as this may damage the switch.
power.
The CC Mode permits the DC-400 to produce a
40-42V AC is available at receptacle pins I and K. A
constant current output characteristic through the
10 amp circuit breaker protects this circuit.
range of 60-500 amps with an open circuit voltage of
approximately 57 volts (54V on 50/60 Hz). Stick
On the Domestic and Export models 110-115V AC is
welding and TIG are done with this position of the
available at receptacle pins A and J. A 10 amp circuit
Mode Switch.
breaker protects this circuit. Note that the 40-42V AC
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
approximately midrange, 5-6. Adjustments up or down
can then be made depending on the electrode,
procedures, and operator preference. Lower settings
K=42
J=31
A=32
will provide less short circuit current and a softer arc.
A setting that is too low may cause the electrode to
I=41
B=GND
stick in the puddle. Higher settings will provide a
L=SPARE N=SPARE
higher short circuit current and a more forceful arc.
Excessive spatter may result if the control setting is
C=2
H=21
too high. For most TIG welding applications adjust
D=4
this control to a minimum for best operating
G=75
characteristics.
E=77 F=76
M=SPARE
ARC CONTROL SWITCH (Effective only in CV
FCAW/GMAW mode) FUNCTION
PIN LEAD NO.
110 - 115V AC (Domestic & Export)
A 32
The ARC CONTROL is a tapped switch numbered CHASSIS CONNECTION
B GND
from 1 to 5 and changes the pinch effect of the arc. TRIGGER CIRCUIT
C 2
This control is most useful in processes that utilize a
TRIGGER CIRCUIT
D 4
OUTPUT CONTROL
E 77
鈥渟horting鈥? metal transfer and controls the spatter, OUTPUT CONTROL
F 76
fluidity, and bead shape. The pinch effect is
OUTPUT CONTROL
G 75
WORK CONNECTION
H 21
increased by turning the control clockwise. 40-42V AC
I 41
110-115V AC (Domestic & Export)
J 31
40-42V AC
K 42
For all applications, a good starting point for the ARC ---
L ---
CONTROL is a midrange dial setting of 3. The control ---
M ---
can be increased or decreased as desired.
---
N ---
鈥? 26 鈥?
Terminal Strip Connections The fan will continue to run. The secondary
thermostat will open either with an excessive overload
or insufficient cooling. The output will be zero and the
Terminal strip TS2 located behind the hinged control
amber protection light will be off.
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
MAINTENANCE
models.
To gain access to the terminal strips simply remote
WARNING
the six #10 sheet metal screws from the perimeter of
the welder nameplate as shown below. Tilt panel
ELECTRIC SHOCK can kill.
forward so it rests in a horizontal position. See Table
showing Front View of 14-Pin Connector Receptacle 鈥? Have an electrician install and service
for lead number functions. this equipment.
鈥? Turn the input power off at the fuse
box before working on equipment.
鈥? Do not touch electrically hot parts.
---------------------------------------------------------------------
1 2
Routine Maintenance
1. The fan motor has sealed bearings which require
6
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
4
5
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.
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
circuit. If the machine is overloaded, the primary
thermostat will open, the output will be zero, and the
amber thermal protection light will be on.
鈥? 27 鈥?
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.
__________________________________________________________________________
Step 3. RECOMMENDED COURSE OF ACTION
This Troubleshooting Guide is provided to help you
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 鈥淧ROBLEM If you do not understand or are unable to perform the
(SYMPTOMS)鈥?. This column describes possible Recommended Course of Action safely, contact your
symptoms that the machine may exhibit. Find the local Lincoln Authorized Field Service Facility.
listing that best describes the symptom that the
machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled 鈥淧OSSIBLE CAUSE鈥? lists
the obvious external possibilities that may contribute
to the machine symptom.
WARNING
ELECTRIC SHOCK can kill.
鈥? Have an electrician install and service
this equipment.
鈥? Turn the input power off at the fuse
box before working on equipment.
鈥? 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.
鈥? 28 鈥?
TROUBLESHOOTING
WHAT TO DO
TROUBLE CAUSE
1. Repair or Replace.
A. Input contactor (CR1) chatters. 1. Faulty input contactor (CR1).
2. Check input power.
2. Low line voltage.
1. Replace if blown - look for
B. Machine input contactor does 1. Supply line fuse blown.
reason first.
not operate.
2. Check control transformer T2
2. Contactor power circuit dead.
and associated leads.
3. Check input voltage at contactor.
3. Broken power lead.
4. Check voltage against
4. Wrong input voltage.
instructions.
5. Open input contactor coil.
5. Replace coil.
6. POWER 鈥淚/0鈥? switch (S1) not
6. Replace switch.
closing.
1. Make sure trigger circuit is being
C. Machine input contactor 1. Trigger circuit between #2 and
closed.
operates, but no output when #4 leads is not being closed.
trying to weld.
2. Repair Connection.
2. Electrode or work lead loose or
broken.
3. Repair.
3. Open main transformer (T1)
primary or secondary circuit.
4. Replace. See Procedure for
4. Defective Control PC Board.
Replacing PC Boards.
5. Amber thermal protection light is
5. Primary or secondary
on: Check for overheating;
thermostats open.
make sure fan is operating and
there is no obstruction to free air
flow.
1. Check 75, 76, or 77 for ground
D. Machine has minimum output 1. Terminals 75, 76 or 77 grounded
to positive output circuit. Nearly
and no control. to positive output.
zero ohms to ground indicates a
grounded circuit. A value
greater than a few thousand
ohms is normal. Self-restraining
fuses on PC Board automatically
reset within a few seconds after
ground is cleared.
鈥? 29 鈥?
TROUBLESHOOTING (CONTINUED)
WHAT TO DO
TROUBLE CAUSE
1. Check 75, 76, or 77 for ground
E. Machine has high output or 1. Terminals 75, 76, or 77
to negative output circuit. Nearly
pulsing output and no control. grounded to negative output.
zero ohms to ground indicates a
grounded circuit. A value
greater than a few thousand
ohms is normal. Self-restoring
fuses on PC Board automatically
reset within a few seconds after
ground is cleared.
1. Check position of switch.
F. Machine has low output and no 1. OUTPUT CONTROL 鈥淟OCAL-
control. REMOTE鈥? switch (S2) in wrong
position.
2. Check switch & replace if faulty.
2. OUTPUT CONTROL switch
faulty.
3. Check wiring and control PC
3. Open in feedback circuitry.
Board wiring harness plugs.
4. Replace. See Procedure for
4. Faulty Control PC Board.
Replacing PC Boards.
5. Check and replace
5. OUTPUT control potentiometer
potentiometer if faulty. Check
circuit open (lead 75).
wiring of lead #75.
1. Check and replace if blown after
G. Machine does not have 1. One input fuse blows.
checking for reason for blown
maximum output.
fuse.
2. Check for open and repair.
2. One phase of main transformer
open.
3. Replace. See Procedure for
3. Faulty Control PC Board.
Replacing PC Boards.
4. Check and Replace if faulty.
4. OUTPUT control potentiometer.
5. Check and repair broken leads.
5. OUTPUT control potentiometer
leads 210, 211 or 75 open.
1. Check and replace if necessary.
H. Machine will not shut off. 1. Input contactor contacts frozen.
2. Replace.
2. Defective POWER 鈥?1/0鈥? switch,
(S1).
鈥? 30 鈥?
TROUBLESHOOTING (CONTINUED)
WHAT TO DO
TROUBLE CAUSE
1. Check and clean all
I. Variable or sluggish welding arc. 1. Poor work or electrode
connections.
connection.
2. Check table in instruction
2. Welding leads too small.
manual.
3. Check procedures for
3. Welding current or voltage too
recommended settings.
low.
4. Check and replace if defective.
4. Defective main SCR bridge.
5. Check and replace if defective.
5. Microswitch S4C or S4D
(If S4C or S4D actuator is found
actuator defective.
defective, replace mode switch
cam also.)
1. Place switch in 鈥淟OCAL鈥?.
J. OUTPUT control not functioning 1. OUTPUT CONTROL switch in
on the machine. wrong position.
2. Check and replace if found
2. Faulty OUTPUT control switch.
faulty.
3. Check and replace if found
3. Faulty OUTPUT control
faulty.
potentiometer.
4. Check lead continuity and
4. Leads or connections open in
connections for an open and
control circuit.
repair if necessary.
5. Replace. See Procedure for
5. Faulty Control PC Board.
Replacing PC Boards.
1. Place switch in 鈥淩EMOTE鈥?.
K. OUTPUT control not 1. OUTPUT CONTROL switch in
functioning on 鈥淩EMOTE鈥? wrong position.
control.
2. Check and replace if found
2. Faulty OUTPUT CONTROL
faulty.
switch.
3. Check and replace if found
3. Faulty remote control
faulty.
potentiometer.
4. Check all leads and
4. Leads or connections open in
connections, internal or remote,
control circuit.
for continuity. Repair if
necessary.
5. Replace. See Procedure for
5. Faulty Control PC Board.
Replacing PC Boards.
鈥? 31 鈥?
TROUBLESHOOTING (CONTINUED)
WHAT TO DO
TROUBLE CAUSE
1. Check Start PC Board and reed
L. Poor arc striking with 1. Defective start circuit.
switch CR3.
semiautomatic or automatic
wire feeders.
2. Work connection must be
2. Poor work connection.
adequate for application.
3. Adjust procedures for improved
3. Improper procedures.
starting.
4. Replace. See Procedure for
4. Defective Control PC Board.
Replacing PC Boards.
1. Short reed switch CR3 leads
M. Poor arc characteristics. 1. Start circuit energized at all
together. If welding improves,
times (read switch CR3 not
replace reed switch.
closing).
2. If problem is still present with
2. Defective Start PC Board.
reed switch shorted, unplug
Start PC Board. If problem
disappears, replace Start PC
Board.
3. Replace. See Procedure for
3. Defective Control PC Board.
Replacing PC Boards.
4. Replace entire bank of
4. Capacitor(s) in output circuit
capacitors. Do not replace
failed. A failure is indicated if
individual capacitors.
the small vent plug on top of a
capacitor 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.
1. Check and replace if found
N. ARC CONTROL has no effect 1. Defective R1, L1, S4C, S4D
defective. (If S4C or S4D
in CV (FCAW/GMAW) mode actuator or S5.
actuator is found defective,
with short circuit transfer
replace mode switch cam also.)
processes.
1. Reset circuit breaker. Make sure
O. 115VAC Receptacle not 1. Circuit Breaker Tripped.
load on does not exceed 15A
working. 2. Defective Circuit Breaker.
rating of circuit breaker.
3. Broken connection in wiring.
2. Replace
3. Check all wiring going to
receptacle and circuit breaker for
possible broken connection.
鈥? 32 鈥?
PROCEDURE FOR REPLACING PC BOARDS FAULT PROTECTION OPERATION
WARNING The overload protection circuit, in the Control PC
ELECTRIC SHOCK can kill. Board will limit the welding current (heat) to 550 amps
if a short or overload is applied to the machine. (Refer
鈥? Have an electrician install and
to the Machine and Circuit Protection section).
service this equipment.
鈥? Turn the input power off at the fuse
CHECKING SNUBBER CIRCUIT
box before working on equipment.
鈥? 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 remove the sides of the machine. (See the
When a PC Board is suspected to be defective, the instruction manual parts list for the exact location.)
following procedure must be followed:
1. Visually inspect the snubber assembly for
1. Visually inspect the PC Board. If the board has overheated components or damaged components.
fuses, check to see if any are blown. Are any of
the components damaged? Is a conductor on the
CHECKING OUTPUT CONTROL RHEOSTAT ON
back side of the board damaged? If electrical
MACHINE
damage is visible on the PC Board, inspect the
machine wiring for grounds or shorts to avoid
damaging a new PC Board, Install a new PC Board Turn machine off (鈥?0鈥? position).
only after a visual inspection of the PC Board and
machine wiring is satisfactory. Remove the control panel screws and open the
2. If the problem is remedied by a new PC Board, control panel (see the section on Terminal Strip
install the old PC Board and see if the problem still Connections for screw locations).
exists. If the problem does not return with the old
board: Turn the OUTPUT CONTROL switch to 鈥淩EMOTE鈥?.
a) Check the PC Board harness plug and PC
Board plug for contamination, corrosion or Disconnect the harness plug from the Control PC
oversize. Board.
b) Check leads in the harness for loose
connections. With an ohmmeter on X1K, connect it to lead 210 and
75 on R4.
CONNECTING THE REMOTE CONTROL TO THE
MACHINE Exercise caution to avoid damaging POT taps.
Extreme caution must be observed when installing or
POWER 鈥淚/0鈥? SWITCH CHECK
extending the wiring of a remote control. Improper
connection of this unit can lead to failure of the output
control rheostat or the control circuit. Only the green 1. Turn off the machine power input (鈥?0鈥? position). S1
lead can and should be grounded to the machine has 115V across it when the input power is
case. When extending the standard remote control, connected.
make sure the leads are the same and the splice is
waterproof. Be very careful not to ground the cable 2. Isolate the switch to be tested by removing all
when in use and don始t let the lugs touch against the connecting leads.
case.
3. Check to make sure the switch is making
connections with an ohmmeter. The meter should
OUTPUT VOLTAGE read zero resistance.
The output circuit voltage of the machine should be 4. Put the ohmmeter on X1K scale and measure the
adjustable from 10 to 46 volts in CV. In the CC mode, resistance between the terminal and the case of
the open circuit voltage should be approximately 57 the machine (touch a self-tapping screw). Reading
volts (54 volts on 50/60 Hz) except at near minimum should be infinite.
settings of the output control where it may be lower. If
any other condition exists, refer to the 5. If either step (3) or step (4) fails, replace the
Troubleshooting Guide. switch.
鈥? 33 鈥?
REMOTE CONTROL CHECK
2. Power Diode Test
Disconnect the remote output control and connect an
ohmmeter across 75 to 76 and rotate the rheostat in a) Establish the polarity of the ohmmeter leads
the remote control. The resistance reading should go and set to X10 scale.
from zero to 10K ohms. Repeat with ohmmeter
across 75 and 76 with same results. Connect b) Connect the ohmmeter positive lead to anode
ohmmeter across 75 and 77. The reading should be and negative lead to cathode.
10K ohms. A lower reading will indicate a shorted or
partially shorted rheostat. A very high reading will c) Reverse the leads of the ohmmeter from
indicate an open rheostat. In either of the last two Step b.
cases, replace rheostat. Check cable for any physical
damage. d) A shorted diode will indicate zero or an equally
low resistance in both directions. An open
diode will have an infinite or high resistance in
POWER RECTIFIER BRIDGE ASSEMBLY both directions and a good diode will have a
CHECKING PROCEDURE low resistance in Step b and Step a much
WARNING
higher resistance in Step c.
ELECTRIC SHOCK can kill.
鈥? Have an electrician install and
service this equipment.
3. Power Silicon Controlled Rectifier Test
鈥? Turn the input power off at the fuse
box before working on equipment.
a) Connect the ohmmeter (set to m X10 scale)
鈥? Do not touch electrically hot parts.
leads to the anode and cathode.
---------------------------------------------------------------------
1. Bridge and Device Isolation (See the b) Reverse the leads of the ohmmeter from Step
instruction manual parts list for the exact a.
location.)
c) A shorted SCR will indicate zero or an equally
Disconnect the following leads from the bridge, low resistance in one or both directions.
shown in Diagram 1:
d) Establish the polarity of the ohmmeter.
a) Unplug P3 (G1, G2, G3 and 204) from the Connect the positive lead to the gate and the
Control PC Board. negative lead to the cathode.
b) Unplug P5 from the Snubber PC Board. e) An open gate circuit will have an infinite or high
resistance. A good gate circuit will read a low
c) Secondary leads X1, X2, and X3 from the resistance, but not zero ohms. If gate circuit
anodes of the SCR始s and cathodes of the reads zero ohms, check gate harness for
diodes. shorts between gate leads and 204 before
replacing SCR.
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 SCR始s are not shorted, bridge test is
completed. If any device appears shorted,
disconnect the cathode lead of each diode (4
total) and repeat Steps 2 and 3.
鈥? 34 鈥?
POWER RECTIFIER BRIDGE
DIAGRAM 1
PLUG TO SNUBBER BOARD
_
220
+
P5
220
223
204
221 222
X1 X2 X3
To (+) side
D1 D2 D3
ANODE
of capacitor
bank
CATHODE
D4
ANODE
SCR1 SCR2 SCR3
GATE CATHODE
SHUNT
_
+
204
204
To
mode
204
G1 G2 G3 switch
204
Gate leads
P3
plug to control
P.C. board
To plug
P1
To T1 main
transformer
鈥? 35 鈥?
鈥? 36 鈥?
WIRING DIAGRAMS
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.
鈥? 37 鈥?
WIRING DIAGRAM FOR CODES 10859, 10880,11083, 11084
WIRING DIAGRAMS
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.
WIRING DIAGRAM FOR CODE 9847, 11349
鈥? 38 鈥?
WIRING DIAGRAMS
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.
鈥? 39 鈥?
WIRING DIAGRAMS
WIRING DIAGRAM FOR CODES 11277, 11278 AND 11279, 11348, 11352, 11353
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.
WARNING
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
electrode with skin or wet clothing.
AVISO DE
G Insulate yourself from work and
ground.
Spanish
PRECAUCION
G No toque las partes o los electrodos G Mantenga el material combustible G Prot茅jase los ojos, los o铆dos y el
bajo carga con la piel o ropa fuera del 谩rea de trabajo. cuerpo.
mojada.
G Aislese del trabajo y de la tierra.
ATTENTION
French G Ne laissez ni la peau ni des G Gardez 脿 l鈥櫭ヽart de tout mat茅riel G Prot茅gez vos yeux, vos oreilles et
v锚tements mouill茅s entrer en contact inflammable. votre corps.
avec des pi猫ces sous tension.
G Isolez-vous du travail et de la terre.
WARNUNG
German G Ber眉hren Sie keine stromf眉hrenden G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und K枚r-
Teile oder Elektroden mit Ihrem perschutz!
K枚rper oder feuchter Kleidung!
G Isolieren Sie sich von den
ATEN脟脙O
Portuguese
Elektroden und dem Erdboden!
G N茫o toque partes el茅tricas e G Mantenha inflam谩veis bem G Use prote莽茫o para a vista, ouvido e
electrodos com a pele ou roupa guardados. corpo.
molhada.
G Isole-se da pe莽a e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER鈥橲 INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER鈥橲 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 ELEKTRODENEINSATZ DES
HERSTELLERS. DIE UNFALLVERH脺TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
WARNING
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to guards off.
AVISO DE
remove fumes from breathing zone.
Spanish
PRECAUCION
G Los humos fuera de la zona de G Desconectar el cable de G No operar con panel abierto o
respiraci贸n. alimentaci贸n de poder de la guardas quitadas.
G Mantenga la cabeza fuera de los m谩quina antes de iniciar cualquier
humos. Utilice ventilaci贸n o servicio.
ATTENTION
aspiraci贸n para gases.
French
G N鈥檕p茅rez pas avec les panneaux
G Gardez la t锚te 脿 l鈥櫭ヽart des fum茅es.
G D茅branchez le courant avant
G Utilisez un ventilateur ou un ouverts ou avec les dispositifs de
l鈥檈ntretien. protection enlev茅s.
aspirateur pour 么ter les fum茅es des
WARNUNG
zones de travail.
German
G Anlage nie ohne Schutzgeh盲use
G Vermeiden Sie das Einatmen von
G Strom vor Wartungsarbeiten oder Innenschutzverkleidung in
Schweibrauch!
G Sorgen Sie f眉r gute Be- und abschalten! (Netzstrom v枚llig Betrieb setzen!
枚ffnen; Maschine anhalten!)
Entl眉ftung des Arbeitsplatzes!
ATEN脟脙O
Portuguese
G Mantenha-se afastado das partes
G Mantenha seu rosto da fuma莽a.
G N茫o opere com as tampas removidas.
G Use ventila莽茫o e exhaust茫o para moventes.
G Desligue a corrente antes de fazer G N茫o opere com os paineis abertos
remover fumo da zona respirat贸ria.
servi莽o. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRU脟脮ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PR脕TICAS DE SEGURAN脟A DO EMPREGADOR.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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