Lincoln Electric RED-D-ARC DC-400 Operator's Manual
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Lincoln Electric RED-D-ARC DC-400 Operator's Manual

Lincoln Electric RED-D-ARC DC-400 Operator's Manual

Lincoln electric welder user manual
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RED-D-ARC
DC-400
For use with machines having Code Numbers:
OPERATOR'S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This welder 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.
1-800-245-3660
North America's Largest Fleet of Welding Equipment
10648; 10699; 11038; 11085 and
11128; 11347
IM655-B
November, 2006
RETURN TO MAIN MENU

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Summary of Contents for Lincoln Electric RED-D-ARC DC-400

  • Page 1 OPERATOR’S MANUAL Red-D-Arc Spec-Built Welding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on You This welder is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...
  • Page 2 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 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.
  • Page 6 The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

  • Page 7: Table Of Contents

    Installation ..Section A Technical Specifications ... A-1 Safety Precautions ...A-2 Location...A-2 Input Power Connection...A-2 Output Connections ...A-2 Output Cables ...A-2 Remote Output Control ...A-2 Remote Control Adapter Cable (K864) ...A-3 Amptrol Adapter Cable (K843) ...A-3 (K843)Amptrol Adapter Installation Instructions...A-3 Hi-Frequency Kit ...A-4 Amptrol Adapter for K799 Hi-Frequency Kit...A-4 Multiprocess Switch ...A-4...
  • Page 8 Maintenance..Section D Safety Precautions...D-1 Routine Maintenance ...D-1 ________________________________________________________________________ Troubleshooting ..Section E How to Use Troubleshooting Guide ...E-1 Troubleshooting Guide ...E-2 thru E-6 ________________________________________________________________________ Wiring Diagrams and Dimension Print ..Section F ________________________________________________________________________ Parts Lists...P355, P239 TABLE OF CONTENTS Page...

  • Page 9: Installation

    TECHNICAL SPECIFICATIONS – DC-400 Standard Voltage Frequency 230/460/575V/60Hz Duty Cycle 100% OUTPUT MAXIMUM OPEN CIRCUIT VOLTAGE Min.----60A 12V CV(22V CC) Max.---500A 42V (CC, CV) RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT INPUT INPUT AMPERE VOLTAGE / RATING ON FREQUENCY NAMEPLATE @ 100%...

  • Page 10: Safety Precautions

    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. •...

  • Page 11: Remote Control Adapter Cable (K864

    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.) The Amptrol arc start switch is...

  • Page 12: Hi-Frequency Kit

    See the appropriate connection diagram for the exact instructions for the wire feeder being used. A cover (Lincoln Electric Part Number S17062-3) is available for the unused 14-pin connector to protect it against dirt and moisture.

  • Page 13: Connection Of Dc-400 To Ln-22 Or Ln25

    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”...

  • Page 14: Auxiliary Power Connections

    This is accomplished through the feedback net- work in the control circuit. SOLID STATE OUTPUT CONTROL The output of the welder is electronically controlled by SCR’s instead of mechanical contactors, providing extra long life for highly repetitive welding applica- tions.

  • Page 15: Arc Force Selector

    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.

  • Page 16: Multiprocess Switch

    WORK To semi- ELECTRODE auto or auto equipment MULTIPROCESS SWITCH 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.

  • Page 17: Operation

    SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK • 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. •...
  • Page 18 Three Phase Power Transformer Rectifier Rectified DC Output Constant Voltage Characteristic Designates welder complies with National Electrical Manufacturers Association requirements EW 1. (Export Model only) Designates welder complies with International Electrotechnical commission requirements 974-1. (European model only) Three Phase Power...
  • Page 19 Constant Current Characteristic Line Connection Shielded Metal Arc Welding Flux Cored Arc Welding Submerged Arc Welding Designates Welder can be used in environments with increased hazard of electric shock. (IEC model only) IP21 Degree of protection provided by the enclosure OPERATION...
  • Page 20 MODE SWITCH WARNING IDENTIFICATION Warning Identification EARTH GROUND CONNECTION Signifying the Earth (Ground) Connection OPERATION 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 tung- sten arc welding).

  • Page 21: General Machine Description

    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), there will be a small spark if the electrode contacts the work or ground within several...

  • Page 22: Power Source Operation

    The amber thermal protection light will be lit if either of the two protective thermostats have opened. The out- put power will be disabled but input power will still be applied to the welder. (Refer to Machine and Circuit Protection section). MODE SWITCH The large MODE SWITCH on the left side of the machine, labeled “Constant Voltage (Submerged Arc),...
  • Page 23 ® welding, other The OUTPUT TERMINALS toggle switch on the con- trol panel labeled “REMOTE - ON” allows the welder output to be activated remotely or to be always on. For remote operation, the toggle switch is set in “REMOTE” position and the welder output will be acti- vated when 2 and 4 are closed when using a wire- feeder.
  • Page 24 To gain access to the terminal strips simply remote the #10 sheet metal screws from the perimeter of the welder nameplate. Tilt panel forward so it rests in a horizontal position. See Table showing Front View of 14-Pin Connector Receptacle for lead number func- tions.

  • Page 25: Accessories

    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.

  • Page 26: Hi-Frequency Kit

    For easy moving of the machine, optional undercar- riages are available with either steel (K817) or rubber tired (K817R) wheels or a platform undercarriage (K841) with mountings for two gas cylinder at rear of welder. Install per instructions provided with undercarriage. DC-400...

  • Page 27: 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.

  • Page 28: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by 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.
  • Page 29 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 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. 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.
  • Page 30 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Machine has high output or pulsing output and no control. Machine has low output and no control. Machine does not have maximum output. Machine will not shut off. Variable or sluggish welding arc. OUTPUT control not functioning on the machine.
  • Page 31 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) OUTPUT control not functioning on “REMOTE” control. Poor arc striking with semiautomat- ic or automatic wire feeders. Poor arc characteristics. ARC CONTROL has no effect in CV (FCAW/GMAW) mode with short circuit transfer processes.

  • Page 32: Troubleshooting Guide

    PROCEDURE FOR REPLACING PC BOARDS WARNING ELECTRIC SHOCK • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. --------------------------------------------------------------------- When a PC Board is suspected to be defective, the following procedure must be followed: 1.
  • Page 33 REMOTE CONTROL CHECK Disconnect the remote output control and connect an ohmmeter across 75 to 76 and rotate the rheostat in the remote control. The resistance reading should go from zero to 10K ohms. Repeat with ohmmeter across 75 and 76 with same results. Connect ohm- meter across 75 and 77.
  • Page 34 WIRING DIAGRAM FOR CODE 10648 AUXILIARY COILS PRIMARY BOTTOM PRIMARY T1 MAIN TRANSFORMER X1 SEC SCR1 GREEN SNUBBER BOARD THERMAL PROTECTION LIGHT MODE SWITCH FRONT GANG CV-FCAW/GMAW CV-SUB ARC ARC CONTROL SWITCH OUTPUT CHOKE MIN. IND. (5) CV-FCAW/GMAW CV-SUB ARC /100W MAX.
  • Page 35 WIRING DIAGRAM FOR CODE 10699 AND ABOVE GROUND GROUND STUD ON OUTPUT PANEL SILVER AUXILIARY COILS PRIMARY BOTTOM PRIMARY T1 MAIN TRANSFORMER X1 SEC SCR1 GREEN SNUBBER BOARD THERMAL PROTECTION LIGHT MODE SWITCH FRONT GANG CV-FCAW/GMAW CV-SUB ARC ARC CONTROL SWITCH OUTPUT CHOKE...
  • Page 36 DIAGRAMS WIRING DIAGRAM FOR CODES 11038, 11085, 11128, 11347 DC-400...
  • Page 37 SCR1 Gate leads plug to control P.C. board DIAGRAMS POWER RECTIFIER BRIDGE DIAGRAM 1 PLUG TO SNUBBER BOARD ANODE CATHODE ANODE SCR2 SCR3 GATE CATHODE DC-400 To (+) side of capacitor bank SHUNT mode switch To plug To T1 main transformer...
  • Page 38 DIMENSION PRINT Part No. Type 30.02 + .11 30.02 + .11 M12244-7 DC-400 32.00 15.39 30.92 1.44 DC-400...
  • Page 39 NOTES DC-400...
  • Page 40 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 41 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 42 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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