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Red-D-Arc DC-400 Operator's 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

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Summary of Contents for Red-D-Arc DC-400

  • Page 1 For use with machines having Code Numbers: 11128; 11347 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.
  • Page 2 SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm.

  • Page 3: Electric Shock Can Kill

    SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
  • Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
  • Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté...
  • Page 6 for selecting a QUALITY product. We want you to take pride in Thank You operating this product ••• as much pride as we have in bringing this product to you! 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.

  • Page 7: Table Of Contents

    Multiprocess Switch .....................A-4 Capacitor Discharge Circuit ..................A-4 Undercarriages......................A-4 Installation of Equipment Required for Recommended Processes ....A-4 thru A-6 Connection of DC-400 to LN-22 or LN25 ..............A-5 Auxiliary Power Connections ..................A-6 Remote Control Connections ..................A-6 Output Connections .....................A-6 Input Connections ......................A-6 Input Line Voltage Compensation ................A-6...
  • Page 8 TABLE OF CONTENTS Page 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...

  • Page 9: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – DC-400 INPUT-THREE PHASE ONLY Standard Input Current at Rated Output (CVI) Voltage 100% Duty Cycle 60% Duty Cycle 50% Duty Cycle Frequency 230/460/575V/60Hz 400Amps/36V 450Amps/38V 500Amps/40V 78/39/31Amps 83/42/33Amps 84/42/34Amps RATED OUTPUT Duty Cycle Amps Volts at Rated Amps...

  • Page 10: Safety Precautions

    . Install and reconnect panel for the proper input voltage per the diagram pasted inside the access panel cover. See Technical Data on A-1. DC-400...

  • Page 11: Remote Control Adapter Cable (K864

    Hi-Freq Kit K963*,K813* SOURCE Amptrol or K870 TION INSTRUCTION Amptrol For use with: DC-250, DC-400, R3R or Weldanpower K843 Adapter Arc start cable K843 Adapter 250 (D-10 and Pro) with remote control power Arc start cable (included with Bolt and nut...

  • Page 12: Hi-Frequency Kit

    TIONS MULTIPROCESS SWITCH (K804-1) For control cable with 14-pin connector: Kit that mounts on the front of the DC-400, and Connect control cable to 14-pin connector on the front includes hinged covers over its output studs. The panel of the machine. See the appropriate connection...

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

    1. Connect wire feed unit electrode and work cables through the rectangular strain relief holes in the a) Turn off all power. base of the DC-400 to the output studs on the left side of the box. b) Place output terminals switch into the “ON” posi- tion.

  • Page 14: Auxiliary Power Connections

    An output stud cover protects against accidental con- tact with the output studs. Cover hinges upward for access to the studs. DC-400...

  • Page 15: Arc Force Selector

    75, 76, 77 and the negative output lead, one of the PC board “self-restoring” fuses will blow, pre- When the DC-400 is used for stick welding or air car- venting any machine damage. bon arc, the control leads and welding cables to any...

  • Page 16: Multiprocess Switch

    RENT (STICK/TIG)” for air carbon arc. d) For stick, TIG or air carbon arc, place OUTPUT TERMINALS switch into the “ON” position. With the DC-400 connected for stick, TIG or air carbon arc welding, the output terminals will be energized at all times.

  • Page 17: Operation

    • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. • This next section applies to DC-400’s without the Capacitor Discharge Option: ---------------------------------------------------------------------- FUMES AND GASES can be dangerous.
  • Page 18 Designates welder complies with National Electrical Manufacturers Association Gas Tungsten Arc Welding requirements EW 1. (Export Model only) IEC 974-1 Designates welder complies with International Electrotechnical Arc Force Current commission requirements 974-1. (European model only) Increase/Decrease of Current Three Phase Power DC-400...
  • 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 DC-400...
  • Page 20 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). WARNING IDENTIFICATION Warning Identification EARTH GROUND CONNECTION Signifying the Earth (Ground) Connection DC-400...

  • Page 21: General Machine Description

    E500. 115 VOLT POWER SWITCH The power input contactor operates from an auxiliary The DC-400 is designed to be used with the LN-7, 115 volt transformer that is energized through the LN-7 GMA, LN-8, LN-9, LN-9 GMA, LN-23P, LN-25, or POWER toggle switch on the machine control panel.

  • Page 22: Power Source Operation

    “LOCAL”. Duty Cycle and Time Period (Exception: When used with an LN-9, LN-9 GMA or The DC-400 is rated at the following duty cycles: NA-5 wire feeder, the OUTPUT CONTROL switch DUTY CYCLE *...
  • Page 23 10 amp circuit breaker protects this circuit. The CC Mode permits the DC-400 to produce a con- On the Domestic and Export models 110-115V AC is stant current output characteristic through the range of available at receptacle pins A and J.
  • Page 24 RESET button will pop out. If the power stays on, go to troubleshooting. If the power goes OFF, the GFCI is working properly. To restore power, press the RESET button. c) Press the TEST button (then RESET button) every month to assure proper operation. DC-400...

  • Page 25: Accessories

    R3R, and DC-600 power sources (K775). The K775 consists of a control box with 28 ft (8.5m) of four con- 1) DC-400 is used in conjunction with any LN-23P or ductor cable. This connects to terminals 75, 76, and older LN-8 or LN-9 semiautomatic wire-feeder.

  • Page 26: Hi-Frequency Kit

    (K799 CODES 8634 AND ABOVE ONLY) Kit supplies the high frequency plus gas valve for DC TIG welding. The DC-400 is shipped with proper R.F. bypass circuitry installed to protect the control circuit when welding with a HI-FREQ unit. K844 Water Valve Option Kit can be used with K799 when TIG welding with water cooled torches.

  • Page 27: Maintenance

    Blow out the machine at regular intervals. 3. In extremely dusty locations, dirt may accumulate on the remote control terminal strip TS1. Wipe or blow this terminal strip off at regular intervals. This is particularly important in damp locations. DC-400...

  • Page 28: Troubleshooting

    CAUTION 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. DC-400...
  • Page 29 CAUTION 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. DC-400...
  • Page 30 5. Faulty Control PC Board. CAUTION 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. DC-400...
  • Page 31 3. Broken Connection in Wiring. CAUTION 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. DC-400...

  • Page 32: Troubleshooting Guide

    Troubleshooting Guide. 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. DC-400...
  • Page 33 Steps 2 and 3. 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. DC-400...
  • Page 34 OUTPUT N.O. ACTUATED CONTROL CONTROL VOLTMETER IN CC ONLY SWITCH OUTPUT CONTROL SWITCH C6 .0047MFD/1400V N.A. GREEN WORK GROUNDING OPTIONAL STUD MULTI-PROCESS SWITCH OUTPUT ELECTRODE TERMINALS SWITCH N.A. TO NEG. TO POS. TO TERM. TERM. STRIP TERM. 12-9-94F L9107 DC-400...
  • Page 35 CONTROL CONTROL VOLTMETER IN CC ONLY SWITCH OUTPUT CONTROL SWITCH C6 .0047MFD/1400V N.A. GREEN WORK GROUNDING OPTIONAL STUD 31 32 76 77 MULTI-PROCESS SWITCH OUTPUT ELECTRODE TERMINALS SWITCH N.A. TO TERM. TO NEG. TO POS. TERM. STRIP TERM. L11460 DC-400...
  • Page 36 DIAGRAMS WIRING DIAGRAM FOR CODES 11038, 11085, 11128, 11347 DC-400...
  • Page 37 POWER RECTIFIER BRIDGE DIAGRAM 1 PLUG TO SNUBBER BOARD ANODE To (+) side of capacitor bank CATHODE ANODE SCR1 SCR2 SCR3 GATE CATHODE SHUNT mode switch Gate leads plug to control P.C. board To plug To T1 main transformer DC-400...

  • Page 38: Dimension Print

    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 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
  • Page 41 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
  • 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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