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IM655-B
November, 2006
RED-D-ARC
DC-400
For use with machines having Code Numbers:
10648; 10699; 11038; 11085 and
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.
However, your overall safety can be increased by proper installation
... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii 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. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque d’incendie dû aux étincelles
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v v for selecting a QUALITY product. We want you to take pride in operating this product ��� as much pride as we have in bringing Thank You 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. Please record your equipment ide
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vi vi TABLE OF CONTENTS Page Installation .. .......................................................................................................Section A Technical Specifications ............................................................................................. A-1 Safety Precautions.......................................................................................................A-2 Location......................................................................................
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vii TABLE OF CONTENTS Page Maintenance... ....................................................................................................Section D Safety Precautions.......................................................................................................D-1 Routine Maintenance...................................................................................................D-1 ________________________________________________________________________ Troubleshooting .. .........
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – DC-400 INPUT-THREE PHASE ONLY Standard Input Current at Rated Output (CVI) (4) 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 (1) Duty Cycle Amps Volts at Rated Amps 100% 400 36 60% 450 38 50% 500 40 OUTPUT OUTPUT MAXIMUM OPEN CIRCUIT VOLTAGE AUXILIARY POWER Min.----
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A-2 A-2 INSTALLATION OUTPUT CABLE CONNECTIONS SAFETY PRECAUTIONS Read this entire section of operating instructions The output leads are connected to the output termi- before operating the machine. nals marked “+” and “-”. They are located at the lower ELECTRIC SHOCK can kill. right and lower left corners of the front panel. Strain � Do not touch electrically live parts or relief for the electrode and work cables is provided by electrodes with your skin or wet routing the leads through the re
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A-3 A-3 INSTALLATION This K843 adapter is used to connect AMPTROL™ REMOTE CONTROL ADAPTER CABLE (K864) (K963*, K813* or K870), remote control (K775), and CABLE RECEPTACLE (6 SOCKET) STRAIGHT PLUG (14 PIN) HI-FREQ™ (K799) accessories to DC-250, DC-400, TO POWER SOURCE TO: 1) K857 REMOTE CONTROL 2) K963 HAND AMPTROL R3R or Weldanpower 250 (D-10 and Pro) with remote 3) K870 FOOT AMPTROL control power sources. The power source "machine/remote" switch must be in "remote" for CABLE RECEPTACL
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A-4 A-4 INSTALLATION 3) DC-400 is used with any semiautomatic wire-feed- HI-FREQUENCY KIT (K799 CODES 8634 er and possible small spark, if electrode touches AND ABOVE ONLY) work just after gun trigger is released, is objection- able. Kit supplies the high frequency plus gas valve for DC TIG welding. The DC-400 is shipped with proper R.F. Install per M17060 instructions included with the bypass circuitry installed to protect the control circuit Kit. when welding with a HI-FREQ unit. K844 Wa
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A-5 A-5 INSTALLATION CONNECTION OF DC-400 TO LN-22 OR LN-25 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. 2. Connect wire feeder control cable and make other terminal strip connections as specified on the con- c) Connect the electrode cable to the output terminal nection diagram for
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A-6 A-6 INSTALLATION 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,
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A-7 A-7 INSTALLATION The individual case sides are removable for easy PARALLELING access for internal service or inspection. There are no provisions on the DC-400 to permit par- The case rear, top section, is equipped with a remov- alleling. able access panel. This provides easy access to the input contactor, easy connection and reconnection of DIODE OPTION input leads, and easy access for service or inspection. The DC-400 Diode option is required to utilize the cold The total construction
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A-8 A-8 INSTALLATION To stick WORK + electrode holder or air carbon To semi- arc torch ELECTRODE auto or auto User supplied equipment 2 4/0 (107 mm ) jumper 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. This does no harm, b
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B-1 B-1 OPERATION SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON Read this entire section of operating instructions THIS MACHINE OR IN THIS MANUAL before operating the machine. ELECTRIC SHOCK can kill. POWER ON-OFF SWITCH � Have an electrician install and ser- vice this equipment. Input (Power) � 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: On ------
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B-2 B-2 OPERATION VOLTMETER SWITCH ARC CONTROL SWITCH Voltmeter Gas Metal Arc Welding Positive Electrode Increase/Decrease of Inductance Negative Electrode Low Inductance RATING PLATE High Inductance Three Phase Power OUTPUT TERMINALS SWITCH Transformer Output (Voltage) Rectifier On Rectified DC Output Remote On/Off ARC FORCE CONTROL DIAL Constant Voltage Characteristic Shielded Metal Arc Welding Designates welder complies NEMA EW 1 with National Electrical Manufacturers Association Gas Tungst
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B-3 B-3 OPERATION RATING PLATE (Continued) Transformer Rectifier Rectified DC Output Constant Voltage Characteristic Constant Current Characteristic Line Connection Shielded Metal Arc Welding Flux Cored Arc Welding Submerged Arc Welding Designates Welder can be used in environments with increased hazard of electric shock. (IEC model only) S Degree of protection provided by the enclosure IP21 DC-400
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B-4 B-4 OPERATION 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 tung- sten arc welding). WARNING IDENTIFICATION Warning Identification EARTH GROUND CONNECTION Signifying the Earth (Ground) Connection DC-400
