Lincoln Electric RED-D-ARC DC-400 Operator'S Manual Download

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RED-D-ARC
DC-400

IM655-B

November, 2006

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.

For use with machines having Code Numbers:

10648; 10699; 11038; 11085 and
11128; 11347

North America’s Largest Fleet of Welding Equipment

1-800-245-3660

OPERATOR’S MANUAL

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

Page 1: ... 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 For use with machines having Code Numbers 10648 10699 11038 11085 and 11128 11347 North America s Largest Fleet ...

Page 2: ...R 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 Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is availa...

Page 3: ...ter for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produ...

Page 4: ...event 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 Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Weldin...

Page 5: ...propriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6...

Page 6: ...ence This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number_________________________________________________________...

Page 7: ...ne Cooling A 6 Case Features A 6 Arc Force Selector A 7 Arc Control A 7 Mode Switch A 7 Stick Welding A 7 Paralleling A 7 Diode Option A 7 Machine Circuit Protection A 7 Multiprocess Switch A 8 ________________________________________________________________________ Operation Section B Safety Precautions B 1 Meanings of Graphic Symbols B 1 thru B 4 General Machine Description B 5 Recommended Proce...

Page 8: ..._____________________________ 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: ...M RATED OUTPUT Duty Cycle 1 Amps Volts at Rated Amps 100 400 36 60 450 38 50 500 40 OUTPUT MAXIMUM OPEN CIRCUIT VOLTAGE AUXILIARY POWER Min 60A 12V CV 22V CC 57V CC 45 5V CVI 115 VAC 15 AMPS Max 500A 42V CC CV 42 VAC 10 AMPS PHYSICAL DIMENSIONS 1 Based upon 10 minute time period i e for 60 duty cycle it is 6 minutes on an 4 minutes off INPUT VOLTAGE FREQUENCY 230 60HZ 460 60HZ 575 60HZ INPUT AMPER...

Page 10: ...ounding terminal on the input box floor marked with the symbol Install and reconnect panel for the proper input voltage per the diagram pasted inside the access panel cover See Technical Data on A 1 OUTPUT CABLE CONNECTIONS The output leads are connected to the output termi nals marked and They are located at the lower right and lower left corners of the front panel Strain relief for the electrode...

Page 11: ...rrent Accessories may be combined and connected in four different ways as shown in Figure 1 2 3 4 WARNING WARNING S T R A I G H T P L U G 1 4 P I N T O P O W E R S O U R C E C A B L E R E C E P T A C L E 6 S O C K E T C A B L E R E C E P T A C L E 1 4 S O C K E T T O 1 K 8 5 7 R E M O T E C O N T R O L 2 K 9 6 3 H A N D A M P T R O L 3 K 8 7 0 F O O T A M P T R O L T O L N 7 W I R E F E E D E R AM...

Page 12: ...r 12 83 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 feed er and possible small spark if electrode touches work just after gun trigger is released is ob...

Page 13: ...ugh the rectangular strain relief holes in the base of the DC 400 to the output studs on the left side of the box 2 Connect wire feeder control cable and make other terminal strip connections as specified on the con nection diagram for the Lincoln wire feeder being used Electrode and Work are connected to the left side of the Multiprocess Switch 3 Connect stick or air carbon arc electrode and work...

Page 14: ...rcuitry consists of six basic circuits 1 the SCR snubber network 2 the SCR firing circuit 3 the control fault protection circuit 4 the starting circuit 5 the power up delay circuit and 6 the power circuit The SCR snubber board consists of a capacitor and resistor connected across each SCR and across the entire bridge and MOV s to protect the control circuitry and SCR s from transient voltages The ...

Page 15: ...nected from the DC 400 for maximum safety unless the Multiprocess switch option is installed PARALLELING There are no provisions on the DC 400 to permit par alleling DIODE OPTION The DC 400 Diode option is required to utilize the cold start and cold electrode sensing features of the NA 3 NA 5 or NA 5R When this option is not used with an NA 3 NA 5 or NA 5R see the DC 400 NA 3 DC 400 NA 5 or DC 400...

Page 16: ...ce MODE SWITCH in the CONSTANT CUR 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 NOTE If stick welding TIG welding or air carbon arc cutting is to be done on the DC 400 along with semi automatic automatic weld...

Page 17: ...umes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn Wear eye ear and body protection See additional waring information under Arc Welding Safety Precautions and in the front of this Operating Manual GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL Input Power On Off POWE...

Page 18: ...Current Increase Decrease of Current Voltmeter VOLTMETER SWITCH Positive Electrode Negative Electrode Three Phase Power RATING PLATE 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 requi...

Page 19: ...rged Arc Welding Rectifier Rectified DC Output Constant Voltage Characteristic Line Connection Shielded Metal Arc Welding Designates Welder can be used in environments with increased hazard of electric shock IEC model only Flux Cored Arc Welding Degree of protection provided by the enclosure IP21 S ...

Page 20: ... SWITCH Warning Identification WARNING IDENTIFICATION Signifying the Earth Ground Connection EARTH GROUND CONNECTION Constant Voltage Submerged Arc Welding Constant Voltage Flux cored arc welding gas metal arc welding Constant Current shield metal arc welding gas tung sten arc welding ...

Page 21: ...l system outstanding arc characteristics are achieved on con stant voltage In addition an arc force control enables the DC 400 to stick weld as well as the E500 OUTPUT CONTROL The OUTPUT control a small 2 watt potentiometer is calibrated from 1 to 10 The OUTPUT control serves as a voltage control in the CV position and a current control in the CC position MACHINE OUTPUT CONTROL SWITCH LOCAL OR REM...

Page 22: ...or by con necting a K775 control to terminals 75 76 and 77 on the terminal strip at the front of the machine or by connecting a K857 control to the 14 pin connector on the front of the machine For control at the machine control panel the toggle switch is set in the LOCAL Exception When used with an LN 9 LN 9 GMA or NA 5 wire feeder the OUTPUT CONTROL switch must be in the REMOTE position or automa...

Page 23: ...control setting is too high For most TIG welding applications adjust this control to a minimum for best operating character istics ARC CONTROL SWITCH Effective only in CV FCAW GMAW mode The ARC CONTROL is a tapped switch numbered from 1 to 5 and changes the pinch effect of the arc This control is most useful in processes that utilize a shorting metal transfer and controls the spatter fluid ity and...

Page 24: ...inue to run The secondary thermo stat will open either with an excessive overload or insufficient cooling The output will be zero and the amber protection light will be off 115VAC GFCI RECEPTACLE Codes 11038 and higher The GFCI receptacle is located near the output studs and protected by a 15 amp circuit breaker Testing the GFCI Receptacle a Turn the welder ON Press the reset button fully Plug a l...

Page 25: ...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 REMOTE CONTROL ADAPTER CABLE K864 A V cable 12 30m long to connect a K857 Remote Control K963 Hand Amptrol or K870 Foot Amptrol 6 pin connector with a wire feeder 14 pin connector and the machine 14 pin connector I...

Page 26: ...connect a K799 Hi Freq kit 5 pin con nector 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 which requires either a K864 adapter to connect with the 14 pin connector on the machine or a K843 adapter to connect to terminals 75 76 77 and the case grounding screw on the machine UNDERCARRIAGES K817 K817R K841 F...

Page 27: ...chine 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 ELECTRIC SHOCK can kill 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 ...

Page 28: ...led POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Authorized Fi...

Page 29: ...t closing Replace switch 1 Trigger circuit between 2 and 4 leads is not being closed Make sure trigger circuit is being closed 2 Electrode or work lead loose or broken Repair Connection 3 Open main transformer T1 pri mary or secondary circuit Repair 4 Defective Control PC Board Replace See Procedure for Replacing PC Boards 5 Primary or secondary thermostats open Amber thermal protection light is o...

Page 30: ...ty Check switch replace if faulty 3 Open in feedback circuitry 4 Faulty Control PC Board 5 OUTPUT control potentiometer circuit open lead 75 1 One input fuse blows Check and replace if blown after checking for reason for blown fuse 2 One phase of main transformer open 3 Faulty Control PC Board 4 OUTPUT control potentiometer 5 OUTPUT control potentiometer leads 210 211 or 75 open 1 Input contactor ...

Page 31: ...TPUT CONTROL switch in wrong position Place switch in REMOTE 2 Faulty OUTPUT CONTROL switch 3 Faulty remote control potentiome ter 4 Leads or connections open in control circuit 5 Faulty Control PC Board 1 Defective start circuit 2 Poor work connection 3 Improper procedures 4 Defective Control PC Board 1 Start circuit energized at all times read switch CR3 not closing 2 Defective Start PC Board 3 ...

Page 32: ...ts in CV In the CC mode the open circuit voltage should be approximately 57 volts 54 volts on 50 60 Hz except at near minimum settings of the output control where it may be lower If any other condition exists refer to the Troubleshooting Guide FAULT PROTECTION OPERATION The overload protection circuit in the Control PC Board will limit the welding current heat to 550 amps if a short or overload is...

Page 33: ... leads e Perform the following steps 2 and 3 If diodes and SCR s are not shorted bridge test is com pleted If any device appears shorted discon nect the cathode lead of each diode 4 total and repeat Steps 2 and 3 2 Power Diode Test a Establish the polarity of the ohmmeter leads and set to X10 scale b Connect the ohmmeter positive lead to anode and negative lead to cathode c Reverse the leads of th...

Page 34: ... TS2 C6 0047MFD 1400V 10K 2W 218 204 208 209 R5 228 204 219 217 204 GREEN 216 MODE SWITCH S4A CC CC S4B F 3 2 1 S 216 R1 219 15 100W ARC CONTROL 6 J6 STARTING BOARD 224 224 75 211 R4 10K 2W OUTPUT CONTROL S2 OUTPUT CONTROL SWITCH 76 212 211 213 77 SWITCH MULTI PROCESS OPTIONAL WORK ELECTRODE 2 TERM TO POS TERM S5 31 32 228 215 218 N C N O N C N O N A 2 75 76 77 218 214 218 234 204 216 CHOKE OUTPUT...

Page 35: ...TOR H1 CONNECT OR INSULATE AS SHOWN ON INPUT CONNECTION DIAGRAM DISCHARGE CAPACITOR SCR3 202 203 METERS TAPE UP SEPARATELY W U 41 42 42 2 41 41 10 AMP CIRCUIT BREAKER SECONDARY PRIMARY THERMOSTATS 42V 42A S 21V S A 21V 21V 41 2 42 Y 9 10 N B W 233 233 LIGHT 240 241 V L1 L2 L3 N B N B N A 225 4 31 32 TS1 TS2 C6 0047MFD 1400V 10K 2W 218 204 208 209 R5 228 204 219 217 204 GREEN 216 MODE SWITCH S4A CC...

Page 36: ...l 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 CODES 11038 11085 11128 11347 ...

Page 37: ... TO SNUBBER BOARD SHUNT P5 221 222 223 204 220 204 204 204 204 220 D1 D2 D3 SCR1 SCR2 SCR3 G1 G2 G3 D4 ANODE CATHODE ANODE CATHODE P3 Gate leads plug to control P C board To T1 main transformer To plug P1 To mode switch To side of capacitor bank _ X1 X2 X3 GATE _ ...

Page 38: ...F 5 DIMENSION PRINT F 5 DC 400 Part No Type A B C D F G H M12244 7 DC 400 32 00 15 39 30 92 1 44 30 02 11 30 02 11 94 ...

Page 39: ...DC 400 NOTES ...

Page 40: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 41: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 42: ...s 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 World s Leader in Welding and Cutting Products ...

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