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IM474-E |
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February, 2011 |
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IDEALARC DC-400 |
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For use with 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, 11567
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’S MANUAL
Copyright © Lincoln Global Inc.
•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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SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS |
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline 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 “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 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 powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
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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 refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
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1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
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1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.
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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right 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.
2.d.5. Do not work next to welding power source.
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SAFETY |
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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.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or 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 the following equipment:
•Semiautomatic DC Constant Voltage (Wire) Welder.
•DC Manual (Stick) Welder.
•AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water 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.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5.b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.
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’s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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SAFETY
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WELDING and CUTTING
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. 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 Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, 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.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to physical damage.
•A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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SAFETY
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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 suivantes:
Sûreté Pour Soudage A L’Arc
1.Protegez-vous contre la secousse électrique:
a.Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b.Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c.Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le refroidir.
e.Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f.Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.
2.Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.
3.Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a.Utiliser un bon masque avec un verre filtrant approprié ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b.Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l‘arc.
c.Protéger l’autre personnel travaillant à proximité au soudage à l’aide d’écrans appropriés 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, pantalons 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.Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.
7.Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8.S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9.Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10.Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11.Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1.Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2.Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.
3.Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4.Garder tous les couvercles et dispositifs de sûreté à leur place.
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Thank You
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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product
••• 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’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 – 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.
•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.
• For On-Line Registration: Go to our WEb SITE at www.lincolnelectric.com. Choose “Quick Links” and then “Product Registration”. 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.
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TAbLE OF CONTENTS |
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Installation ....................................................................................................... |
Section A |
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Technical Specifications ........................................................................................ |
A-1 |
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Safety Precautions .......................................................................................... |
A-2 |
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Correct Operational use .................................................................................. |
A-2 |
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Stacking and Lifting......................................................................................... |
A-2 |
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Input Power Connections ................................................................................ |
A-2 |
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Output Connections ........................................................................................ |
A-3 |
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Installation of Field Installed Options..................................................................... |
A-3 |
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K843 Amptrol Installation Instructions ................................................................... |
A-4 |
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Installation of Equipment Requied for Recommended Processes |
..........A-5 Thru A-6 |
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Operational ...................................................................................................... |
Section b |
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Safety Precautions................................................................................................. |
B-1 |
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Meaning of Graphic Symbols................................................................... |
B-1 thru B-3 |
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General Machine Description ................................................................................ |
B-4 |
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Recommended Processes & Equipment............................................................... |
B-4 |
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Operational Features and Control ......................................................................... |
B-4 |
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Power Source Operation and Controls .................................................... |
B-5 thru B-7 |
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Auxiliary Power Connections .......................................................................... |
B-8 |
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Solid State Output Control .............................................................................. |
B-8 |
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Case Features................................................................................................. |
B-8 |
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Stick Welding .................................................................................................. |
B-9 |
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Paralleling ....................................................................................................... |
B-9 |
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Machine & Circuit Protection........................................................................... |
B-9 |
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Accessories ..................................................................................................... |
Section C |
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TIG Welding Options / Accessories....................................................................... |
C-1 |
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Optional Equipment ............................................................................................. |
C-1 thru C-2 |
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Maintenance .................................................................................................... |
Section D |
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Safety Precautions ................................................................................................ |
D-1 |
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Routine Maintenance............................................................................................. |
D-1 |
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Troubleshooting .............................................................................................. |
Section E |
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Safety Precautions................................................................................................. |
E-1 |
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How to Use Troubleshooting Guide....................................................................... |
E-1 |
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Troubleshooting Guide............................................................................. |
E-2 thru E-5 |
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Procedure for Replacing P.C. Boards............................................................ |
E-6, E-7 |
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Wiring Diagrams .............................................................................................. |
Section F |
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Parts Pages ................................................................................................. |
P-234, P-239 |
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A-1 |
INSTALLATION |
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A-1 |
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TECHNICAL SPECIFICATIONS – DC-400 |
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INPUT-THREE PHASE ONLY |
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Standard |
Input Current at Rated Output (CVI) |
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Voltage |
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Frequency |
100% Duty Cycle |
60% Duty Cycle |
50% Duty Cycle |
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400Amps/36V |
450Amps/38V |
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500Amps/40V |
230/460/575V/60Hz |
78/39/31Amps |
83/41/33Amps |
84/42/34Amps |
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400Amps/36V |
450Amps/38V |
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500Amps/40V |
220/230/380/400/415/440V/50/60Hz 81/77/47/45/43/41Amps |
85/81/49/47/45/42Amps |
86/82/50/48/46/43Amps |
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RATED OUTPUT |
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Duty Cycle (1) |
Amps |
Volts at Rated Amps |
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100% |
400 |
36 |
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60% |
450 |
38 |
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50% |
500 |
40 |
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OUTPUT |
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OUTPUT |
MAXIMUM OPEN CIRCUIT VOLTAGE |
AUXILIARY POWER |
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Min.----60A 12V CV(22V CC) |
57V. (CC) 45.5V. (CVI) |
60Hz |
115 VAC, 15 AMPS |
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Max.---500A 42V (CC, CV) |
54V. (CC) 45.5V. (CVI) |
50/60 Hz |
42 VAC, 10 AMPS |
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RECOMMENDED INPUT WIRE AND FUSE SIzES FOR MAXIMUM RATED OUTPUT. |
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IN ADDITION, FOLLOW LATEST NATIONAL ELECTRICAL CODE AND LOCAL CODE. |
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INPUT |
INPUT AMPERE |
TYPE 75°C |
TYPE 75°C |
VOLTAGE / |
RATING ON |
COPPER WIRE IN |
GROUND WIRE IN |
FREQUENCY |
NAMEPLATE |
CONDUIT AWG |
CONDUIT AWG |
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@100% |
(IEC) SIZES (mm2) |
(IEC) SIZES (mm2) |
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Duty Cycle |
40°C(104°F) |
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230/60Hz |
78 |
3(25) |
6(16) |
460/60Hz |
39 |
8(10) |
10(6) |
575/60Hz |
31 |
10(6) |
10(6) |
BUSSMANN SUPER LAG |
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FUSE SIZE AND |
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CATALOG NUMBER* |
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FUSE SIZE |
CATALOG NUMBER |
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100 |
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REN-100 |
50 |
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RES-50 |
40 |
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RES-40 |
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220/50/60Hz 230/50/60Hz 380/50/60Hz 400/50/60Hz 415/50/60Hz 440/50/60Hz
HEIGHT
27.50 in. 699 mm
81 |
3(25) |
8(10) |
100 |
REN-100 |
77 |
3(25) |
8(10) |
100 |
REN-100 |
47 |
6(16) |
10(6) |
60 |
RES-60 |
45 |
6(16) |
10(6) |
60 |
RES-60 |
43 |
8(10) |
10(6) |
60 |
RES-60 |
41 |
8(10) |
10(6) |
50 |
RES-50 |
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PHYSICAL DIMENSIONS |
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WIDTH |
DEPTH |
WEIGHT |
22.25 in. |
32.0 in. |
473 lbs. |
565 mm |
988 mm |
215 kg. |
TEMPERATURE RANGES |
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OPERATING TEMPERATURE RANGE |
STORAGE TEMPERATURE RANGE |
-22°F to 104°F(-30°C +40°C) |
-40°F to 140°F(-40°C+60°C) |
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(1) Based upon 10 minute time period (i.e., for 60% duty cycle, it is 6 minutes on an 4 minutes off).
*Use only bussmann Super-Lag fuses specified. Other fuses may not protect the welder and may cause overheating and possible fire damage.
Insulation class 155(F)
IDEALARC® DC-400
A-2 |
INSTALLATION |
A-2 |
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
•Do not touch electrically live parts or electrode with skin or wet clothing.
•Insulate yourself from work and ground.
•Always wear dry insulating gloves.
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FUMES AND GASES can be dangerous.
•Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.
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WELDING SPARKS can cause fire or 
explosion.
•Keep flammable material away.
•Do not weld on closed containers.
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ARC RAYS can burn eyes and skin.
•Wear eye, ear and body protection.
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See additional warning information at front of this operator’s manual.
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CORRECT OPERATIONAL USE
The machine should be located in a clean dry place where there is free circulation of clean air such that air movement in through the front and out through the back will not be restricted. Dirt and dust that can be drawn into the machine should be kept to a minimum.
Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown of the machine.
LIMIT ON STACKING
WARNING
FALLING EQUIPMENT can cause injury.
• Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder.
•Lift only with equipment of adequate lifting capacity.
•be sure machine is stable when lifting.
•Do not stack more than three high.
•Do not stack the DC-400 on top of any other machine.
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 level, well supported surface.
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 being stacked on.
Input Power Connections
By removing the rear access panel the three phase input power is connected to the three line terminals on the input contactor, and the earth grounding lead to the grounding 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 Specification Page:
IDEALARC® DC-400
A-3 |
INSTALLATION |
A-3 |
CAUTION
*Failure to follow these instructions can cause immediate failure of components within the machine.
•When powering welder from a generator be sure to turn off the welder first, before generator is shut down in order to prevent damage to welder.
Output Cable Connections
The output leads are connected to the output terminals marked “+” and “-”. They are located at the lower right and lower left corners of the front panel.
Output Cables
CAbLE SIzES FOR COMbINED LENGTH OF
ELECTRODE AND WORK CAbLE
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MACHINE LOAD |
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400A |
500A |
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(100% DUTY |
(50% DUTY |
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CAbLE LENGTHS |
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CYCLE) |
CYCLE) |
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UP TO 50 ft |
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3/0 |
2/0 |
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(15m) |
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85 mm2 |
67 mm2 |
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50 to 100 ft |
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3/0 |
2/0 |
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(15-30 m) |
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85 mm2 |
67 mm2 |
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100-150 ft |
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3/0 |
3/0 |
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(30-46 m) |
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85 mm2 |
85 mm2 |
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150-200 ft |
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3/0 |
3/0 |
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(46-61 m) |
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85 mm2 |
85 mm2 |
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200-250 ft |
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4/0 |
4/0 |
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(67-76 m) |
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107 mm2 |
107 mm2 |
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INSTALLATION OF FIELD INSTALLED OPTIONS
REMOTE CONTROL ADAPTER CAbLE (K864)
S T R A I G H T P L U G ( 1 4 P I N ) |
C A B L E R E C E P T A C L E ( 6 S O C K E T ) |
T O P O W E R S O U R C E |
T O : 1 ) K 8 5 7 R E M O T E C O N T R O L |
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2 ) K 9 6 3 H A N D A M P T R O L |
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3 ) K 8 7 0 F O O T A M P T R O L |
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C A B L E R E C E P T A C L E ( 1 4 S O C K E T ) |
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T O L N - 7 W I R E F E E D E R |
A “V” cable 12” (.30m) long to connect a K857 Remote Control (6 pin connector) with a wire-feeder (14-pin connector) and the machine (14-pin connector). If a remote control is used alone the wire-feeder connection is then not used.
WARNING
ELECTRIC SHOCK can kill.
•Turn the power switch of the welding power source “OFF” before installing plugs on cables or when connecting or disconnecting plugs to welding power source.
AMPTROL ADAPTER CAbLE (843)
A five wire cable, 12” (.30m ) long, used for easy 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.) The Amptrol arc start switch is nonfunctional unless used with a K799 Hi-Frequency Kit.
Remote Output Control (K857 or K857-1 with K864 Adapter)
An optional “remote out control” is available. The K857 or K857-1 are the same remote control options that are used on other Lincoln power sources. The 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.
See Amptrol Adapter installation Instructions on next page.
IDEALARC® DC-400
K843 AMPTROL™ 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
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This K843 adapter is used to connect AMPTROL™ (K963*, |
The power source "machine/remote" switch must be in "remote" |
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K813* or K870), remote control (K775), and HI-FREQ™ (K799) |
for Amptrol™ to control current. Accessories may be combined |
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accessories to DC-250, DC-400, R3R or Weldanpower 250 |
and connected in four different ways, as shown below. |
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(D-10 and Pro) with remote control power sources. |
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AMPTROL™ ONLY |
AMPTROL™ PLUS |
AMPTROL™ AND |
AMPTROL™ AND HI-FREQ.™ KIT |
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REMOTE LIMIT CONTROL |
HI-FREQ.™ KIT |
PLUS REMOTE LIMIT CONTROL |
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The Amptrol™ provides remote |
The Amptrol™ provides remote |
The Amptrol™ will start the Hi-Freq™ |
The Amptrol™ switch will start the |
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current control through the full range |
current control from the minimum of |
kit to turn on gas and high frequency |
Hi-Freq™ kit to turn on gas and high |
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of the power source. |
the power source to a maximum set |
starting for DC TIG welding. The |
frequency starting for DC TIG |
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by the remote limit control. |
Amptrol™ controls current |
through |
welding. The Amptrol™ controls |
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K963*, K813* or |
the full range of the power source. |
current from the minimum of the |
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POWER |
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POWER |
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power source to a maximum set by |
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K963*, K813* or |
K870 Amptrol™ |
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SOURCE |
SOURCE |
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the remote limit control. |
K775 Remote |
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K870 Amptrol™ |
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K775 Remote |
K799 |
POWER |
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K963*,K813* |
K799 |
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Limit Control |
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POWER |
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SOURCE |
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Hi-Freq™ |
K963*,K813* |
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Limit Control |
Hi-Freq™ Kit |
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or K870 |
Kit |
SOURCE |
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Amptrol™ |
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or K870 |
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K843 |
Bolt and nut |
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Amptrol™ |
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K843 |
Power source |
Adapter |
connection. |
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Insulate |
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Adapter |
terminal |
75 |
and tape. |
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K843 Adapter |
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strip |
76 77 |
Arc start cable |
Arc start cable |
K843 Adapter |
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77 |
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(included with |
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Bolt and nut |
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76 |
K799) |
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(included |
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with K799) |
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connection. |
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75 |
76 77 |
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75 |
76 |
77 |
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insulate |
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75 |
76 |
77 and tape. |
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{ |
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{ |
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77 |
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Black and white |
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76 |
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CUT OFF |
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CUT OFF |
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leads not used. |
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Black and white leads |
Tape and |
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ARC START |
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ARC START |
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K775 |
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SWITCH and connect black |
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SWITCH and |
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not used. Tape |
insulate. |
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lead to black and white |
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connect black |
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K843 |
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and insulate. |
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lead to white. |
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lead to black and |
K799 |
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white lead to white. |
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FIG. 1 |
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FIG. 2 |
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FIG. 3 |
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FIG. 4 |
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4-A
INSTALLATION
4-A
A-5 |
INSTALLATION |
A-5 |
INSTALLATION OF EQUIPMENT REQUIRED FOR RECOMMENDED PROCESSES
WIRE FEEDER CONTROL CAbLE CONNECTIONS
For control cable with 14-pin connector:
Connect control cable to 14-pin connector on the front panel of the machine. See the appropriate connection diagram for the exact instructions for the wire feeder being used. Refer to Section 2.4.1 for connector pin functions.
For control cable with terminal strip connectors:
The control cable from the wire feeding equipment is connected to the terminal strips behind the control panel*. A strain relief box connector is provided for access into the terminal strip section. A chassis ground screw is also provided below the terminal strip marked with the symbol 
for connecting the automatic equipment grounding wire. 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.
*See Terminal Strip Connections section for access to the terminal strips.
CONNECTION OF DC-400 TO LN-22 OR LN-25
a)Turn off all power.
b)Place output terminals switch into the “ON” position.
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” position unless a Remote Control is connected to the DC-400.
e)Place MODE SWITCH in “CONSTANT VOLTAGE (FCAW, GMAW)”.
NOTE: The output terminals are energized at all times.
MULTIPROCESS SWITCH CONNECTION AND OPERATION
PURPOSE
A Multiprocess Switch has been designed for use with the DC-400 or DC-600. With this switch installed on the DC-400, it permits easy changing of the polarity of the wire feed unit connected and also provides separate terminals for connection of stick or air carbon arc. The Multiprocess Switch is available as either a factory installed or field installed option.
NOTE: IF THE DC-400 IS TO BE USED FOR BOTH SEMIAUTOMATIC/AUTOMATIC AND STICK/ AIR CARBON ARC, THEN A MULTIPROCESS SWITCH IS REQUIRED.
DESIGN
The Multiprocess Switch consists of a 3-position switch assembly that is mounted in a sheet metal enclosure that has two output terminals on each end of the box. The two terminals on the left side of the box are for connection of wire feed electrode and work leads. The two terminals on the right side of the box are for connection of work and electrode for stick or air carbon arc. The output terminals are protected against accidental contact by hinged covers.
The switch mounts to the front of the DC-400 by means of a bracket that fastens to the case sides. Two 4/0 (107 mm2) leads connect the switch assembly to each output stud.
CONNECTIONS
1.Connect wire feed unit electrode and work cables through 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 connection 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 cables through the rectangular strain relief holes in the base of the DC-400 to the output studs on the right side of the box.
OPERATION
IDEALARC® DC-400
A-6 |
INSTALLATION |
A-6 |
The operation of the switch is as follows:
A semiautomatic or automatic wire feed unit electrode and work cables are connected to the terminals on the left side of the box. Stick or air carbon arc electrode and work leads are connected to the terminals on the right side of the box. There are three positions on the switch. With the switch in the left position, the wire feed terminals are electrode negative. In the center position, the wire feeder terminals are electrode positive. In both the left and center switch position, the right side stick terminals are disconnected. In the right switch position, the wire feed terminals are disconnected from the DC-400 and the stick terminals connected. The polarity of the stick terminals is marked on the end of the box. To change polarity, the electrode and work leads must be interchanged. In the stick position, the stick terminals are energized at all times.
CONNECTIONS
(For those applications where it is not necessary to have separate work cables for stick and semiautomatic welding.)
If both stick and semiautomatic welding is done on the same workpiece, only one work lead is required. To do this, connect a 4/0 (107 mm2) jumper from the work terminal on the semiautomatic side to the terminal to be used for work on the stick side. The work lead from the semiautomatic side then serves as the work lead for both semiautomatic and stick welding.
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WORK |
+ |
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To stick |
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electrode |
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holder or |
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air carbon |
o semi- |
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ELECTRODE |
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arc torch |
auto or |
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auto |
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User supplied |
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uipment |
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4/0 (107 mm2 ) |
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jumper |
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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, but if the user desires, a 1/4” or 3/8” bolt and nut may be placed in the hole in the undercarriage tow bar to limit the travel of the undercarriage handle.
STICK, TIG OR AIR/CARbON ARC *
a)Turn off all power.
b)Disconnect all wire feed unit control, electrode, and work leads.
c)Place MODE SWITCH in the “CONSTANT CURRENT (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 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.
IDEALARC® DC-400
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