Lincoln IDEALARC DC-400 Operator's Manual
IDEALARC
9847 thru 9852, 9854, 9855, 9857, 10008,
10275, 10276, 10859, 10880, 11083, 11084,
11277, 11278, 11279 11348, 11349, 11350,
11351, 11352, 11353, 11567
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Specications and availability of optional
features may have changed.
®
DC-400
IM474-E
February, 2011
For use with machines having Code Numbers:
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.
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• Sales and Service through Subsidiaries and Distributors Worldwide •
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
i
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
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.
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
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
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.
____________________________________________________
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.
____________________________________________________
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.
___________________________________________________
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.
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.
___________________________________________________
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.
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.
ii
SAFETY
ii
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
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
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.
vapors
to
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.
iii
SAFETY
iii
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
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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
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.
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.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
iv
SAFETY
iv
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 LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent 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 nʼimporte quelle partie
du corps.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Thank You
vv
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!
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 customerʼs 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.
CUSTOMER ASSISTANCE POLICY
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
“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:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
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.
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions ..........................................................................................A-2
Correct Operational use ..................................................................................A-2
Stacking and Lifting.........................................................................................A-2
Input Power Connections ................................................................................A-2
Output Connections ........................................................................................A-3
Installation of Field Installed Options.....................................................................A-3
K843 Amptrol Installation Instructions ...................................................................A-4
Installation of Equipment Requied for Recommended Processes..........A-5 Thru A-6
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Operational ......................................................................................................Section B
Safety Precautions.................................................................................................B-1
Meaning of Graphic Symbols...................................................................B-1 thru B-3
General Machine Description ................................................................................B-4
Recommended Processes & Equipment...............................................................B-4
Operational Features and Control .........................................................................B-4
Power Source Operation and Controls ....................................................B-5 thru B-7
Auxiliary Power Connections ..........................................................................B-8
Solid State Output Control ..............................................................................B-8
Case Features.................................................................................................B-8
Stick Welding ..................................................................................................B-9
Paralleling .......................................................................................................B-9
Machine & Circuit Protection...........................................................................B-9
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Accessories.....................................................................................................Section C
TIG Welding Options / Accessories.......................................................................C-1
Optional Equipment .............................................................................................
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-5
Procedure for Replacing P.C. Boards............................................................E-6, E-7
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Wiring Diagrams..............................................................................................Section F
________________________________________________________________________
Parts Pages.................................................................................................P-234, P-239
C-1 thru C-2
vivi
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – DC-400
INPUT-THREE PHASE ONLY
Standard
Voltage
Frequency
100% Duty Cycle
Input Current at Rated Output (CVI)
60% Duty Cycle
50% Duty Cycle
A-1
500Amps/40V
84/42/34Amps
500Amps/40V
86/82/50/48/46/43Amps
230/460/575V/60Hz
220/230/380/400/415/440V/50/60Hz
400Amps/36V
78/39/31Amps
400Amps/36V
81/77/47/45/43/41Amps
450Amps/38V
83/41/33Amps
450Amps/38V
85/81/49/47/45/42Amps
RATED OUTPUT
Duty Cycle
100% 400 36
60% 450 38
50% 500 40
(1)
Amps Volts at Rated Amps
OUTPUT
OUTPUT MAXIMUM OPEN CIRCUIT VOLTAGE AUXILIARY POWER
Min.----60A 12V CV(22V CC) 57V. (CC) 45.5V. (CVI) 60Hz 115 VAC, 15 AMPS
Max.---500A 42V (CC, CV) 54V. (CC) 45.5V. (CVI) 50/60 Hz 42 VAC, 10 AMPS
RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT.
IN ADDITION, FOLLOW LATEST NATIONAL ELECTRICAL CODE AND LOCAL CODE.
INPUT
VOLTAGE /
FREQUENCY
230/60Hz
460/60Hz
575/60Hz
INPUT AMPERE
RATING ON
NAMEPLATE
@100%
Duty Cycle
78
39
31
TYPE 75°C
COPPER WIRE IN
CONDUIT AWG
(IEC) SIZES (mm
40°C(104°F)
3(25)
8(10)
10(6)
2
)
TYPE 75°C
GROUND WIRE IN
CONDUIT AWG
(IEC) SIZES (mm
6(16)
10(6)
10(6)
2
BUSSMANN SUPER LAG
FUSE SIZE AND
CATALOG NUMBER
)
FUSE SIZE CATALOG NUMBER
100 REN-100
50 RES-50
40 RES-40
*
220/50/60Hz
230/50/60Hz
380/50/60Hz
400/50/60Hz
415/50/60Hz
440/50/60Hz
81
77
47
45
43
41
3(25)
3(25)
6(16)
6(16)
8(10)
8(10)
8(10)
8(10)
10(6)
10(6)
10(6)
10(6)
100 REN-100
100 REN-100
60 RES-60
60 RES-60
60 RES-60
50 RES-50
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
27.50 in. 22.25 in. 32.0 in. 473 lbs.
699 mm 565 mm 988 mm 215 kg.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-22°F to 104°F(-30°C +40°C)
(1) Based upon 10 minute time period (i.e., for 60% duty cycle, it is 6 minutes on an 4 minutes off).
STORAGE TEMPERATURE RANGE
-40°F to 140°F(-40°C+60°C)
* 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
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.
------------------------------------------------------------------------
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
------------------------------------------------------------------------
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
• Do not weld on closed containers.
------------------------------------------------------------------------
ARC RAYS can burn eyes and skin.
• Wear eye, ear and body
protection.
------------------------------------------------------------
See additional warning information at
front of this operatorʼs manual.
-----------------------------------------------------------
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.
A-2
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
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 “-”.
right and lower left corners of the front panel.
Output Cables
CABLE SIZES FOR COMBINED LENGTH OF
ELECTRODE AND WORK CABLE
CABLE LENGTHS
UP TO 50 ft
(15m)
They are located at the lower
MACHINE LOAD
400A
(100% DUTY
CYCLE)
3/0
85 mm
2
500A
(50% DUTY
CYCLE)
2/0
67 mm
2
REMOTE CONTROL ADAPTER CABLE (K864)
STRAIGHT PLUG (14 P IN)
TO POWER SOURCE
CABLE RECEPTACLE (6 SOCKET)
TO: 1) K857 REMOTE CONTROL
2) K963 HAND AMPTROL
3) K870 FOOT AMPTROL
CABLE RECEPTACLE (14 SOCKET)
TO LN-7 W IRE FEEDER
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.
A-3
50 to 100 ft
(15-30 m)
100-150 ft
(30-46 m)
150-200 ft
(46-61 m)
200-250 ft
(67-76 m)
3/0
85 mm
3/0
85 mm
3/0
85 mm
4/0
107 mm
2/0
2
67 mm
2
3/0
2
85 mm
2
3/0
2
85 mm
2
4/0
2
107 mm
2
INSTALLATION OF FIELD INSTALLED
OPTIONS
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).
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.
See Amptrol Adapter installation Instructions on next
page.
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.
IDEALARC® DC-400
A-4
INSTALLATION
A-4
may be combined
and connected in four different ways, as shown below.
The power source "machine/remote" switch must be in "remote"
for Amptrol™ to control current. Accessories
K775 Remote
Limit Control
a maximum set by
PLUS REMOTE LIMIT CONTROL
AMPTROL™ AND HI-FREQ.™ KIT
AMPTROL™ AND
The Amptrol™ switch will start the
Hi-Freq™ kit to turn on gas and high
frequency starting for DC TIG
welding. The Amptrol™ controls
HI-FREQ.™ KIT
for DC TIG welding. The
The Amptrol™ will start the Hi-Freq™
Amptrol™ controls current through
kit to turn on gas and high frequency
starting
current from the minimum of the
the full range of the power source.
power source to
the remote limit control.
K799
K963*,K813*
POWER
K963*,K813*
or K870
Amptrol™
POWER
SOURCE
Hi-Freq™
Kit
or K870
Amptrol™
SOURCE
K799
Hi-Freq™ Kit
Bolt and nut
K843 Adapter
(included
Arc start cable
K843 Adapter
K799)
(included with
Arc start cable
insulate
and tape.
connection.
75 7776
with K799)
75 7776
77
76
K775
K843
K799
FIG. 4
{
CUT OFF
ARC START
lead to black and
white lead to white.
SWITCH and
connect black
FIG. 3
{
lead to white.
lead to black and white
ARC START
SWITCH and connect black
CUT OFF
Bolt and nut
K870 Amptrol™
with remote control power sources.
K963*, K813* or
Limit Control
K775 Remote
AMPTROL™ PLUS
For use with: DC-250, DC-400, R3R or Weldanpower 250 (D-10 and Pro)
REMOTE LIMIT CONTROL
The Amptrol™ provides remote
current control from the minimum of
K843 AMPTROL™ ADAPTER INSTALLATION INSTRUCTIONS
the power source to a maximum set
by the remote limit control.
POWER
SOURCE
K843
WARNING: TURN THE POWER SOURCE OFF BEFORE INSTALLATION
K870 Amptrol™
K963*, K813* or
(D-10 and Pro) with remote control power sources.
accessories to DC-250, DC-400, R3R or Weldanpower 250
K813* or K870), remote control (K775), and HI-FREQ™ (K799)
This K843 adapter is used to connect AMPTROL™ (K963*,
AMPTROL™ ONLY
POWER
SOURCE
current control through the full range
The Amptrol™ provides remote
76
insulate
and tape.
77
connection.
Bolt and nut
K775
K963*,K813*
or K870
Amptrol™
K775 Remote
Limit Control
K843
K843 Adapter
K799
a maximum set by
FIG. 4
757776
POWER
SOURCE
{
may be combined
PLUS REMOTE LIMIT CONTROL
AMPTROL™ AND HI-FREQ.™ KIT
K799
Hi-Freq™
Kit
the remote limit control.
current from the minimum of the
welding. The Amptrol™ controls
power source to
The Amptrol™ switch will start the
Hi-Freq™ kit to turn on gas and high
frequency starting for DC TIG
SWITCH and
connect black
white lead to white.
ARC START
lead to black and
CUT OFF
(included
with K799)
Arc start cable
Amptrol™
K963*,K813*
or K870
K843 Adapter
POWER
FIG. 3
SOURCE
757776
HI-FREQ.™ KIT
AMPTROL™ AND
{
for DC TIG welding. The
K799
K799)
the full range of the power source.
Amptrol™ controls current through
The Amptrol™ will start the Hi-Freq™
kit to turn on gas and high frequency
starting
Hi-Freq™ Kit
lead to white.
lead to black and white
CUT OFF
ARC START
SWITCH and connect black
(included with
and connected in four different ways, as shown below.
The power source "machine/remote" switch must be in "remote"
for Amptrol™ to control current. Accessories
Arc start cable
76
Insulate
and tape.
77
connection.
Bolt and nut
77
K870 Amptrol™
K963*, K813* or
with remote control power sources.
Limit Control
K775 Remote
76
FIG. 2
75
AMPTROL™ PLUS
K843
REMOTE LIMIT CONTROL
Adapter
Tape and
leads not used.
insulate.
Black and white
POWER
SOURCE
For use with: DC-250, DC-400, R3R or Weldanpower 250 (D-10 and Pro)
current control from the minimum of
the power source to a maximum set
by the remote limit control.
The Amptrol™ provides remote
K843 AMPTROL™ ADAPTER INSTALLATION INSTRUCTIONS
WARNING: TURN THE POWER SOURCE OFF BEFORE INSTALLATION
strip
terminal
Power source
K870 Amptrol™
K963*, K813* or
FIG. 1
accessories to DC-250, DC-400, R3R or Weldanpower 250
This K843 adapter is used to connect AMPTROL™ (K963*,
K813* or K870), remote control (K775), and HI-FREQ™ (K799)
(D-10 and Pro) with remote control power sources.
757677
AMPTROL™ ONLY
K843
Adapter
Black and white leads
and insulate.
not used. Tape
POWER
SOURCE
current control through the full range
of the power source.
The Amptrol™ provides remote
of the power source.
Insulate
and tape.
connection.
77
76
75
Adapter
strip
terminal
Power source
K843
Adapter
77
76
75 76 77
Black and white
leads not used.
Tape and
Black and white leads
insulate.
not used. Tape
FIG. 2
FIG. 1
and insulate.
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
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
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.
STICK/
a) Turn off all power.
b) Place output terminals switch into the “ON” posi-
tion.
c) Connect the electrode cable to the output terminal
of polarity required by electrode. Connect the work
lead to the other terminal.
d) Place the OUTPUT CONTROL Switch at “LOCAL”
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.
IDEALARC® DC-400
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
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
have separate work cables for stick and semiautomatic welding.)
necessary to
To stick
electrode
holder or
air carbon
arc torch
User supplied
4/0 (107 mm )
jumper
2
o semi-
auto or
auto
ipment
WORK
ELECTRODE
+
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 *
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.
a) Turn off all power.
b) Disconnect all wire feed unit control, electrode, and
work leads.
c) Place 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 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
the DC-400 before connecting the DC-400 for
stick or air carbon arc cutting.
be disconnected from
IDEALARC® DC-400
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