Lincoln Electric DC-400 User Manual

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Lincoln Electric DC-400 User Manual

RED-D-ARC DC-400

IM655-B

November, 2006

For use with machines having Code Numbers: 10648;

10699; 11038; 11085 and

 

 

11128;

11347

RETURN TO MAIN MENU

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OPERATOR’S MANUAL

Red-D-Arc Spec-Built Welding Equipment

This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric.

Safety Depends on You

This welder is designed and built with safety in mind.

However, your overall safety can be increased by proper installation

... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.

And, most importantly, think before you act and be careful.

1-800-245-3660

North America’s Largest Fleet of Welding Equipment

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

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.

____________________________________________________

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.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.

Mar ‘95

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 below Threshold Limit Values (TLV) 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.

AUG 06

iii

SAFETY

iii

WELDING 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.

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.

Mar ‘95

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 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.

Mar. ‘93

v

Thank You

v

for selecting a QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

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.

vi

TABLE OF CONTENTS

vi

 

 

Page

 

Installation .. .......................................................................................................

Section A

 

Technical Specifications .............................................................................................

A-1

 

Safety Precautions .......................................................................................................

A-2

 

Location........................................................................................................................

A-2

 

Input Power Connection...............................................................................................

A-2

 

Output Connections .....................................................................................................

A-2

 

Output Cables ..............................................................................................................

A-2

 

Remote Output Control ................................................................................................

A-2

 

Remote Control Adapter Cable (K864) ........................................................................

A-3

 

Amptrol Adapter Cable (K843) .....................................................................................

A-3

 

(K843)Amptrol Adapter Installation Instructions...........................................................

A-3

 

Hi-Frequency Kit ..........................................................................................................

A-4

 

Amptrol Adapter for K799 Hi-Frequency Kit.................................................................

A-4

 

Multiprocess Switch .....................................................................................................

A-4

 

Capacitor Discharge Circuit .........................................................................................

A-4

 

Undercarriages.............................................................................................................

A-4

 

Installation of Equipment Required for Recommended Processes .................

A-4 thru A-6

 

Connection of DC-400 to LN-22 or LN25 .....................................................................

A-5

 

Auxiliary Power Connections .......................................................................................

A-6

 

Remote Control Connections .......................................................................................

A-6

 

Output Connections .....................................................................................................

A-6

 

Input Connections ........................................................................................................

A-6

 

Input Line Voltage Compensation ................................................................................

A-6

 

Solid State Output Control ..........................................................................................

A-6

 

Solid State Control System ..........................................................................................

A-6

 

Machine Cooling ..........................................................................................................

A-6

 

Case Features .............................................................................................................

A-6

 

Arc Force Selector .......................................................................................................

A-7

 

Arc Control ...................................................................................................................

A-7

 

Mode Switch.................................................................................................................

A-7

 

Stick Welding ...............................................................................................................

A-7

 

Paralleling ....................................................................................................................

A-7

 

Diode Option ................................................................................................................

A-7

 

Machine & Circuit Protection........................................................................................

A-7

 

Multiprocess Switch .....................................................................................................

A-8

 

________________________________________________________________________

 

Operation ...........................................................................................................

Section B

 

Safety Precautions .....................................................................................................

B-1

 

Meanings of Graphic Symbols .......................................................................

B-1 thru B-4

 

General Machine Description.......................................................................................

B-5

 

Recommended Processes and Equipment...... ...........................................................

B-5

 

Operational Features & Controls ...........................................................................

B-5

 

Power Source Operation..........................................................................

B-6 thru B-8

 

________________________________________________________________________

 

Accessories .. .....................................................................................................

Section C

 

Factory or Field Installed Options ................................................................................

C-1

 

Diode Option..........................................................................................................

C-1

 

Multi-Process Switch ............................................................................................

C-1

 

Field Installed Options .................................................................................................

C-1

 

Remote Output Control..........................................................................................

C-1

 

Amptrol Adapter Cable ..........................................................................................

C-1

 

Remote Control Adapter Cable ............................................................................

C-1

 

Multi-Process Switch ............................................................................................

C-1

 

Capacitor Discharge Circuit...................................................................................

C-1

 

Hi-Frequency Kit....................................................................................................

C-2

 

Optional Amptrol Adapter for Hi-Frequency Kit .....................................................

C-2

 

Undercarriages......................................................................................................

C-2

________________________________________________________________________

vii

TABLE OF CONTENTS

 

Page

Maintenance... ....................................................................................................

Section D

Safety Precautions.......................................................................................................

D-1

Routine Maintenance ...................................................................................................

D-1

________________________________________________________________________

Troubleshooting .. ..............................................................................................

Section E

How to Use Troubleshooting Guide .............................................................................

E-1

Troubleshooting Guide ...................................................................................

E-2 thru E-6

________________________________________________________________________

Wiring Diagrams and Dimension Print .. ..........................................................Section F

________________________________________________________________________

Parts Lists

.....................................................................................................P355, P239

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS – DC-400

 

INPUT-THREE PHASE ONLY

 

Standard

 

Input Current at Rated Output (CVI)

Voltage

100% Duty Cycle

60% Duty Cycle(4)

50% Duty Cycle

Frequency

 

 

 

230/460/575V/60Hz

400Amps/36V

450Amps/38V

500Amps/40V

 

78/39/31Amps

83/42/33Amps

84/42/34Amps

RATED OUTPUT

Duty Cycle (1)

Amps

Volts at Rated Amps

100%

400

36

60%

450

38

50%

500

40

 

 

 

OUTPUT

 

 

 

OUTPUT

MAXIMUM OPEN CIRCUIT VOLTAGE

AUXILIARY POWER

 

 

 

Min.----60A 12V CV(22V CC)

57V. (CC) 45.5V. (CVI)

115 VAC, 15 AMPS

Max.---500A 42V (CC, CV)

 

42 VAC, 10 AMPS

 

 

 

RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT

INPUT

INPUT AMPERE

 

TYPE 75°C GROUND

 

TYPE 75°C COPPER

TYPE 75°C

VOLTAGE /

RATING ON

WIRE IN CONDUIT

WIRE IN CONDUIT

SUPER LAG

FREQUENCY

NAMEPLATE

AWG (IEC)

AWG (IEC)

OR BREAKER

 

@ 100%

SIZES (mm2)

SIZES (mm2)

SIZE(AMPS)

 

Duty Cycle

40°C(104°F)

 

 

 

 

 

 

 

230/60HZ

78

3(25)

6(10)

125

460/60HZ

39

8(10)

10(6)

60

575/60HZ

31

10(6)

10(6)

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.

 

 

 

 

 

 

 

 

(1) Based upon 10 minute time period (i.e., for 60% duty cycle, it is 6 minutes on an 4 minutes off).

DC-400

A-2

INSTALLATION

A-2

 

 

 

SAFETY PRECAUTIONS

Read this entire section of operating instructions before operating the machine.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrodes with your skin or wet clothing.

Insulate yourself from the 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 containers that have held combustibles.

------------------------------------------------------------------------

ARC RAYS can burn.

• Wear eye, ear, and body protection.

------------------------------------------------------------------------

Observe additional guidelines detailed in the beginning of this manual.

LOCATION

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.

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surface directly under stationary or fixed electrical equipment, the surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not more than 5.90”(150mm) beyond the equipment on all sides.

-------------------------------------------------------------------------------

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 Data on A-1.

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. Strain relief for the electrode and work cables is provided by routing the leads through the rectangular holes in the base before connecting them to the output terminals. Lift the output stud cover to gain access to the output studs. Lower stud cover after connecting output leads.

OUTPUT CABLES

Installation of Field Installed Options

CABLE SIZES FOR COMBINED LENGTH OF ELEC-

TRODE AND GROUND CABLE

 

MACHINE LOAD

 

 

 

CABLE

400A (100%

500A (50%

DUTY

DUTY

LENGTHS

CYCLE)

CYCLE)

UP TO 50 ft

3/0

2/0

85 mm(2)

87 mm(2)

(15m)

3/0

2/0

50 to 100 ft

85 mm(2)

67 mm(2)

(15-30 m)

3/0

3/0

100-150 ft

85 mm(2)

85 mm(2)

(30-46 m)

3/0

3/0

150-200 ft

85 mm(2)

85 mm(2)

(46-61 m)

4/0

4/0

200-250 ft

107 mm(2)

107 mm(2)

(67-76 m)

 

 

REMOTE OUTPUT CONTROL

(K857 WITH K864 ADAPTER OR K775 )

The K857 has a 6-pin MS-style connector. The K857 requires a K864 adapter cable which connects to the 14-pin connector on the machine.

An optional “remote output control” is available. This is the same remote control that is used on the Lincoln R3R, and DC-600 power sources (K775). The K775 consists of a control box with 28 ft (8.5m) of four conductor cable. This connects to terminals 75, 76, and 77 on the terminal strip and the case grounding screw so marked with the symbol on the machine. These terminals are located behind the control panel on the front of the power source. This control will give the same control as the output control on the machine.

DC-400

A-3

 

 

 

 

 

 

 

 

 

 

 

 

 

INSTALLATION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A-3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REMOTE CONTROL ADAPTER CABLE (K864)

 

This K843 adapter is used to connect AMPTROL™

 

(K963*, K813* or K870), remote control (K775), and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C A B L E R E C E P T A C L E ( 6 S O C K E T )

 

S T R A I G H T P L U G ( 1 4 P I N )

 

 

 

 

 

 

 

 

 

HI-FREQ™ (K799) accessories to DC-250, DC-400,

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2 ) K 9 6 3 H A N D A M P T R O L

 

R3R or Weldanpower 250 (D-10 and Pro) with remote

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3 ) K 8 7 0 F O O T A M P T R O L

 

control

 

 

 

 

power sources. The

 

 

power

 

source

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C A B L E R E C E P T A C L E ( 1 4 S O C K E T ) "machine/remote" switch must be in "remote" for

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T O L N - 7 W I R E F E E D E R

 

Amptrol™ to control current. Accessories may be

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

combined and connected in four different ways, as

A “V” cable 12” (.30m) long to connect a K857

 

shown in Figure 1,2,3, & 4.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Remote Control, K963 Hand Amptrol or K870 Foot

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Amptrol (6-pin connector) with a wire-feeder (14-pin

 

 

 

 

AMPTROL™ ONLY

 

 

 

 

AMPTROL™ PLUS

 

connector) and the machine (14-pin connector). If a

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REMOTE LIMIT CONTROL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

remote control or amptrol is used alone the wire-feed-

The Amptrol provides remote

 

The Amptrol

 

 

provides remote

 

er connection is then not used.

current control through the full range

 

current control from the minimum of

 

of the power source.

 

 

 

 

 

 

 

 

 

 

the power source to a maximum set

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

by the remote limit control.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WARNING

 

 

 

POWER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POWER

 

 

 

 

 

 

 

 

 

 

 

 

K870 Amptrol

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K963*, K813* or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SOURCE

 

 

 

 

 

 

 

K963*, K813* or

 

 

SOURCE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRIC SHOCK can kill.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K870 Amptrol

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Turn the power switch of the welding

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K775 Remote

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Limit Control

 

 

 

 

 

 

 

 

 

power source “OFF” before installing

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

plugs on cables or when connecting

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K843

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Bolt and nut

 

 

 

 

 

 

 

 

 

or disconnecting plugs to welding

 

 

 

K843

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Adapter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

connection.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Power source

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Insulate

 

 

 

 

 

 

 

 

 

power source.

 

 

Adapter

 

 

 

 

 

 

 

 

 

 

 

 

 

terminal

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

and tape.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

strip

 

 

 

 

75

76

 

 

 

 

77

 

77

 

 

 

 

------------------------------------------------------------------------

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

76

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AMPTROL™ ADAPTER CABLE (K843)

75

76

 

 

 

 

 

77

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A five wire cable, 12” (.30m) long, is available for easy

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Black and white

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

connection of standard K963 Hand Amptrol or K870

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

leads not used.

 

 

 

 

 

 

 

 

 

 

 

Black and white leads

 

 

Tape and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Foot Amptrol. The cable has a 6-pin MS-style con-

 

 

 

insulate.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

not used. Tape

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

nector which connects to the Amptrol and terminals

 

and insulate.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

which connect to 75, 76 and 77 on the machine termi-

 

 

 

 

 

 

 

 

 

 

 

 

FIG. 1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIG. 2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

nal strip and to the case grounding screw. The

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AMPTROL™ AND

 

AMPTROL™ AND HI-FREQ.™ KIT

 

Amptrol will control the same range of output as the

 

 

 

 

 

 

 

 

 

 

 

 

 

HI-FREQ.™ KIT

 

PLUS REMOTE LIMIT CONTROL

 

current control on the welder. (If a smaller range of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The Amptrol will start the Hi-Freq

 

The Amptrol

 

switch will start the

 

control is desired for finer adjustment, a K775

 

 

 

 

 

kit to turn on gas and high frequency

 

Hi-Freq

kit to turn on gas and high

 

Remote may be used in conjunction with the Amptrol

 

starting for DC TIG welding. The

 

frequency starting for DC TIG

 

Adapter Cable Kit.)

The Amptrol arc start switch is

 

Amptrol controls current through

 

welding. The Amptrol

controls

 

 

the full range of the power source.

 

current from the minimum of the

 

nonfunctional unless used with a K799 Hi-Frequency

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

power source to a maximum set by

 

Kit.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the remote limit control.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K775 Remote

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POWER

 

 

 

 

K963*,K813*

 

K799

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Limit Control

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K843 AMPTROL™ ADAPTER INSTALLA-

 

 

 

 

K799

 

SOURCE

 

 

 

 

 

Hi-Freq

 

 

 

POWER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

or K870

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K963*,K813*

 

 

Hi-Freq Kit

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Kit

 

 

 

SOURCE

 

 

TION INSTRUCTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Amptrol

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

or K870

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Amptrol

 

For use with: DC-250, DC-400, R3R or Weldanpower

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Arc start cable

 

 

 

 

 

 

 

 

 

 

 

K843 Adapter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K843 Adapter

 

250 (D-10 and Pro) with remote control power

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Arc start cable

 

 

 

 

 

 

 

 

 

(included with

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Bolt and nut

 

sources.

 

 

 

 

 

 

 

 

 

 

 

 

 

K799)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(included

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

connection.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

with K799)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

75

 

76

 

 

 

 

 

77

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

insulate

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

75

76

 

 

77

 

 

and tape.

 

 

 

 

 

 

 

 

 

 

WARNING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

{

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

{

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

77

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRIC SHOCK can kill.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

76

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CUT OFF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CUT OFF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Turn the power switch of the welding

 

ARC START

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ARC START

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K775

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH and connect black

SWITCH and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

power source “OFF” before installing

 

lead to black and white

 

 

 

 

 

 

 

 

 

connect black

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

lead to white.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

lead to black and

 

K799

K843

 

 

 

 

 

 

 

 

 

plugs on cables or when connecting

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

white lead to white.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIG. 3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIG. 4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

or disconnecting plugs to welding

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

power source.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

------------------------------------------------------------------------

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DC-400

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A-4

INSTALLATION

A-4

 

 

 

HI-FREQUENCY KIT (K799 CODES 8634 AND ABOVE ONLY)

Kit supplies the high frequency plus gas valve for DC TIG welding. The DC-400 is shipped with proper R.F. bypass circuitry installed to protect the control circuit when welding with a HI-FREQ unit. K844 Water Valve Option Kit can be used with K799 when TIG welding with water cooled torches. See Hi-Frequency Kit Instruction Manual for installation information.

AMPTROL ADAPTER FOR K799 HI-FRE- QUENCY KIT (K915-1, REQUIRES K864 ADAPTER)

A “V” cable to connect a K799 Hi-Freq Kit (5-pin connector) with either a K963 Hand Amptrol or a K870 Foot Amptrol (6-pin connector) and the machine. The cable going to the machine has a 6-pin connector which requires a K864 adapter to connect with the 14pin connector on the DC-400. Refer to S20909 instructions for connection information.

MULTIPROCESS SWITCH (K804-1)

Kit that mounts on the front of the DC-400, and includes hinged covers over its output studs. The switch has three positions: Positive semiautomatic/automatic, negative semiautomatic /automatic, and stick/air carbon arc. Required when using the DC-400 for both semiautomatic/automatic and stick/air carbon arc.

Install per M17137 instructions included with the field installed kit.

CAPACITOR DISCHARGE CIRCUIT (K828-1)

Circuit that mounts inside the DC-400. Recommended when:

1)DC-400 is used in conjunction with any LN-23P or older LN-8 or LN-9 semiautomatic wire-feeder. Eliminates possible arc flash re-start of weld when trigger interlock is used. Not required with current LN-8 (above Code 8700), or LN-9’s with serial numbers above 115187 (manufactured after 12/83), or any LN-9 having an L6043-1 Power PC Board.

2)DC-400 is used with an LN-22 equipped with an older K279 Contactor-Voltage Control Option. Eliminates electrode overrun when gun trigger is released. Not required when later K279 (above Code 8800) is used.

3)DC-400 is used with any semiautomatic wire-feed- er and possible small spark, if electrode touches work just after gun trigger is released, is objectionable.

Install per M17060 instructions included with the Kit.

UNDERCARRIAGES (K817, K817R, K841)

For easy moving of the machine, optional undercarriages are available with either steel (K817) or rubber tired (K817R) wheels or a platform undercarriage (K841) with mountings for two gas cylinder at rear of welder.

Install per instructions provided with undercarriage.

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.

DC-400

A-5

INSTALLATION

A-5

 

 

 

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.

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

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.

DC-400

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