Lincoln-electric IM655 RED-D-ARC DC-400 User Manual

RED-D-ARCDC-400IM655-BNovember, 2006Red-D-Arc Spec-Built Welding EquipmentThis RED-D-ARC welder is built to RED-D-ARC Extreme Dutydesign specification

A-2INSTALLATION DC-400A-2SAFETY PRECAUTIONSRead this entire section of operating instructionsbefore operating the machine.ELECTRIC SHOCK can kill.•

A-3INSTALLATION DC-400A-3REMOTE CONTROL ADAPTER CABLE (K864)A “V” cable 12” (.30m) long to connect a K857Remote Control, K963 Hand Amptrol or K870 F

A-4INSTALLATION DC-400A-4HI-FREQUENCY KIT (K799 CODES 8634AND ABOVE ONLY)Kit supplies the high frequency plus gas valve for DCTIG welding. The DC-4

A-5INSTALLATION DC-400A-5CONNECTION OF DC-400 TO LN-22 OR LN-25a) Turn off all power.b) Place output terminals switch into the “ON” posi-tion.c)

A-6INSTALLATION DC-400A-6AUXILIARY POWER CONNECTIONSThe power source is equipped to furnish nominally110-115 volt AC and 40-42 volt AC auxiliary pow

A-7INSTALLATION DC-400A-7The individual case sides are removable for easyaccess for internal service or inspection. The case rear, top section, is e

A-8INSTALLATION DC-400A-8To change stick polarity, reverse the leads at the (+)and (-) terminals on the right side of the MultiprocessSwitch.NOTE: W

B-1OPERATIONDC-400B-1SAFETY PRECAUTIONSRead this entire section of operating instructionsbefore operating the machine.ELECTRIC SHOCK can kill.• Have a

DC-400B-2OPERATIONB-2Gas Metal Arc WeldingARC CONTROL SWITCHIncrease/Decrease of InductanceLow InductanceHigh InductanceOutput (Voltage)OUTPUT TERMIN

DC-400B-3OPERATIONB-3RATING PLATE (Continued)TransformerConstant Current Characteristic Submerged Arc Welding RectifierRectified DC Output Constant V

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

DC-400B-4OPERATIONB-4Do not switch if output voltage or current is present.MODE SWITCHWarning IdentificationWARNING IDENTIFICATIONSignifying the Earth

B-5OPERATIONB-5GENERAL MACHINE DESCRIPTIONThe DC-400 is an SCR controlled three phase DCpower source. It is designed with a single rangepotentiometer

B-6OPERATIONB-6POWER SOURCE OPERATIONDuty Cycle and Time PeriodThe DC-400 is rated at the following duty cycles:* Based upon 10 minute time period (i.

B-7OPERATIONB-7In this position, the dynamic characteristics of themachine under welding conditions provide optimumwelding characteristics for Innersh

B-8OPERATIONB-8Terminal Strip ConnectionsTerminal strip TS2 located behind the hinged controlpanel on the front of the power source supplies110-115V A

C-1ACCESSORIESC-1Factory Installed OptionsDIODE OPTIONThis internally installed option allows the use of thecold start and cold electrode sensing feat

C-2ACCESSORIESC-2HI-FREQUENCY KIT(K799 CODES 8634 AND ABOVE ONLY)Kit supplies the high frequency plus gas valve for DCTIG welding. The DC-400 is ship

DC-400D-1MAINTENANCED-1Routine Maintenance1. The fan motor has sealed bearings which requireno service.2. In extremely dusty locations, dirt may clo

DC-400E-1TROUBLESHOOTINGE-1If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

E-2TROUBLESHOOTINGE-2Observe all Safety Guidelines detailed throughout this manualPROBLEMS(SYMPTOMS)POSSIBLECAUSERECOMMENDEDCOURSE OF ACTIONInput cont

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

E-3TROUBLESHOOTINGE-3Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures or are u

E-4TROUBLESHOOTINGE-4Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures or are u

DC-400E-5TROUBLESHOOTINGE-5If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

DC-400E-6TROUBLESHOOTINGE-6If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

F-1DIAGRAMSF-1DC-400 L9107 131415161718H2H3H4ELECTRICAL SYMBOLS PERE1537CONNECTOR CAVITYNUMBERING SEQUENCE(COMPONENT SIDE OF P.C.BOARD)NOTESN.A.C

F-2DIAGRAMSF-2DC-400NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram

F-3DIAGRAMSF-3DC-400NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram

F-4DIAGRAMSF-4DC-400POWER RECTIFIER BRIDGEDIAGRAM 1PLUG TO SNUBBER BOARDSHUNTP5221 222223204220204204204204220D1 D2 D3SCR1 SCR2 SCR3G1 G2 G3D4ANODECAT

F-5DIMENSION PRINTF-5DC-400Part No. Type ABCD F G HM12244-7 DC-400 32.00 15.39 30.92 1.44 30.02 +.11 30.02 +.11 .94

DC-400NOTES

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB

ivSAFETYivMar. ‘93PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques q

Thank Youfor selecting a QUALITY product. We want you to take pride inoperating this product ••• as much pride as we have in bringingthis product to y

viviTABLE OF CONTENTSPageInstallation .. ...Sectio

viiTABLE OF CONTENTSPageMaintenance... .......Section DSa

A-1INSTALLATION DC-400A-1TECHNICAL SPECIFICATIONS – DC-400Standard Input Current at Rated Output (CVI)Voltage 100% Duty Cycle 60% Duty Cycl