Lincoln Electric DC-400 specifications Machine Load, Cable, 400A 100% 500A 50%, Duty Lengths Cycle

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.

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FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

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WELDING SPARKS can cause fire or explosion.

•Keep flammable material away.

•Do not weld on containers that have held combustibles.

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ARC RAYS can burn.

• Wear eye, ear, and body protection.

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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 shut- down of the machine.

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SURFACES. Where there is a combustible surface directly under station- ary or fixed electrical equipment, the surface shall be cov- ered 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.

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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 termi- nals 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 con- ductor 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