Lincoln Electric Connection of DC-400 to LN-22 or LN-25, Design, Operation, Connections

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INSTALLATION

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CONNECTION OF DC-400 TO LN-22 OR LN-25

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.

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 sepa- rate terminals for connection of stick or air carbon arc. The Multiprocess Switch is available as either a facto- ry 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 MULTI- PROCESS 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 assem- bly 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 con- nection 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 posi- tive. 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 dis- connected 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 semiautomat- ic 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 termi- nal 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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Contents 10699 11038 11085 11128 11347 RED-D-ARC DC-400California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéOn-Line Product Registration Please Examine Carton and Equipment For Damage ImmediatelyTable of Contents Section D ViiSection E Technical Specifications DC-400 InstallationOutput Maximum Open Circuit Voltage Auxiliary Power Height Width Depth WeightCable Machine Load400A 100% 500A 50% Duty Lengths CycleRemote Control Adapter Cable K864 Multiprocess Switch K804-1 Connection of DC-400 to LN-22 or LN-25 Multiprocess Switch Connection and Operation PurposeDesign OperationRemote Control Connections Auxiliary Power ConnectionsCase Features Output ConnectionsMachine & Circuit Protection Thermal Protection Light STICK, TIG or AIR/CARBON ARC Multiprocess SwitchElectric Shock can kill OperationOutput Terminals Switch ARC Control SwitchVoltmeter Switch Rating Plate ARC Force Control DialDegree of protection provided by the enclosure IP21Earth Ground Connection 4OPERATIONB-4Signifying the Earth Ground Connection DC-400 Recommended Processes & Equipment Voltmeter Switch Power Source OperationDuty Cycle and Time Period Duty Cycle Amps VoltsARC Control Switch Effective only in CV FCAW/GMAW mode ARC Force Control Dial Effective only in CC modeFront View of 14-PIN Connector Receptacle PIN Lead no FunctionMachine and Circuit Protection Terminal Strip ConnectionsFactory Installed Options AccessoriesField Installed Options Undercarriages K817, K817R, K841 HI-FREQUENCY KIT K799 Codes 8634 and Above onlyRoutine Maintenance 1MAINTENANCED-1HOW to USE Troubleshooting Guide TroubleshootingContact your local Authorized Field Service Facility Output Control Local Your local Authorized Field Service FacilityConnecting the Remote Control to the Machine Procedure for Replacing PC BoardsFault Protection Operation Power I/0 Switch CheckPower Diode Test Remote Control CheckPower Rectifier Bridge Assembly Checking Procedure Power Silicon Controlled Rectifier TestWiring Diagram for Code DiagramsPasted inside Number Wiring Diagram for Code 10699 and Above11085, 11128 Power Rectifier Bridge Diagram Type M12244-7 DC-400 32.00 15.39 30.92 30.02 +.11 Dimension PrintDC-400 Precaucion Warnung
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DC-400 specifications

The Lincoln Electric DC-400 is a versatile and robust DC arc welding power source designed to meet the demands of various industrial applications. Known for its reliability and performance, the DC-400 is ideal for both professional welders and fabrication shops requiring robust equipment that can handle challenging welding tasks.

One of the main features of the DC-400 is its ability to provide a smooth, stable arc, which is essential for achieving high-quality welds. This welding machine is capable of delivering a wide amperage range, typically from 20 to 400 amperes, making it suitable for various welding processes, including MIG, TIG, and Stick welding. The unit's high output capabilities allow it to effectively weld a variety of materials, such as steel, stainless steel, and various alloys.

In terms of technology, the DC-400 integrates advanced power conversion technology that enhances energy efficiency while minimizing heat loss during operation. This not only contributes to lower operating costs but also ensures a longer service life for the machine. The DC-400 features a durable, rugged design, with a robust steel frame that can withstand the rigors of heavy industrial use while providing an IP23 rating for protection against moisture and dust.

Another notable characteristic of the DC-400 is its ease of use. The intuitive controls allow for quick adjustments to settings, enabling welders to easily adapt to different job requirements. The arc characteristics of the DC-400 can be fine-tuned to optimize performance for different welding applications, ensuring consistent results every time.

Moreover, the DC-400 is equipped with built-in safety features such as thermal overload protection, which prevents damage to the machine in case of prolonged operation under heavy loads. This feature enhances the safety of the operator and extends the life of the welding machine.

Overall, the Lincoln Electric DC-400 stands out as a reliable and efficient welding power source. Its combination of high-performance capabilities, advanced technology, and next-level usability makes it a popular choice in the industry. Whether for heavy fabrication, maintenance, or repair work, the DC-400 continues to prove itself as an indispensable tool for professional welders seeking quality and durability in their equipment.
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