Lincoln Electric Official Lincoln Welder Manual: Operation and Features of the DC-400
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B-5

OPERATION

B-5

 

 

 

GENERAL MACHINE DESCRIPTION

The DC-400 is an SCR controlled three phase DC power source. It is designed with a single range potentiometer control.

When using a DC-400 power source with wire feeders which do not have an electrical trigger interlock (or with wire feeders with the electrical trigger interlock in the OFF position), there will be a small spark if the electrode contacts the work or ground within several seconds after releasing the trigger.

When used with some wire feeders with the electrical trigger interlock in the ON position, the arc can restart if the electrode touches the work or ground during these several seconds.

WARNING

•Be sure to select OUTPUT TERMINALS “REMOTE ON/OFF” for operation with wire feed- ers that have leads numbered 2 and 4.

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RECOMMENDED PROCESSES & EQUIPMENT

The DC-400 model is designed for all open arc processes including Innershield® and all solid wire and gas procedures within the capacity of the machine, plus the capability of stick and TIG welding and air carbon arc gouging up to 5/16” (8mm) diameter. A mode switch selects CV (FCAW, GMAW), CV Submerged Arc, or CC (Stick/TIG). Stick welding per- formance is similar to that of the E500.

The DC-400 is designed to be used with the LN-7, LN-7 GMA, LN-8, LN-9, LN-9 GMA, LN-23P, LN-25, or LN-742 semiautomatic wire feeders, the NA-3, NA-5 and NA-5R automatics, and the LT-56 and LT-7 tractors, within the 400 ampere capacity of the machine. The DC-400 Diode Kit option is required to utilize the cold start and cold electrode sensing fea- tures of the NA-3, NA-5 and NA-5R.

OPERATIONAL FEATURES & CONTROLS

ARC CHARACTERISTICS

Through the unique combination of the transformer, three phase semiconverter rectifier, capacitor bank, arc control choke, and the solid state control system, outstanding arc characteristics are achieved on con- stant voltage.

In addition, an arc force control enables the DC-400 to stick weld as well as the E500.

OUTPUT CONTROL

The OUTPUT control, a small 2 watt potentiometer, is calibrated from 1 to 10. The OUTPUT control serves as a voltage control in the CV position and a current control in the CC position.

MACHINE OUTPUT CONTROL SWITCH “LOCAL” OR “REMOTE”

The machine output can be controlled by either the OUTPUT control on the machine control panel, the output control on the wire feed unit, or an optional “remote control” that is available. This switch selects the mode of control, either “LOCAL” or “REMOTE”.

OUTPUT TERMINALS “ON” OR OUTPUT TERMI- NALS “REMOTE”

This switch provides an alternative to the “2 to 4” jumpering function by energizing the machine’s output regardless of whether “2 or 4” is jumpered or not.

POLARITY SELECTION

Polarity selection is made by appropriately connecting the electrode and work welding cables to either the “+“ stud or to the “-” stud. Select “VOLTMETER” switch for “+” or “-” electrode, for the remote (#21) work sensing lead.

VOLTMETER SWITCH “+” ELECTRODE OR “-” ELECTRODE

This switch selects electrode polarity for the remote (#21) work sensing lead of automatic or semiautomat- ic equipment.

115 VOLT POWER SWITCH

The power input contactor operates from an auxiliary 115 volt transformer that is energized through the POWER toggle switch on the machine control panel.

“I “ is on and “0” is off.

PILOT LIGHT

A white light on the machine control panel indicates when the power source input contactor is closed. This means the main power transformer and all auxiliary and control transformers are energized.

THERMAL PROTECTION LIGHT

An amber light on the machine control panel indicates when either of the two protective thermostats have opened. Output power will be removed but input power will still be applied to the machine.

INPUT CONTACTOR

The power source is equipped with an input contactor.

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 Vii Section DSection 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 IP214OPERATIONB-4 Earth Ground ConnectionSignifying 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 ConnectionsAccessories Factory Installed OptionsField 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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