Lincoln Electric Welder DC 400 User Manual
IM655-B  
November, 2006  
RED-D-ARC  
DC-400  
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 onYou  
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  
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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
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.  
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.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
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.  
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.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
• AC Welder with Reduced Voltage Control.  
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.  
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.  
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 spe-  
cific 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.  
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.  
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 prod-  
ucts.  
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.  
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  
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SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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.  
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.  
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.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
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.  
•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.  
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).  
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.  
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.  
FOR ELECTRICALLY  
powered equipment.  
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 cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
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.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
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SAFETY  
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.  
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 suiv-  
antes:  
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.  
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.  
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 lev-  
age, 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.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
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.  
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.  
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.  
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.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
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 ray-  
onnement 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.  
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.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
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, pan-  
talons sans revers, et chaussures montantes.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
Mar. ‘93  
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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!  
Thank 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.  
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TABLE OF CONTENTS  
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  
________________________________________________________________________  
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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  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS – DC-400  
INPUT-THREE PHASE ONLY  
Standard  
Voltage  
Frequency  
Input Current at Rated Output (CVI)  
(4)  
100% Duty Cycle  
60% Duty Cycle  
50% Duty Cycle  
230/460/575V/60Hz  
400Amps/36V  
78/39/31Amps  
450Amps/38V  
83/42/33Amps  
500Amps/40V  
84/42/34Amps  
RATED OUTPUT  
Duty Cycle (1)  
Amps  
Volts at Rated Amps  
100%  
60%  
50%  
400  
450  
500  
36  
38  
40  
OUTPUT  
OUTPUT  
MAXIMUM OPEN CIRCUIT VOLTAGE  
AUXILIARY POWER  
Min.----60A 12V CV(22V CC)  
Max.---500A 42V (CC, CV)  
57V. (CC) 45.5V. (CVI)  
115 VAC, 15 AMPS  
42 VAC, 10 AMPS  
RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT  
INPUT  
VOLTAGE /  
FREQUENCY  
INPUT AMPERE  
RATING ON  
NAMEPLATE  
@ 100%  
TYPE 75°C GROUND  
WIRE IN CONDUIT  
AWG (IEC)  
TYPE 75°C COPPER  
WIRE IN CONDUIT  
AWG (IEC)  
TYPE 75°C  
SUPER LAG  
OR BREAKER  
SIZE(AMPS)  
2
2
SIZES (mm )  
SIZES (mm )  
40°C(104°F)  
Duty Cycle  
230/60HZ  
460/60HZ  
575/60HZ  
78  
39  
31  
125  
60  
50  
6(10)  
10(6)  
10(6)  
3(25)  
8(10)  
10(6)  
PHYSICAL DIMENSIONS  
HEIGHT  
27.50 in.  
699 mm  
WIDTH  
22.25 in.  
565 mm  
DEPTH  
WEIGHT  
32.0 in.  
473 lbs.  
215 kg.  
988 mm  
(1) Based upon 10 minute time period (i.e., for 60% duty cycle, it is 6 minutes on an 4 minutes off).  
DC-400  
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A-2  
A-2  
INSTALLATION  
OUTPUT CABLE CONNECTIONS  
SAFETY PRECAUTIONS  
Read this entire section of operating instructions  
before operating the machine.  
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.  
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.  
OUTPUT CABLES  
Installation of Field Installed Options  
CABLE SIZES FOR COMBINED LENGTH OF ELEC-  
TRODE AND GROUND CABLE  
MACHINE LOAD  
• Keep flammable material away.  
• Do not weld on containers that have  
held combustibles.  
400A (100%  
DUTY  
500A (50%  
DUTY  
------------------------------------------------------------------------  
ARC RAYS can burn.  
CABLE  
LENGTHS  
CYCLE)  
3/0  
CYCLE)  
2/0  
87 mm  
• Wear eye, ear, and body protection.  
(2)  
(2)  
UP TO 50 ft  
(15m)  
85 mm  
------------------------------------------------------------------------  
Observe additional guidelines detailed in the  
beginning of this manual.  
3/0  
85 mm  
2/0  
50 to 100 ft  
(15-30 m)  
100-150 ft  
(30-46 m)  
150-200 ft  
(46-61 m)  
200-250 ft  
(67-76 m)  
(2)  
(2)  
67 mm  
3/0  
85 mm  
3/0  
(2)  
(2)  
85 mm  
LOCATION  
3/0  
85 mm  
3/0  
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.  
(2)  
(2)  
85 mm  
4/0  
107 mm  
4/0  
(2)  
(2)  
107 mm  
REMOTE OUTPUT CONTROL  
(K857 WITH K864 ADAPTER OR K775 )  
CAUTION  
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.  
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.  
-------------------------------------------------------------------------------  
INPUT POWER CONNECTIONS  
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.  
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  
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.  
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.  
DC-400  
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A-3  
A-3  
INSTALLATION  
This K843 adapter is used to connect AMPTROL™  
(K963*, K813* or K870), remote control (K775), and  
HI-FREQ™ (K799) accessories to DC-250, DC-400,  
R3R or Weldanpower 250 (D-10 and Pro) with remote  
control power sources. The power source  
"machine/remote" switch must be in "remote" for  
Amptrol™ to control current. Accessories may be  
combined and connected in four different ways, as  
shown in Figure 1,2,3, & 4.  
REMOTE CONTROL ADAPTER CABLE (K864)  
CABLE RECEPTACLE (6 SOCKET)  
STRAIGHT PLUG (14 PIN)  
TO POWER SOURCE  
TO: 1) K857 REMOTE CONTROL  
2) K963 HAND AMPTROL  
3) K870 FOOT AMPTROL  
CABLE RECEPTACLE (14 SOCKET)  
TO LN-7 WIRE FEEDER  
A “V” cable 12” (.30m) long to connect a K857  
Remote Control, K963 Hand Amptrol or K870 Foot  
Amptrol (6-pin connector) with a wire-feeder (14-pin  
connector) and the machine (14-pin connector). If a  
remote control or amptrol is used alone the wire-feed-  
er connection is then not used.  
AMPTROL™ PLUS  
AMPTROL™ ONLY  
REMOTE LIMIT CONTROL  
The Amptrol provides remote  
current control through the full range  
of the power source.  
The Amptrol provides remote  
current control from the minimum of  
the power source to a maximum set  
by the remote limit control.  
K963*, K813* or  
K870 Amptrol  
WARNING  
POWER  
SOURCE  
POWER  
SOURCE  
K963*, K813* or  
K870 Amptrol  
ELECTRIC SHOCK can kill.  
• Turn the power switch of the welding  
power source “OFF” before installing  
plugs on cables or when connecting  
or disconnecting plugs to welding  
power source.  
K775 Remote  
Limit Control  
K843  
Bolt and nut  
Adapter  
connection.  
Insulate  
K843  
Adapter  
Power source  
and tape.  
terminal  
strip  
75  
76  
77  
77  
76  
------------------------------------------------------------------------  
75  
76  
77  
AMPTROL™ ADAPTER CABLE (K843)  
A five wire cable, 12” (.30m) long, is available for easy  
connection of standard K963 Hand Amptrol or K870  
Foot Amptrol. The cable has a 6-pin MS-style con-  
nector which connects to the Amptrol and terminals  
which connect to 75, 76 and 77 on the machine termi-  
nal strip and to the case grounding screw. The  
Amptrol will control the same range of output as the  
current control on the welder. (If a smaller range of  
control is desired for finer adjustment, a K775  
Remote may be used in conjunction with the Amptrol  
Adapter Cable Kit.) The Amptrol arc start switch is  
nonfunctional unless used with a K799 Hi-Frequency  
Kit.  
Black and white  
leads not used.  
Tape and  
Black and white leads  
not used. Tape  
and insulate.  
insulate.  
FIG. 1  
FIG. 2  
AMPTROL™ AND  
HI-FREQ.™ KIT  
AMPTROL™ AND HI-FREQ.™ KIT  
PLUS REMOTE LIMIT CONTROL  
The Amptrol will start the Hi-Freq  
kit to turn on gas and high frequency  
starting for DC TIG welding. The  
Amptrol controls current through  
the full range of the power source.  
The Amptrol switch will start the  
Hi-Freq kit to turn on gas and high  
frequency starting for DC TIG  
welding. The Amptrol controls  
current from the minimum of the  
power source to a maximum set by  
the remote limit control.  
K775 Remote  
Limit Control  
POWER  
K799  
Hi-Freq  
Kit  
K963*,K813*  
or K870  
Amptrol  
SOURCE  
K799  
Hi-Freq Kit  
POWER  
SOURCE  
K963*,K813*  
or K870  
Amptrol  
K843 AMPTROL™ ADAPTER INSTALLA-  
TION INSTRUCTION  
For use with: DC-250, DC-400, R3R or Weldanpower  
250 (D-10 and Pro) with remote control power  
sources.  
K843 Adapter  
Arc start cable  
(included with  
K799)  
K843 Adapter  
Arc start cable  
(included  
with K799)  
Bolt and nut  
connection.  
insulate  
75  
76  
77  
and tape.  
75  
76  
77  
WARNING  
77  
76  
{
{
CUT OFF  
ARC START  
SWITCH and connect black  
lead to black and white  
lead to white.  
CUT OFF  
ELECTRIC SHOCK can kill.  
• Turn the power switch of the welding  
power source “OFF” before installing  
plugs on cables or when connecting  
or disconnecting plugs to welding  
power source.  
ARC START  
SWITCH and  
connect black  
lead to black and  
white lead to white.  
K775  
K843  
K799  
FIG. 3  
FIG. 4  
------------------------------------------------------------------------  
DC-400  
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A-4  
A-4  
INSTALLATION  
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 objection-  
able.  
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.  
Install per M17060 instructions included with the  
Kit.  
UNDERCARRIAGES (K817, K817R, K841)  
For easy moving of the machine, optional undercar-  
riages 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.  
AMPTROL ADAPTER FOR K799 HI-FRE-  
QUENCY KIT (K915-1, REQUIRES K864  
ADAPTER)  
Install per instructions provided with undercarriage.  
A “V” cable to connect a K799 Hi-Freq Kit (5-pin con-  
nector) 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 14-  
pin connector on the DC-400. Refer to S20909  
instructions for connection information.  
INSTALLATION OF EQUIPMENT  
REQUIRED FOR RECOMMENDED  
PROCESSES  
WIRE FEEDER CONTROL CABLE CONNEC-  
TIONS  
MULTIPROCESS SWITCH (K804-1)  
For control cable with 14-pin connector:  
Kit that mounts on the front of the DC-400, and  
includes hinged covers over its output studs. The  
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.  
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.  
For control cable with terminal strip connectors:  
Install per M17137 instructions included with the field  
installed kit.  
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  
CAPACITOR DISCHARGE CIRCUIT (K828-1)  
marked with the symbol  
for connecting the auto-  
Circuit that mounts inside the DC-400.  
Recommended when:  
matic equipment grounding wire. See the appropriate  
connection diagram for the exact instructions for the  
wire feeder being used.  
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.  
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.  
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.  
DC-400  
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A-5  
A-5  
INSTALLATION  
CONNECTION OF DC-400 TO LN-22 OR LN-25  
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.  
a) Turn off all power.  
b) Place output terminals switch into the “ON” posi-  
tion.  
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.  
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.  
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.  
e) Place MODE SWITCH in “CONSTANT VOLTAGE  
(FCAW, GMAW)”.  
OPERATION  
NOTE: The output terminals are energized at all  
The operation of the switch is as follows:  
times.  
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.  
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.  
CONNECTIONS  
DESIGN  
(For those applications where it is not necessary to  
have separate work cables for stick and semiautomat-  
ic welding.)  
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.  
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.  
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.  
DC-400  
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A-6  
A-6  
INSTALLATION  
AUXILIARY POWER CONNECTIONS  
SOLID STATE CONTROL SYSTEM  
The power source is equipped to furnish nominally  
110-115 volt AC and 40-42 volt AC auxiliary power for  
operating wire feeding equipment, etc. The auxiliary  
power is available at the 14-pin MS-style connector  
receptacle on the control panel and/or at a terminal  
strip behind the hinged control panel on the front of  
the power source. 110-115V AC is available at recep-  
tacle pins A and J (Domestic and Export models only),  
terminals 31 and 32 (all models) and at duplex recep-  
tacle. 40-42V AC is available only at receptacle pins I  
and K. The 110-115V AC and the 40-42V AC are iso-  
lated circuits and each is protected by circuit breakers,  
15 amp on 115VAC circuit, and 10A on 42 Vac circuit.  
The control circuitry consists of six basic circuits: (1)  
the SCR snubber network, (2) the SCR firing circuit,  
(3) the control/fault protection circuit, (4) the starting  
circuit, (5) the power-up delay circuit, and (6) the  
power circuit.  
The SCR snubber board consists of a capacitor and  
resistor connected across each SCR and across the  
entire bridge and MOV’s to protect the control circuitry  
and SCR’s from transient voltages. The snubber  
board is mounted on the back of the case front.  
The SCR firing circuit, the control fault protection cir-  
cuit, the power-up delay circuit, and the power circuit  
are mounted on the control PC board located behind  
the front control panel. (The front control panel hinges  
down for easy access to the board.)  
REMOTE CONTROL CONNECTIONS  
Remote control connections are available both at a  
14-pin connector receptacle located on the control  
panel, and on terminal strips with screw connections  
located behind the hinged control panel on the front of  
the power source.  
The starting circuit board is located on the back of the  
control box.  
MACHINE COOLING  
OUTPUT CONNECTIONS  
The fan pulls air in through the louvered front of the  
machine over the internal parts and exhausts out the  
louvered rear of the machine. The fan motor is fully  
enclosed, has sealed ball bearings, requires no lubri-  
cation, and operates when the power switch is turned  
on.  
The output terminals are recessed on the case front  
and labeled “+” and “-”.  
INPUT CONNECTIONS  
The three input lines are brought in through the rear  
panel of the power source and attached to the input  
contactor. Removal of the removable access panel  
makes the contactor accessible for the input cable  
connections.  
CASE FEATURES  
The machine uses a 32” (813mm) long base. The low  
profile case facilitates installation of the machine  
under a workbench.  
INPUT LINE VOLTAGE COMPENSATION  
The case front incorporates a recessed control panel  
where all the machine controls are mounted. This  
recessed panel protects the controls and minimizes  
the possibilities of accidental contact. This control  
panel can be easily opened to permit access to the  
enclosed control section which contains the terminal  
strips, PC board, etc.  
The power source is equipped with input line voltage  
compensation as standard. For a line voltage fluctua-  
tion of ±10% the output will remain essentially con-  
stant. This is accomplished through the feedback net-  
work in the control circuit.  
SOLID STATE OUTPUT CONTROL  
The output lead terminals are also recessed to avoid  
any object or person accidentally coming in contact  
with an output terminal. Strain relief is provided by  
holes in the front of the base. The leads are routed up  
through these holes to the output terminals. This pre-  
vents any damage of the output studs or insulation of  
same in the event the cables are pulled excessively.  
An output stud cover protects against accidental con-  
tact with the output studs. Cover hinges upward for  
access to the studs.  
The output of the welder is electronically controlled by  
SCR’s instead of mechanical contactors, providing  
extra long life for highly repetitive welding applica-  
tions.  
DC-400  
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A-7  
A-7  
INSTALLATION  
The individual case sides are removable for easy  
access for internal service or inspection.  
PARALLELING  
There are no provisions on the DC-400 to permit par-  
alleling.  
The case rear, top section, is equipped with a remov-  
able access panel. This provides easy access to the  
input contactor, easy connection and reconnection of  
input leads, and easy access for service or inspection.  
DIODE OPTION  
The DC-400 Diode option is required to utilize the cold  
start and cold electrode sensing features of the NA-3,  
NA-5 or NA-5R. When this option is not used with an  
NA-3, NA-5 or NA-5R, see the DC-400/NA-3, DC-  
400/NA-5 or DC-400/NA-5R connection diagram for  
instructions on how to disable this circuit. If the circuit  
is not disabled, the wire cannot be inched down.  
The total construction of the machine permits outdoor  
operation. The enclosure is designed with air intake  
louvers that keep dripping water from being drawn into  
the unit. The transformer, SCR bridge assembly, and  
choke are double-dipped in a special corrosion resis-  
tant coating.  
A permanent lifting hook is located at the top of the  
machine and is positioned so that it acts as nearly as  
possible through the center of gravity.  
Machine & Circuit Protection  
(Thermal Protection Light)  
The power source is thermostatically protected with  
proximity thermostats against overload or insufficient  
cooling. One thermostat is located on the nose of the  
center bottom primary coil and a second thermostat is  
attached to the lead connecting the secondaries.  
Both thermostats are connected in a series with the 2-  
4 circuit. If the machine is overloaded, the primary  
thermostat will be open, the output will be zero, and  
the amber thermal protection light will be on. The fan  
will continue to run. The secondary thermostat will  
open either with an excessive overload or insufficient  
cooling. The output will be zero and the amber pro-  
tection light will be on. When the thermostats reset  
the protection light will be off.  
ARC FORCE SELECTOR  
(Effective only on CC for Stick and TIG Processes)  
An ARC FORCE selector is provided similar to that  
used on the E500. This control allows the user to  
select the ideal arc force for the procedure and elec-  
trode being used.  
ARC CONTROL  
(Effective Only When Using CVI Mode)  
The ARC CONTROL is a five-position switch that  
changes the pinch effect of the arc. This results in the  
control of spatter, fluidity, and bead shape. The ARC  
CONTROL is set to provide optimum welding depend-  
ing on the process being used, position, electrode,  
etc. The pinch effect is increased by turning the con-  
trol clockwise and may be adjusted while the machine  
is in operation.  
The power source is also protected against overloads  
on the SCR bridge assembly through an electronic  
protection circuit. This circuit senses an overload on  
the power source and limits the output to 550 amps by  
phasing back the SCR’s.  
MODE SWITCH  
Protection is provided to protect the circuitry from  
accidental grounds. If the customer accidentally  
“grounds” 75, 76, or 77 to the positive output lead, the  
DC-400 will be reduced to a low value, thus prevent-  
ing any damage to the machine. If the ground occurs  
between 75, 76, 77 and the negative output lead, one  
of the PC board “self-restoring” fuses will blow, pre-  
venting any machine damage.  
A MODE SWITCH selects between Constant Voltage  
(FCAW/GMAW), Constant Voltage (Submerged Arc),  
and Constant Current (Stick/TIG).  
STICK WELDING  
When the DC-400 is used for stick welding or air car-  
bon arc, the control leads and welding cables to any  
semiautomatic or automatic wire feeders must be dis-  
connected from the DC-400 for maximum safety  
(unless the Multiprocess switch option is installed).  
DC-400  
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A-8  
A-8  
INSTALLATION  
To stick  
WORK  
+
electrode  
holder or  
air carbon  
arc torch  
To semi-  
ELECTRODE  
auto or  
auto  
equipment  
User supplied  
4/0 (107 mm2 )  
jumper  
MULTIPROCESS SWITCH  
To change stick polarity, reverse the leads at the (+)  
and (-) terminals on the right side of the Multiprocess  
Switch.  
NOTE: When a DC-400 equipped with Multiprocess  
Switch is mounted on an undercarriage, the  
undercarriage handle in the resting position  
can hit the case of the Multiprocess Switch.  
This does no harm, but if the user desires, a  
1/4” or 3/8” bolt and nut may be placed in the  
hole in the undercarriage tow bar to limit the  
travel of the undercarriage handle.  
STICK, TIG OR AIR/CARBON ARC *  
a) Turn off all power.  
b) Disconnect all wire feed unit control, electrode, and  
work leads.  
c) Place MODE SWITCH in the “CONSTANT CUR-  
RENT (STICK/TIG)” for air carbon arc.  
d) For stick, TIG or air carbon arc, place OUTPUT  
TERMINALS switch into the “ON” position. With  
the DC-400 connected for stick, TIG or air carbon  
arc welding, the output terminals will be energized  
at all times.  
*NOTE: If stick welding, TIG welding or air carbon arc  
cutting is to be done on the DC-400 along  
with semi-automatic/automatic welding, then  
a K804-1 Multiprocess Switch is required. If  
the Multiprocess Switch is not used, then all  
control, electrode, and work leads to wire  
feed equipment must be disconnected from  
the DC-400 before connecting the DC-400 for  
stick or air carbon arc cutting.  
DC-400  
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B-1  
B-1  
OPERATION  
SAFETY PRECAUTIONS  
Read this entire section of operating instructions  
before operating the machine.  
GRAPHIC SYMBOLS THAT APPEAR ON  
THIS MACHINE OR IN THIS MANUAL  
ELECTRIC SHOCK can kill.  
POWER ON-OFF SWITCH  
• Have an electrician install and ser-  
vice this equipment.  
Input (Power)  
• Turn the input power off at the fuse  
box before working on equipment.  
• Do not touch electrically hot parts.  
• This next section applies to DC-400’s without  
the Capacitor Discharge Option:  
----------------------------------------------------------------------  
FUMES AND GASES can be dangerous.  
• Keep your head out of fumes.  
On  
Off  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
------------------------------------------------------------------------  
WELDING SPARKS can cause fire or  
explosion.  
OUTPUT CONTROL DIAL  
Output (Control)  
• Keep flammable material away.  
• Do not weld on containers that have  
held combustibles.  
------------------------------------------------------------------------  
ARC RAYS can burn.  
• Wear eye, ear, and body protection.  
Increase/Decrease of  
------------------------------------------------------------------------  
See additional waring information under Arc  
Welding Safety Precautions and in the front of this  
Operating Manual.  
Output  
(Voltage or  
Current)  
------------------------------------------------------------------------  
OUTPUT CONTROL “LOCAL-REMOTE” SWITCH  
Remote Output  
Voltage or Current  
Control  
Local Output Voltage  
or Current Control  
CIRCUIT BREAKER  
Circuit Breaker  
THERMAL PROTECTION LIGHT  
High Temperature  
DC-400  
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B-2  
B-2  
OPERATION  
VOLTMETER SWITCH  
ARC CONTROL SWITCH  
Voltmeter  
Gas Metal Arc Welding  
Positive Electrode  
Negative Electrode  
Increase/Decrease of Inductance  
Low Inductance  
RATING PLATE  
High Inductance  
Three Phase Power  
OUTPUT TERMINALS SWITCH  
Transformer  
Rectifier  
Output (Voltage)  
On  
Rectified DC Output  
Remote On/Off  
ARC FORCE CONTROL DIAL  
Constant Voltage  
Characteristic  
Shielded Metal Arc Welding  
Gas Tungsten Arc Welding  
Designates welder complies  
with National Electrical  
Manufacturers Association  
requirements EW 1. (Export  
Model only)  
NEMA EW 1  
IEC 974-1  
Designates welder complies with  
International Electrotechnical  
commission requirements 974-1.  
(European model only)  
Arc Force Current  
Increase/Decrease of Current  
Three Phase Power  
DC-400  
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B-3  
B-3  
OPERATION  
RATING PLATE (Continued)  
Transformer  
Rectifier  
Rectified DC Output  
Constant Voltage Characteristic  
Constant Current Characteristic  
Line Connection  
Shielded Metal Arc Welding  
Flux Cored Arc Welding  
Submerged Arc Welding  
Designates Welder can be used in environments with  
increased hazard of electric shock. (IEC model only)  
S
Degree of protection provided by the enclosure  
IP21  
DC-400  
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B-4  
B-4  
OPERATION  
MODE SWITCH  
Do not switch if output voltage or current is present.  
Constant Voltage (Submerged Arc Welding)  
Constant Voltage (Flux cored arc welding, gas  
metal arc welding).  
Constant Current (shield metal arc welding, gas tung-  
sten arc welding).  
WARNING IDENTIFICATION  
Warning Identification  
EARTH GROUND CONNECTION  
Signifying the Earth (Ground) Connection  
DC-400  
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B-5  
B-5  
OPERATION  
OUTPUT CONTROL  
GENERAL MACHINE DESCRIPTION  
The DC-400 is an SCR controlled three phase DC  
power source. It is designed with a single range  
potentiometer 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.  
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.  
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”.  
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.  
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.  
WARNING  
• Be sure to select OUTPUT TERMINALS  
“REMOTE ON/OFF” for operation with wire feed-  
ers that have leads numbered 2 and 4.  
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.  
------------------------------------------------------------------------  
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.  
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.  
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.  
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.  
OPERATIONAL FEATURES & CONTROLS  
ARC CHARACTERISTICS  
THERMAL PROTECTION LIGHT  
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.  
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.  
In addition, an arc force control enables the DC-400 to  
stick weld as well as the E500.  
DC-400  
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B-6  
B-6  
OPERATION  
OUTPUT CONTROL “LOCAL-REMOTE” SWITCH©  
POWER SOURCE OPERATION  
The OUTPUT CONTROL toggle switch on the control  
panel labeled “LOCAL-REMOTE” gives the operator  
the option of controlling the output at the machine  
control panel or at a remote station. For remote con-  
trol, the toggle switch is set in the “REMOTE” position  
and controlled at the wire feed unit control, or by con-  
necting a K775 control to terminals 75, 76, and 77 on  
the terminal strip at the front of the machine, or by  
connecting a K857 control to the 14-pin connector on  
the front of the machine. For control at the machine  
control panel, the toggle switch is set in the “LOCAL”.  
WARNING  
ELECTRIC SHOCK can kill.  
• Have an electrician install and service  
this equipment.  
• Turn the input power off at the fuse  
box before working on equipment.  
• Do not touch electrically hot parts.  
---------------------------------------------------------------------  
Duty Cycle and Time Period  
(Exception: When used with an LN-9, LN-9 GMA or  
NA-5 wire feeder, the OUTPUT CONTROL switch  
must be in the “REMOTE” position or automatic shut-  
down of the LN-9 or NA-5 may occur.)  
The DC-400 is rated at the following duty cycles:  
DUTY CYCLE *  
AMPS  
VOLTS  
100%  
60%  
50%  
400  
450  
500  
36  
38  
40  
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”  
* Based upon 10 minute time period (i.e., for 60% duty  
cycle, it is 6 minutes on and 4 minutes off).  
switch for “+” or “-” electrode for the remote (#21)  
work sensing lead.  
Overloading the DC-400 may result in opening of an  
internal protective thermostat as indicated by the  
amber thermal protection light turning on.  
VOLTMETER SWITCH  
STARTING THE MACHINE  
Select “+” for positive electrode or “-” for negative  
electrode polarity for the remote (#21) work sensing  
lead of automatic or semiautomatic equipment.  
The POWER toggle switch at the extreme right side of  
the control panel in the “I“ position energizes and clos-  
es the three phase input contactor from a 115 volt  
auxiliary transformer. This in turn energizes the main  
power transformer.  
THERMAL PROTECTION LIGHT  
The amber thermal protection light will be lit if either of  
the two protective thermostats have opened. The out-  
put power will be disabled but input power will still be  
applied to the welder. (Refer to Machine and Circuit  
Protection section).  
The machine is de-energized when the POWER  
switch is in the “0” position.  
The white light below the POWER switch indicates  
when the input contactor is energized.  
MODE SWITCH  
OUTPUT CONTROL DIAL  
The large MODE SWITCH on the left side of the  
machine, labeled “Constant Voltage (Submerged Arc),  
Constant Voltage (FCAW/GMAW) and Constant  
Current (Stick/TIG)”, is used to select the proper  
welder characteristics for the process being used.  
The OUTPUT control to the right of the center of the  
control panel is a continuous control of the machine  
output. The control may be rotated from minimum to  
maximum while under load to adjust the machine out-  
put.  
The CV (FCAW/GMAW) Mode permits the DC-400 to  
produce essentially a flat output characteristic that can  
be varied from approximately. 12 to 42 volts.  
The machine is equipped with line voltage compensa-  
tion as a standard feature. This will hold the output  
constant except at maximum output of the machine,  
through a fluctuation of ±10% input line voltage.  
DC-400  
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B-7  
B-7  
OPERATION  
In this position, the dynamic characteristics of the  
machine under welding conditions provide optimum  
welding characteristics for Innershield® welding, other  
open arc processes including short arc MIG welding,  
and air carbon arc. Most submerged arc welding can  
also be done in this mode.  
OUTPUT TERMINALS SWITCH  
The OUTPUT TERMINALS toggle switch on the con-  
trol panel labeled “REMOTE - ON” allows the welder  
output to be activated remotely or to be always on.  
For remote operation, the toggle switch is set in  
“REMOTE” position and the welder output will be acti-  
vated when 2 and 4 are closed when using a wire-  
feeder. For welder output to always be activated, set  
the switch to the “ON” position.  
The CV (Submerged Arc) Mode also produces an  
essentially flat output characteristic that can be varied  
from approximately 12 to 42 volts. The dynamic  
characteristics of the CV Submerged Arc Mode make  
possible improved submerged arc welding over that  
possible using the Constant Voltage Innershield  
Mode. The improvement is most noticeable on high  
deposition, slow travel speed welds.  
110-115V AC and 40-42V AC Auxiliary  
Power and Control Connections  
14-PIN CONNECTOR  
The 14-pin connector receptacle supplies auxiliary  
power.  
There are no means provided to switch between any  
of the modes remotely. Do not change the position of  
the MODE SWITCH if output voltage or current is pre-  
sent as this may damage the switch.  
40-42V AC is available at receptacle pins I and K. A  
10 amp circuit breaker protects this circuit.  
The CC Mode permits the DC-400 to produce a con-  
stant current output characteristic through the range of  
60-500 amps with an open circuit voltage of approxi-  
mately 57 volts (54V on 50/60 Hz). Stick welding and  
TIG are done with this position of the Mode Switch.  
On the Domestic and Export models 110-115V AC is  
available at receptacle pins A and J. A 10 amp circuit  
breaker protects this circuit. Note that the 40-42V AC  
and 110-115V AC circuits are electrically isolated from  
each other.  
ARC FORCE CONTROL DIAL (Effective only in CC  
mode)  
FRONT VIEW OF 14-PIN  
CONNECTOR RECEPTACLE  
The ARC FORCE control is calibrated from one to ten.  
For most welding, the dial should be set at approxi-  
mately midrange, 5-6. Adjustments up or down can  
then be made depending on the electrode, proce-  
dures, and operator preference. Lower settings will  
provide less short circuit current and a softer arc. A  
setting that is too low may cause the electrode to stick  
in the puddle. Higher settings will provide a higher  
short circuit current and a more forceful arc.  
Excessive spatter may result if the control setting is  
too high. For most TIG welding applications adjust  
this control to a minimum for best operating character-  
istics.  
K=42  
J=31  
A=32  
B=GND  
I=41  
L=SPARE  
C=2  
D=4  
E=77  
N=SPARE  
H=21  
G=75  
F=76  
ARC CONTROL SWITCH (Effective only in CV  
FCAW/GMAW mode)  
M=SPARE  
PIN  
LEAD NO.  
FUNCTION  
The ARC CONTROL is a tapped switch numbered  
from 1 to 5 and changes the pinch effect of the arc.  
This control is most useful in processes that utilize a  
“shorting” metal transfer and controls the spatter, fluid-  
ity, and bead shape. The pinch effect is increased by  
turning the control clockwise.  
A
B
C
D
E
F
G
H
I
J
K
L
M
N
32  
GND  
2
110 - 115V AC  
CHASSIS CONNECTION  
TRIGGER CIRCUIT  
TRIGGER CIRCUIT  
OUTPUT CONTROL  
OUTPUT CONTROL  
OUTPUT CONTROL  
WORK CONNECTION  
40-42V AC  
4
77  
76  
75  
21  
41  
31  
42  
---  
110-115V AC  
For all applications, a good starting point for the ARC  
CONTROL is a midrange dial setting of 3. The control  
can be increased or decreased as desired.  
40-42V AC  
---  
---  
---  
---  
---  
DC-400  
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B-8  
B-8  
OPERATION  
NOTE:  
Terminal Strip Connections  
The GFCI receptacle is in a 115v circuit where the  
neutral is floating with respect to ground.  
Consequently if a GFCI tester is plugged into the  
GFCI receptacle, the tester will show that there is an  
"open ground". This indication of an "open ground" is  
normal and the GFCI will function properly in the  
event of a ground fault current as the GFCI is  
designed to do.  
Terminal strip TS2 located behind the hinged control  
panel on the front of the power source supplies  
110-115V AC. A 15 amp circuit breaker protects this  
circuit. Note that this 110-115V AC is also available in  
the 14-pin connector on the Domestic and Export  
models.  
To gain access to the terminal strips simply remote  
the #10 sheet metal screws from the perimeter of the  
welder nameplate. Tilt panel forward so it rests in a  
horizontal position. See Table showing Front View of  
14-Pin Connector Receptacle for lead number func-  
tions.  
Machine and Circuit Protection  
The power source is thermostatically protected with  
proximity thermostats against overload or insufficient  
cooling. One thermostat is located on the nose of the  
center bottom primary coil and a second thermostat is  
attached to the lead connection the secondaries.  
Both thermostats are connected in series with 2-4 cir-  
cuit. If the machine is overloaded, the primary ther-  
mostat will open, the output will be zero, and the  
amber thermal protection light will be on.  
The fan will continue to run. The secondary thermo-  
stat will open either with an excessive overload or  
insufficient cooling. The output will be zero and the  
amber protection light will be off.  
115VAC GFCI RECEPTACLE  
(Codes 11038 and higher)  
The GFCI receptacle is located near the output studs  
and protected by a 15 amp circuit breaker.  
Testing the GFCI Receptacle  
a.) Turn the welder ON. Press the reset button fully.  
Plug a lamp or radio into the GFCI (and leave it  
plugged in) to verify that the power is ON. If there  
is no power, go to Troubleshooting.  
b) Press the TEST button in order to trip the  
device.This should stop the flow of electricity, mak-  
ing the lamp or radio shut OFF. Note that the  
RESET button will pop out. If the power stays on,  
go to troubleshooting. If the power goes OFF, the  
GFCI is working properly. To restore power, press  
the RESET button.  
c) Press the TEST button (then RESET button) every  
month to assure proper operation.  
DC-400  
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C-1  
C-1  
ACCESSORIES  
REMOTE CONTROL ADAPTER CABLE (K864)  
Factory Installed Options  
DIODE OPTION  
CABLE RECEPTACLE (6 SOCKET)  
STRAIGHT PLUG (14 PIN)  
TO POWER SOURCE  
TO: 1) K857 REMOTE CONTROL  
2) K963 HAND AMPTROL  
3) K870 FOOT AMPTROL  
This internally installed option allows the use of the  
cold start and cold electrode sensing features of the  
NA-3, NA-5 or NA-5R.  
CABLE RECEPTACLE (14 SOCKET)  
TO LN-7 WIRE FEEDER  
MULTIPROCESS SWITCH  
A “V” cable 12” (.30m) long to connect a K857  
Remote Control, K963 Hand Amptrol or K870 Foot  
Amptrol (6-pin connector) with a wire-feeder (14-pin  
connector) and the machine (14-pin connector). If a  
remote control or amptrol is used alone the wire-feed-  
er connection is then not used.  
Factory or field installed kit that mounts on the front of  
the DC-400, and includes hinged covers over its out-  
put 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. The field installed kit equiva-  
MULTIPROCESS SWITCH (K804-1)  
lent is identified as  
K804-1. For details on the  
Multiprocess Switch, see the Installation of Equipment  
section.  
Field installed kit that mounts on the front of the DC-  
400, and includes hinged covers over its output studs.  
The switch has three positions:Positive semiautomat-  
ic/automatic,negative semiautomatic/automatic, and  
stick/air carbon arc. Required when using the DC-400  
for both semiautomatic/automatic and stick/air carbon  
arc. The field installed kit is equivalent to the factory  
installed option. For details on the Multiprocess  
Switch, see the section for Installation of Equipment  
Required for Recommended Processes.  
Field Installed Options  
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.  
CAPACITOR DISCHARGE CIRCUIT (K828-1)  
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  
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.  
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.  
AMPTROL™ ADAPTER CABLE (K843)  
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.  
A five wire cable, 12” (.30m) long, is available for easy  
connection of standard K963 Hand Amptrol or K870  
Foot Amptrol. The cable has a 6-pin MS-style con-  
nector which connects to the Amptrol and terminals  
which connect to 75, 76 and 77 on the machine termi-  
nal strip and to the case grounding screw. The  
Amptrol will control the same range of output as the  
current control on the welder. (If a smaller range of  
control is desired for finer adjustment, a K775  
Remote may be used in conjunction with the Amptrol  
Adapter Cable Kit. Connection information is included  
with the Amptrol Adapter Cable Kit.) The Amptrol arc  
start switch is nonfunctional in this application.  
3) DC-400 is used with any semiautomatic  
wire-feeder and possible small spark, if electrode  
touches work just after gun trigger is released, is  
objectionable.  
DC-400  
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C-2  
C-2  
ACCESSORIES  
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.  
OPTIONAL AMPTROL ADAPTER FOR K799 HI-  
FREQUENCY KIT (K915-1 REQUIRES K864  
ADAPTER OR K843 ADAPTER)  
A “V” cable to connect a K799 Hi-Freq kit (5-pin con-  
nector) 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 either a K864 adapter to connect with  
the 14-pin connector on the machine or a K843  
adapter to connect to terminals 75, 76, 77 and the  
case grounding screw on the machine.  
UNDERCARRIAGES (K817, K817R, K841)  
For easy moving of the machine, optional undercar-  
riages 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.  
DC-400  
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D-1  
D-1  
MAINTENANCE  
WARNING  
ELECTRIC SHOCK can kill.  
• Have an electrician install and service  
this equipment.  
• Turn the input power off at the fuse  
box before working on equipment.  
• Do not touch electrically hot parts.  
----------------------------------------------------------------------  
Routine Maintenance  
1. The fan motor has sealed bearings which require  
no service.  
2. In extremely dusty locations, dirt may clog the air  
channels causing the welder to run hot. Blow out  
the machine at regular intervals.  
3. In extremely dusty locations, dirt may accumulate  
on the remote control terminal strip TS1. Wipe or  
blow this terminal strip off at regular intervals. This  
is particularly important in damp locations.  
DC-400  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs  
performed on this equipment may result in danger to the technician and machine operator and will  
invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all  
safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Authorized Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
DC-400  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Input contactor (CR1) chatters.  
1. Faulty input contactor (CR1).  
Repair or Replace.  
2. Low line voltage.  
Check input power.  
Machine input contactor does not  
operate.  
1. Supply line fuse blown. Replace if  
blown - look for reason first.  
2. Contactor power circuit dead.  
Check control transformer T2 and  
associated leads.  
3. Broken power lead. Check input  
voltage at contactor.  
4. Wrong input voltage. Check volt-  
age against instructions.  
5. Open input contactor coil.  
Replace coil.  
6. POWER “I/0” switch (S1) not  
closing. Replace switch.  
Machine input contactor operates, 1. Trigger circuit between #2 and #4  
but no output when trying to weld.  
leads is not being closed. Make  
sure trigger circuit is being  
closed.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Authorized  
Field Service Facility.  
2. Electrode or work lead loose or  
broken. Repair Connection.  
3. Open main transformer (T1) pri-  
mary or secondary circuit. Repair.  
4. Defective Control PC Board.  
Replace. See Procedure for  
Replacing PC Boards.  
5. Primary or secondary thermostats  
open. Amber thermal protection  
light is on: Check for overheat-  
ing; make sure fan is operating  
and there is no obstruction to free  
air flow.  
Machine has minimum output and 1. Terminals 75, 76 or 77 grounded  
no control. to positive output.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
DC-400  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Machine has high output or pulsing 1. Terminals 75, 76, or 77 grounded  
output and no control.  
to negative output.  
Machine has low output and no  
control.  
1. OUTPUT CONTROL “LOCAL-  
REMOTE” switch (S2) in wrong  
position. Check position of  
switch.  
2. OUTPUT CONTROL switch  
faulty. Check switch & replace if  
faulty.  
3. Open in feedback circuitry.  
4. Faulty Control PC Board.  
5. OUTPUT control potentiometer  
circuit open (lead 75).  
Machine does not have maximum 1. One input fuse blows. Check and  
output.  
replace if blown after checking for  
reason for blown fuse.  
2. One phase of main transformer  
open.  
3. Faulty Control PC Board.  
4. OUTPUT control potentiometer.  
5. OUTPUT control potentiometer  
leads 210, 211 or 75 open.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Authorized Field  
Service Facility.  
Machine will not shut off.  
1. Input contactor contacts frozen.  
2. Defective POWER “1/0” switch,  
(S1).  
1. Poor work or electrode connec-  
tion. Place switch in “LOCAL”.  
2. Welding leads too small.  
3. Welding current or voltage too  
low.  
Variable or sluggish welding arc.  
4. Defective main SCR bridge.  
5. Microswitch S4C or S4D actuator  
defective.  
1. OUTPUT CONTROL switch in  
wrong position.  
OUTPUT control not functioning on  
the machine.  
2. Faulty OUTPUT control switch.  
3. Faulty OUTPUT control poten-  
tiometer.  
4. Leads or connections open in  
control circuit.  
5. Faulty Control PC Board.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
DC-400  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT control not functioning on 1. OUTPUT CONTROL switch in  
“REMOTE” control.  
wrong position. Place switch in  
“REMOTE”.  
2. Faulty OUTPUT CONTROL  
switch.  
3. Faulty remote control potentiome-  
ter.  
4. Leads or connections open in  
control circuit.  
5. Faulty Control PC Board.  
Poor arc striking with semiautomat- 1. Defective start circuit.  
ic or automatic wire feeders.  
2. Poor work connection.  
3. Improper procedures.  
4. Defective Control PC Board.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Authorized Field  
Service Facility.  
Poor arc characteristics.  
1. Start circuit energized at all times  
(read switch CR3 not closing).  
2. Defective Start PC Board.  
3. Defective Control PC Board.  
4. Capacitor(s) in output circuit  
failed. A failure is indicated if the  
small vent plug on top of a capac-  
itor is raised or blown out.  
ARC CONTROL has no effect in  
CV (FCAW/GMAW) mode with  
short circuit transfer processes.  
1. Defective R1, L1, S4C, S4D actu-  
ator or S5.  
115VAC Receptacle not working.  
1. Circuit Breaker Tripped.  
2. Defective Circuit Breaker.  
3. Broken Connection in Wiring.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
DC-400  
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E-5  
E-5  
TROUBLESHOOTING  
FAULT PROTECTION OPERATION  
PROCEDURE FOR REPLACING PC BOARDS  
The overload protection circuit, in the Control PC  
Board will limit the welding current (heat) to 550 amps  
if a short or overload is applied to the machine. (Refer  
to the Machine and Circuit Protection section).  
WARNING  
ELECTRIC SHOCK can kill.  
• Have an electrician install and service  
this equipment.  
• Turn the input power off at the fuse  
box before working on equipment.  
CHECKING SNUBBER CIRCUIT  
• Do not touch electrically hot parts.  
---------------------------------------------------------------------  
In case of an SCR malfunction or failure the snubber  
assembly should be checked. Turn the machine off  
and remove the sides of the machine. (See the  
instruction manual parts list for the exact location.)  
When a PC Board is suspected to be defective, the  
following procedure must be followed:  
1. Visually inspect the snubber assembly for over-  
heated components or damaged components.  
1. Visually inspect the PC Board. If the board has  
fuses, check to see if any are blown. Are any of  
the components damaged? Is a conductor on the  
back side of the board damaged? If electrical  
damage is visible on the PC Board, inspect the  
machine wiring for grounds or shorts to avoid dam-  
aging a new PC Board, Install a new PC Board  
only after a visual inspection of the PC Board and  
machine wiring is satisfactory.  
2. If the problem is remedied by a new PC Board,  
install the old PC Board and see if the problem still  
exists. If the problem does not return with the old  
board:  
CHECKING OUTPUT CONTROL RHEOSTAT ON  
MACHINE  
Turn machine off (“0” position).  
Remove the control panel screws and open the con-  
trol panel (see the section on Terminal Strip  
Connections for screw locations).  
Turn the OUTPUT CONTROL switch to “REMOTE”.  
a) Check the PC Board harness plug and PC  
Board plug for contamination, corrosion or over-  
size.  
Disconnect the harness plug from the Control PC  
Board.  
b) Check leads in the harness for loose connec-  
tions.  
With an ohmmeter on X1K, connect it to lead 210 and  
75 on R4.  
CONNECTING THE REMOTE CONTROL TO THE  
MACHINE  
Exercise caution to avoid damaging POT taps.  
POWER “I/0” SWITCH CHECK  
Extreme caution must be observed when installing or  
extending the wiring of a remote control. Improper  
connection of this unit can lead to failure of the output  
control rheostat or the control circuit. Only the green  
lead can and should be grounded to the machine  
case. When extending the standard remote control,  
make sure the leads are the same and the splice is  
waterproof. Be very careful not to ground the cable  
when in use and don’t let the lugs touch against the  
case.  
1. Turn off the machine power input (“0” position). S1  
has 115V across it when the input power is con-  
nected.  
2. Isolate the switch to be tested by removing all con-  
necting leads.  
3. Check to make sure the switch is making connec-  
tions with an ohmmeter. The meter should read  
zero resistance.  
OUTPUT VOLTAGE  
4. Put the ohmmeter on X1K scale and measure the  
resistance between the terminal and the case of  
the machine (touch a self-tapping screw). Reading  
should be infinite.  
The output circuit voltage of the machine should be  
adjustable from 10 to 46 volts in CV. In the CC mode,  
the open circuit voltage should be approximately 57  
volts (54 volts on 50/60 Hz) except at near minimum  
settings of the output control where it may be lower. If  
any other condition exists, refer to the  
Troubleshooting Guide.  
5. If either step (3) or step (4) fails, replace the  
switch.  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
DC-400  
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E-6  
E-6  
TROUBLESHOOTING  
REMOTE CONTROL CHECK  
2. Power Diode Test  
Disconnect the remote output control and connect an  
ohmmeter across 75 to 76 and rotate the rheostat in  
the remote control. The resistance reading should go  
from zero to 10K ohms. Repeat with ohmmeter  
across 75 and 76 with same results. Connect ohm-  
meter across 75 and 77. The reading should be 10K  
ohms. A lower reading will indicate a shorted or par-  
tially shorted rheostat. A very high reading will indi-  
cate an open rheostat. In either of the last two cases,  
replace rheostat. Check cable for any physical dam-  
age.  
a) Establish the polarity of the ohmmeter leads  
and set to X10 scale.  
b) Connect the ohmmeter positive lead to anode  
and negative lead to cathode.  
c) Reverse the leads of the ohmmeter from  
Step b.  
d) A shorted diode will indicate zero or an equally  
low resistance in both directions. An open  
diode will have an infinite or high resistance in  
both directions and a good diode will have a  
low resistance in Step b and Step a much high-  
er resistance in Step c.  
POWER RECTIFIER BRIDGE ASSEMBLY  
CHECKING PROCEDURE  
WARNING  
ELECTRIC SHOCK can kill.  
• Have an electrician install and service  
this equipment.  
3. Power Silicon Controlled Rectifier Test  
• Turn the input power off at the fuse  
box before working on equipment.  
• Do not touch electrically hot parts.  
---------------------------------------------------------------------  
a) Connect the ohmmeter (set to m X10 scale)  
leads to the anode and cathode.  
b) Reverse the leads of the ohmmeter from Step  
a.  
1. Bridge and Device Isolation (See the instruc-  
tion manual parts list for the exact location.)  
c) A shorted SCR will indicate zero or an equally  
low resistance in one or both directions.  
Disconnect the following leads from the bridge,  
shown in Diagram 1:  
d) Establish the polarity of the ohmmeter.  
Connect the positive lead to the gate and the  
negative lead to the cathode.  
a) Unplug P3 (G1, G2, G3 and 204) from the  
Control PC Board.  
b) Unplug P5 from the Snubber PC Board.  
e) An open gate circuit will have an infinite or high  
resistance. A good gate circuit will read a low  
resistance, but not zero ohms. If gate circuit  
reads zero ohms, check gate harness for  
shorts between gate leads and 204 before  
replacing SCR.  
c) Secondary leads X1, X2, and X3 from the  
anodes of the SCR’s and cathodes of the  
diodes.  
d) Disconnect positive bridge lead from shunt and  
positive capacitor bank lead and from lug with  
triple 204 leads.  
e) Perform the following steps 2 and 3. If diodes  
and SCR’s are not shorted, bridge test is com-  
pleted. If any device appears shorted, discon-  
nect the cathode lead of each diode (4 total)  
and repeat Steps 2 and 3.  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
DC-400  
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F-1  
F-1  
DIAGRAMS  
WIRING DIAGRAM FOR CODE 10648  
230/460/575V.  
(SHOWN CONNECTED FOR 230 V.)  
H3  
N.B.  
H4  
TO SUPPLY  
LINES  
RECONNECT PANEL  
H2  
L1  
L3 L2  
13  
14  
15  
X1  
3
9
8
2
7
1
W
TO GROUND PER NATIONAL  
ELECTRICAL CODE  
N.B.  
4
5
16  
17  
18  
V
U
6
FAN MOTOR  
CR1  
233  
CONTACTOR  
TO PRIMARY  
COILS  
10 AMP  
CIRCUIT  
BREAKER  
232  
H1  
CONNECT OR  
INSULATE AS  
SHOWN ON  
INPUT  
CONNECTION  
DIAGRAM  
31  
42  
42  
X1  
H2  
T2  
AUXILIARY  
COILS  
115V  
CONTROL  
10  
H3  
H4  
42A  
S
32A  
12  
TRANSFORMER  
X2  
231  
42V  
S
115V  
2
241  
SECONDARY  
8
5
9
7
PRIMARY  
231  
201  
S
THERMOSTATS  
203  
21V  
4
202  
41  
41  
TOP  
14  
15  
13  
CAPACITOR  
DISCHARGE  
RELAY  
21V  
21V  
PRIMARY  
41  
S
CR4  
204  
S
6
3
CAPACITOR  
DISCHARGE  
OPTION  
4
1
BOTTOM  
PRIMARY  
2
N.A.  
N.C.  
10A  
0.5 /50W  
0.5 /50W  
SLOW  
BLOW  
17  
X2 SEC  
18  
X3 SEC  
16  
T1 MAIN  
TRANSFORMER  
X1 SEC  
DIODE  
OPTION  
204  
254  
P5  
220  
221  
222  
223  
225  
C1  
C2  
C3  
C4  
C5  
+
+
+
+
+
1
2
3
4
5
6
204  
RECTIFIER  
ASSEMBLY  
D1  
D2  
D3  
31,000 MFD  
50V EACH  
D4  
REED  
SWITCH  
CR3  
J5  
SHUNT  
SCR3  
SCR1  
+
-
224  
GREEN  
227  
204  
7
8
205 206  
204  
204  
204  
216  
215  
7.5 /100W  
G3  
G2  
G1  
SNUBBER  
BOARD  
204  
R2  
40 /50W  
225  
225  
P2  
P1  
P3  
LEAD NOT PRESENT WITH  
DIODE OPTION  
3
2
4
1
1
2
209  
214  
217  
204  
206  
206  
208  
213  
75  
1
2
3
4
5
6
7
8
201  
202  
203  
232  
PILOT  
LIGHT  
3
4
ELECTRICAL SYMBOLS PER  
E1537  
J3  
204  
225  
W
7
8
9
10 4  
11 5  
12 6  
1
2
3
233  
5
6
1
J1  
6
7
220  
233  
5
6
7
8
1
41  
2
4
5
6
1
2
3
2
J2  
8
3
4
5
4
2
7
8
S1  
3
4
1
9
10  
3
4
42  
}
POWER  
SWITCH  
9
10  
2
240  
Y
9
4
PIN  
J3  
6
PIN  
J6  
8
PIN  
J5  
10 PIN  
J1  
12 PIN  
J2  
10  
11  
12  
212  
205  
205  
231  
206  
THERMAL  
PROTECTION  
LIGHT  
CONNECTOR CAVITY  
NUMBERING SEQUENCE  
(COMPONENT SIDE OF P.C.  
BOARD)  
+
-
CONTROL BOARD  
VM  
MODE SWITCH  
FRONT GANG  
225  
+
-
205  
206  
CV-FCAW/GMAW  
CV-SUB ARC  
AM  
P6  
CC  
NOTES  
STARTING  
BOARD  
ARC CONTROL  
SWITCH  
S5  
31  
4
1
2
3
5
6
N.A.  
N.B.  
CIRCUITRY PRESENT ON  
METERS  
S4A  
L1  
32  
CAPACITOR DISCHARGE  
ONLY.  
OUTPUT  
CHOKE  
228  
216  
215  
218  
MIN. IND. (5)  
J6  
CV-FCAW/GMAW  
S
2
CC  
TAPE UP SEPARATELY  
TO PROVIDE AT LEAST  
1
CV-SUB ARC  
S4B  
15 /100W  
234  
219  
MAX. IND.  
(1)  
600  
V
INSULATION.  
R1  
3
F
218  
216  
N.C. CIRCUITRY PRESENT ON  
DIODE OPTION.  
N.C.  
210  
204 208 209  
32A  
224  
212 210 211  
76  
213  
77  
217  
S4D  
ACTUATED  
224  
225  
211  
N.O.  
75  
234  
CV-FCAW/GMAW  
10A  
R4  
}
204  
N.C.219  
218  
ONLY  
CIRCUIT  
10K /2W  
ARC FORCE CONTROL  
10K /2W  
BREAKER  
21  
S4C  
N.O.  
OUTPUT  
S6  
ACTUATED  
IN CC ONLY  
214  
204  
VOLTMETER  
SWITCH  
S2  
CONTROL  
32  
OUTPUT CONTROL  
SWITCH  
42  
}
228  
C6 .0047MFD/1400V  
32  
31  
41  
21  
2
4
77  
N.A.  
GREEN  
WORK  
+
224  
GROUNDING  
STUD  
OPTIONAL  
MULTI-PROCESS  
SWITCH  
75  
76  
4
2
31 32  
75  
76 77  
21  
4
2
S3  
OUTPUT  
-
ELECTRODE  
2
TERMINALS  
SWITCH  
225  
TS1  
TS2  
N.A.  
4
TO NEG.  
TERM.  
TO POS.  
TERM.  
TO TERM.  
STRIP  
12-9-94F  
L9107  
DC-400  
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F-2  
F-2  
DIAGRAMS  
WIRING DIAGRAM FOR CODE 10699 AND ABOVE  
230/460/575V.  
H3  
H4  
(SHOWN CONNECTED FOR  
230 V.)  
N.B.  
TO SUPPLY  
LINES  
RECONNECT PANEL  
GROUND  
H2  
L1  
L3 L2  
13  
3
GROUND STUD ON  
OUTPUT PANEL  
X1  
14  
9
W
15  
8
2
7
1
N.B.  
4
5
32  
16  
17  
18  
V
U
CR1  
TO GROUND PER NATIONAL  
ELECTRICAL CODE  
6
FAN MOTOR  
15A  
233 CONTACTOR  
SILVER  
TO PRIMARY  
COILS  
10 AMP  
CIRCUIT  
BREAKER  
32  
32A  
232  
H1  
31  
31  
42  
42  
CONNECT OR  
31  
INSULATE AS  
SHOWN ON  
INPUT  
X1  
AUXILIARY  
COILS  
H2  
T2  
32A  
115V  
CONNECTION  
CONTROL  
A
10  
42A  
DIAGRAM  
H3  
H4  
12  
32  
TRANSFORMER  
66V  
S
X2  
231  
42V  
S
241  
SECONDARY  
66V  
S
201  
2
8
9
7
PRIMARY  
231  
THERMOSTATS  
203  
21V  
4
202  
41  
41  
TOP  
14  
15  
13  
CAPACITOR  
DISCHARGE  
RELAY  
21V  
21V  
PRIMARY  
41  
S
S
204  
S
5
2
6
CAPACITOR  
DISCHARGE  
OPTION  
4
1
BOTTOM  
PRIMARY  
3
N.A.  
10A  
0.5 /50W  
0.5 /50W  
SLOW  
BLOW  
17  
X2 SEC  
18  
X3 SEC  
N.C.  
16  
T1 MAIN  
TRANSFORMER  
X1 SEC  
DIODE  
OPTION  
204  
254  
P5  
220  
1
C1  
C2  
C3  
C4  
C5  
+
+
+
+
+
204  
RECTIFIER  
ASSEMBLY  
221  
222  
223  
225  
224  
GREEN  
2
3
4
5
6
7
8
D1  
D2  
D3  
31,000 MFD  
50V EACH  
D4  
REED  
SWITCH  
CR3  
J5  
SHUNT  
2
SCR  
SCR3  
SCR1  
+
-
A
227  
204  
205 206  
204  
204  
204  
216  
232  
215  
7.5 /100W  
SNUBBER  
BOARD  
G3  
G2  
G1  
204  
R2  
40 /50W  
225  
225  
P2  
1
P1  
P3  
ENT WITH  
2
4
3
LEAD NOT PRES  
DIODE OPTION  
1
209  
214  
217  
204  
206  
206  
208  
213  
75  
1
2
3
4
5
6
7
8
201  
2
3
4
202  
203  
204  
225  
220  
41  
PILOT  
LIGHT  
ELECTRICAL SYMBOLS PER  
E1537  
J3  
W
7
8
9
1
2
3
233  
5
6
7
J1  
6
7
1
233  
5
6
7
8
1
2
3
4
2
4
5
6
1
2
3
10 4  
11 5  
12 6  
J2  
8
3
4
5
4
S1  
POWER  
SWITCH  
1
2
9
10  
3
4
42  
8
9
10  
11  
12  
2
9
10  
240  
Y
10 PIN  
J1  
12 PIN  
J2  
4 PIN 6 PIN 8 PIN  
J3 J5  
J6  
212  
205  
205  
231  
206  
THERMAL  
PROTECTION  
LIGHT  
CONNECTOR CAVITY  
+
-
CONTROL BOARD  
NUMBERING SEQUENCE  
VM  
MODE SWITCH  
FRONT GANG  
(COMPONENT SIDE OF P.C.  
BOARD)  
225  
+
-
CV-FCAW/GMAW  
CV-SUB ARC  
205  
206  
AM  
CC  
P6  
NOTES  
STARTING  
BOARD  
ARC CONTROL  
31  
32  
4
N.A.  
N.B.  
CIRCUITRY PRESENT ON  
CAPACITOR DISCHARGE  
ONLY.  
METERS  
S4A  
SW  
ITCH  
L1  
1
OUTPUT  
CHOKE  
S5  
2
3
5
6
228  
216  
215  
218  
MIN. IND. (5)  
J6  
CV-FCAW/GMAW  
S
2
CC  
TAPE UP SEPARATELY  
TO PROVIDE AT LEAST  
600 V INSULATION.  
1
3
CV-SUB ARC  
S4B  
15 /100W  
234  
219  
MAX. IND.  
(1)  
R1  
F
218  
216  
N.C. CIRCUITRY PRESENT ON  
DIODE OPTION.  
N.C.  
210  
204 208 209  
224  
76  
212 210 211  
213  
77  
217  
S4D  
224  
225  
211  
N.O.  
75  
ACTUATED  
234  
N.C.219  
218  
CV-FCAW/GMAW  
R4  
204  
ONLY  
10K  
/2W  
10K  
/2W  
21  
S4C  
ARC FORCE CONTROL  
N.O.  
OUTPUT  
S6  
ACTUATED  
IN CC ONLY  
214  
204  
228  
VOLTMETER  
SWITCH  
S2  
CONTROL  
OUTPUT CONTROL  
SWITCH  
42  
32  
C6 .0047MFD/1400V  
31  
A
41  
21  
A
2
4
77  
N.A.  
GREEN  
WORK  
+
GROUNDING  
STUD  
224  
OPTIONAL  
MULTI-PROCESS  
SWITCH  
75  
76  
4
2
31 32  
75 76 77  
TS1  
21  
4
2
S3  
OUTPUT  
-
ELECTRODE  
TERMINALS  
SWITCH  
225  
TS2  
N.A.  
2
4
TO NEG.  
TERM.  
TO POS.  
TERM.  
TO TERM.  
STRIP  
L11460  
DC-400  
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F-3  
F-3  
DIAGRAMS  
WIRING DIAGRAM FOR CODES 11038, 11085, 11128, 11347  
DC-400  
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F-4  
F-4  
DIAGRAMS  
POWER RECTIFIER BRIDGE  
DIAGRAM 1  
PLUG TO SNUBBER BOARD  
P5  
220  
_
+
220  
223  
204  
221  
222  
X1  
X2  
X3  
D1  
D2  
ANODE D3  
To (+) side  
of capacitor  
bank  
CATHODE  
D4  
ANODE  
SCR1  
SCR2  
SCR3  
GATE  
CATHODE  
SHUNT  
_
+
204  
204  
To  
mode  
switch  
204  
204  
G1  
G2  
G3  
Gate leads  
plug to control  
P.C. board  
P3  
To plug  
P1  
To T1 main  
transformer  
DC-400  
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F-5  
F-5  
DIMENSION PRINT  
Part No.  
Type  
A
B
C
D
F
G
H
+
+
M12244-7 DC-400 32.00 15.39 30.92 1.44  
30.02 .11  
30.02 .11  
.94  
DC-400  
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NOTES  
DC-400  
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● Do not touch electrically live parts or  
electrode with skin or wet clothing.  
● Insulate yourself from work and  
ground.  
● Keep flammable materials away.  
● Wear eye, ear and body protection.  
WARNING  
Spanish  
● No toque las partes o los electrodos ● Mantenga el material combustible  
● Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
● Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
● Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
● Gardez à l’écart de tout matériel  
inflammable.  
● Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
● Isolez-vous du travail et de la terre.  
German  
● Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
● Isolieren Sie sich von den  
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
● Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
● Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE  
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-  
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
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● Keep your head out of fumes.  
● Use ventilation or exhaust to  
remove fumes from breathing zone.  
● Turn power off before servicing.  
● Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
● Los humos fuera de la zona de res-  
piración.  
● Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
● Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
● No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux  
tien.  
● Gardez la tête à l’écart des fumées.  
● Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
● Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
● Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
● Vermeiden Sie das Einatmen von  
Schweibrauch!  
● Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
● Não opere com as tampas removidas.  
● Desligue a corrente antes de fazer  
serviço.  
● Mantenha-se afastado das partes  
moventes.  
● Não opere com os paineis abertos  
ou guardas removidas.  
● Mantenha seu rosto da fumaça.  
● Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
● Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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