Lincoln Electric INVERTEC CC400-S Manual de usuario

Rev. 01

IM7008-1

August, 2012

Rev. 01

INVERTEC® CC400-S/-S PLUS

For use with machine Part Number K60060-1, Code 76115 INVERTEC CC 400-S /

K60060-3, Code 76135 INVERTEC CC 400-S Plus

•World’s Leader in Welding and Cutting•

THE SHANGHAI LINCOLN ELECTRIC COMPANY

No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907

www.lincolnelectric.com.cn

Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built

with safety in mind. However, your

overall safety can be increased by

proper installation and thoughtful

operation on you 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.

Rev. 01

Thank you for selecting QUALITY Lincoln Electric products.

Please examine the packaging and equipment for damage. Claims for material damaged in shipment must be

notified immediately to the authorized dealer from whom you purchased the machine.

For future reference,please record your equipment identification information in the table below. Model Name,

Code & Serial Number can be found on the machine rating plate.

Model Name

□Invertec®CC400-S

□Invertec®CC400-S PLUS

Code & Serial number

Date & Where Purchased

Authorized dealer’s shop

Declaration of conformity

THE SHANGHAI LINCOLN ELECTRIC COMPANY

Designed in conformance with the following norm:

GB15579.1

EN 60974-1

THE SHANGHAI LINCOLN ELECTRIC COMPANY

No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907

iSAFETY i

INVERTEC®CC400-S/-S PLUS

Rev.01

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM

POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER

WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR

PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

ELECTRIC AND

MAGNETIC FIELDS

may be dangerous.

1.a Electric current flowing through any conductor

causes localized Electric and Magnetic Field

(EMF). Welding current creates EMF fields

around welding cables and welding machines.

1.b EMF fields may interfere with some pacemakers,

and welders having a pacemaker should consult

their physican before welding.

1.c All welders should use the following procedures

in order to minimize exposure to EMF fields from

the welding circuit:

1.d.1 Route the electrode and work cables

together –Secure them with tape when

possible.

1.d.2 Never coil the electrode lead around your

body.

1.d.3 Do not place your body between the

electrode and work cables. If the electrode

cable is on your right side, the work cable

should also be on your right side.

1.d.4 Connect the work cable to the workpiece

as close as possible to the area being

welded.

ARC RAYS can burn.

2.a Use a shield with the proper filter and cover

plates to protect your eyes from sparks and the

rays of the arc. Headshield and filter lens should

conform to ANSI Z87. I standards.

2.b Use suitable clothing made from durable flame-

resistant material to protect your skin and that of

your helpers from the arc rays.

2.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.

ELECTRIC SHOCK can

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

hand.

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.

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, grating 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:

Semiautomatic DC Constant Voltage (Wire)

Welder.

DC Manual (Stick) Welder.

AC Welder with Reduced Voltage Control.

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.

3.g Never dip the electrode in water for cooling.

3.h Never simultaneously touch electrically “hot”

parts of electrode holder to two welders because

voltage between the two can be total of the open

circuit voltage of both welders.

ii SAFETY ii

INVERTEC®CC400-S/-S PLUS

Rev.01

FUMES AND GASES

can be dangerous.

4.a Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases. When welding, keep your

head out of fume. Use enough ventilation and/or

exhaust at the arc to keep 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.

4.b Do not weld in locations near chlorinated

hydrocarbon vapors coming from degreasing,

cleaning or spraying operations. The heat and

rays or the arc can react with solvent vapors to

form phosgene, a highly toxic gas, and other

irritating products.

4.c 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.

4.d 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.

FOR ELECTRICALLY

powered equipment.

5.a Turn off input power using the disconnect switch

at the fuse box before working on the equipment.

5.b Install equipment in accordance with the national

standard, all local standards and the

manufacturer’s recommendations.

5.c Ground the equipment in accordance with the

national standards and the manufacturer’s

recommendations.

WELDING SPARKS

can cause fire or

explosion.

6.a Remove fire hazards from the welding area. If

this is not possible, cover them to prevent 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.

6.b 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.

6.c 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 subtances

inside. They can cause an explosion even

though they have been “cleaned”.

6.d Sparks and spatter are thrown from the welding

arc. Wear oil free protective garments such as

leather gloves, heavy shirt, cuffless trouses, high

shoes and a cap over your hair.

CYLINDER may

explode if damaged.

7.a Use only compressed gas cylinders containing

the correct shielding gas for the 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.

7.c Cylinder should be located:

Away from areas where they may be struck or

subjected to physical damage.

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.

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.

A-1INSTALLATION A-1

INVERTEC®CC400-S/-S PLUS

Rev.01

TECHNICAL SPECIFICATIONS –INVERTEC®CC400-S/-S PLUS

INPUT –THREE PHASE ONLY

INVERTEC®CC400-S/-S

PLUS

Standard Voltage/Phase/Frequency

380V ~ 415V(±10%)/3/50 or 60 Hz

Input Power at Rated Output

17KW @ 60% Duty Cycle

RATED OUTPUT –DC ONLY

INVERTEC®CC400-S/-S

PLUS

Duty Cycle

60%

100%

Amperes

400A

310A

Volts at Rated Amperes

36V

32.4V

OUTPUT

INVERTEC®CC400-S/-S

PLUS

Welding Current Range

10A ~ 400A

Open Circuit Voltage

68V @380V Input

73V @415V Input

Welding Voltage Range

20.2 V ~ 36V

RECOMMENDED INPUT WIRE AND FUSE SIZES

INVERTEC®CC400-S/-S

PLUS

Input

Voltage/

Frequency

(Hz)

380/415V

Maximum

Input

Ampere

38/30A

Maximum

Effective

Supply

Current

29/23A

60°C Copper

Wire in

Conduct

Sizes

6mm2

Fuse or

Breaker Size

(Super Lag)

40A

Grounding

Conductor

Size

4mm2

PHYSICAL DIMENSIONS

INVERTEC®CC400-S

PLUS

Height

480mm

Width

350mm

Depth

730mm

Weight

32Kg

36Kg

Temperature Range

Operating Temperature Range

-10°C ~ +40°C

Storage Temperature Range

-25°C ~ +55°C

For any maintenance or repair operation it is recommended to contact the nearest technical service center or directly

consult machine division of the Shanghai Lincoln Electric. Maintenance or repairs performed by unauthorized service

center or personnel will void the manufacturer’s warranty.

A-2INSTALLATION A-2

INVERTEC®CC400-S/-S PLUS

Rev.01

SAFETY PRECAUTIONS

Read the entire installation section before starting

installation.

ELECTRIC SHOCK can kill.

Only qualified personnel should

perform this installation.

Turn the input power OFF at the

main switch or fuse box before

working on this equipment. Turn

off the input power to any other equipment

connected to the welding system at the main

switch or fuse box before working on the

equipment.

Do not touch electrically “Hot”parts.

Always connect the INVERTEC®grounding lug

(located at the rear of the case) to a proper safety

(Earth) ground. INVERTEC®is for use on a 4 wire

system with earthed neutral.

SELECT SUITABLE LOCATION

This power source should not be subjected to falling

water, nor should any parts of it be submerged in water.

Doing so may cause improper operation as well as pose

a safety hazard. The best practice is to keep the machine

in a dry, sheltered area.

The bottom of machine must always be placed on a

firm, secure, level surface. There is a danger of the

machine toppling over if this precaution is not taken.

Place the welder where clean cooling air can freely

circulate in through the back louvers and out through the

case sides. Water,dirt, dust or any foreign material that

can be drawn into the welder should be kept to a

minimum. Failure to observe these precautions can result

in excessive operating temperatures and nuisance

shutdowns.

Locate the INVERTEC®machine away from radio

controlled machinery. Normal operation of the welder

may adversely affect the operation of RF controlled

equipment, which may result in bodily injury or damage to

the equipment.

INPUT POWER AND GROUNDING

CONNECTION

Only a qualified electrician should connect the input

leads to the INVERTEC®. Connections should be

made in accordance with the connection diagram.

Failure to do so may result in bodily injury or death.

Open the input box on the rear of the case. Use a three-

phase supply line, the three live wires should go through

the three holes of the input wire holder and be securely

clamped and fixed. Connect L1, L2, L3 and ground

according to the Input Supply Connection Diagram decal,

refer to Figure A.1 on this page.

Make sure the amount of power available from the input

connection is adequate for normal operation of the

machine. Refer to the Technical Specifications at the

beginning of this Installation section for recommended

fuse and wire sizes. Fuse the input circuit with the

recommended super lug fuse or delay type breakers.

Using fuses or circuit breakers smaller than

recommended may result in “nuisance” shut-offs from

welder inrush currents, even if the machine is not being

used at high currents.

CABLECONNECTIONS

Connect a couple of electrode and work leads with

sufficient size between the proper output studs on the

power source and the electrode or the work. Be sure the

connection to the work makes tight metal to metal

electrical contact. Poor work lead connections can result

in poor welding performance.

To avoid interference problems with other equipment

and to achieve the best possible operation, route all

cables directly to the electrode and the work. Avoid

excessive lengths and do not coil excess cable.

Cable sizes are increased for greater lengths primarily for

the purpose of minimizing cable drop.

Minimum work and electrode cable sizes are as follows:

TABLE A.1

Current (60% Duty Cycle)

Minimum Copper

Work Cable Size

200A

300A

400A

Up To 30m Length

30 mm2

50 mm2

70 mm2

Note: The recommended cable size may need to change

depending on its quality. When the rated current flow

goes through, the total voltage drop on ground cable and

electrode cable must not exceed 4 volts.

WARNING

CAUTION

WARNING

FIGURE A.1

B-1 OPERATION B-1

INVERTEC®CC400-S/-S PLUS

Rev.01

SAFETY PRECAUTIONS

Read this entire section of operating

instructions before operating the machine.

ELECTRIC SHOCK can kill.

Do not touch electrically live

parts or electrode with skin or

wet clothing.

Insulate yourself from 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.

Keep flammable material away.

Do not weld on closed

containers.

ARC RAYS can burn eyes and

skin.

Wear eye, ear and body

protection.

PLEASE SEE ADDITIONAL WARNING

INFORMATION AT THE FRONT OF THIS

OPERATOR’S MANUAL.

DUTY CYCLE

The duty cycle of a welding machine is the percentage of

time in a 10 minute cycle at which the welder can operate

the machine at rated welding current.

60% duty cycle:

Weld for 6 minutes

Break for 4 minutes

Excessive extension of the duty cycle will maybe cause

the thermal protection circuit to activate.

THERMAL PROTECTION

The INVERTEC®machine is equipped with a thermal

protection device. When the machine has gone into

thermal overload, the output will be turned off and the

thermal indicator light will be turned “ON“. When the

machine has cooled to a safe temperature, the Thermal

Indicator Light will go out and the machine may resume

normal operation.

Note:

The machine’s welding output will be available after a

thermal protection shutdown.

GENERAL DESCRIPTION

The INVERTEC CC400-S/-S PLUS is a 400A arc welding

power source that utilizes three phases input power, to

produce constant current output. The welding response of

this INVERTEC has been optimized for stick (SMAW) and

TIG (GTAW).

OPERATIONAL FEATURES AND

CONTROLS

FRONT PANEL (SEE FIGURE B.1)

FIGURE B.1

1. A/V DISPLAY SWITCH

When the switch is in position “A” the meter will indicate

preset current or actual output current; When the switch

is in position “V” the meter will indicate actual output

voltage.

2. CURRENT CONTROL POT

This controls the output current. This control may be

adjusted while under load to change power source

output. When using remote control this function becomes

disabled.

3. LOCAL/REMOTE SWITCH

WARNING

B-2 OPERATION B-2

INVERTEC®CC400-S/-S PLUS

Rev.01

Place in the “LOCAL” position to allow output adjustment

at the machine. Place in the “REMOTE” position to allow

output adjustment at remote pot or amptrol.

Note:

The switch is unavailable on CC400-S machine.

4. HOT START POT

Controls the amount of starting energy in stick mode. The

hot start can be either turned on or off. When on, it

provides a striking current at 150% of the set current or

400A whichever is larger then quickly reverts to the set

current in 0.5S.

5. STICK/TIG SWITCH

Stick mode for all stick welding. Output energized when

machine is on.

TIG mode for touch start use. Short circuit current is

limited to approximately 20A to aid in touch starting.

Mode

LOCAL/REMOT

E SWITCH

DIP SWITCH

OUTPUT

Stick

LOCAL &

REMOTE

OFF(DOWN)

ENERGIZED

Stick

REMOTE

ON(UP)

CONTROL

BY REMOTE

SWITCH

TIG

LOCAL &

REMOTE

OFF(DOWN)

ENERGIZED

TIG

REMOTE

ON(UP)

CONTROL

BY REMOTE

SWITCH

Note:

The switch is unavailable on CC400-S machine.

6. DIGITAL DISPLAY METER

The meter displays preset and actual current or actual

voltage.

7. ALARM LIGHT

The machine has these protection functions of

overvoltage, undervoltage, overcurrent and disconnected

relay. The alarm light will be ON when these troubles

occurred, meanwhile the output will be shut down until

fault goes away.

8. THERMAL LIGHT

The light will illuminate if an internal thermostat has been

activated. Machine output will return after the internal

components have returned to a normal operating

temperature. For additional information see Thermal

Protection section in this Operation chapter.

9. ARC FORCE POT

This controls functions in stick modes to adjust the arc

force. The arc is soft at the minimum settings and more

forceful or driving at the maximum settings. Higher

spatter levels maybe present at the maximum settings.

Full range is from 0(soft) to 10(crisp).

10. ON/OFF POWER SWITCH

Place the lever in the upside position to energize the

machine. When the power is on the output will be

energized in STICK mode and TIG mode if the DIP

SWITCH 1 is set to OFF(down). At power up the thermal

light and alarm light will flash for a short time and fan will

start to run.

11.REMOTE CONNECTOR

The remote connector can be used for connecting to

remote control box if customers would like to remotely

control output current.

Note:

The remote connector is unavailable on CC400-S

machine.

12. POSITIVE OUTPUT TERMINAL

13.NEGATIVE OUTPUT TERMINAL

Note:

These quick disconnect terminals provide connection

points for the electrode and work cables. For positive

polarity welding connect the electrode cable to the

positive terminal and the work cable to the negative

terminal. To weld negative polarity reverse the electrode

and work cables.

REAR PANEL (PLEASE SEE FIGURE B.2).

FIGURE B.2

14. INPUT BOX

This insulation box is used to cover the input connections.

This insulation box must be secure before turning on

the main power supply.

15. INPUT CABLE HOLDING BRACKET

This bracket securely holds the three phase power cables

in place.

WARNING

B-3 OPERATION B-3

INVERTEC®CC400-S/-S PLUS

Rev.01

16. GROUND CABLE CONNECTION

Connect the ground cable to the paint-free location on the

case back by securing its lug-end with the screw into the

case hole.

DIP SWITCHES

INVERTEC® CC400-S/-S PLUS machine offers a DIP

switch on the control board, which allows user to have

additional features. There are 2 individual switches

integrated into this DIP switch ( Please see FIGURE B.3

below ).

FIGURE B.3

1. DIP SWITCH 1

Controls when output power is available. Please see 5

STICK/TIG SWITCH section in this Operation chapter for

details.

2. DIP SWITCH 2

The DIP switch is for test mode. It should always be

OFF (down)for customers.

THERMAL PROTECTION

Thermostats protect the machine from excessive

operating temperatures. Excessive temperatures maybe

caused by a lack of cooling air or operating the machine

beyond the duty cycle and output rating. If excessive

operating temperature should occur, the thermostats will

prevent output voltage or current.

Thermostats are self-resetting once the machine cools

sufficiently.

FAN

The fan will run anytime once the machine powers on.

CONSTANT CURRENT PROCESSES

MANUAL ARC WELDING (STICK)

The INVERTEC maybe utilized as a manual DC arc

welder with the electrode cable, work cable, and

electrode holder being the only equipment required.

Note:

If the electrode is shorted to the workpiece for longer than

5 seconds, the machine output current will phase back to

20A until electrode is taken off the workpiece. circuitry

activated.

AIR CARBON ARC CUTTING

Air carbon arc cutting maybe performed with the

INVERTEC within its output rating using 5mm diameter

carbon rods. Output cables, an air carbon arc electrode

cable assembly, and a source of compressed air are

required.

TIG WELDING

The INVERTEC is capable of touch start TIG welding. An

electrode cable, work cable, TIG torch, and gas supply

with regulator are required.

Touch starting is done as follows:

1. Place the shield cup edge on the work piece.

2. Rock the tungsten down to touch.

3. Trigger the output, if using remote control.

4. Gently rock back the tungsten from the

workpiece.

OPTIONS/ACCESSORIES

REMOTE CONTROL BOX

Consists of a control box with choice of three cable

lengths. Permits remote adjustment of output, 6 pin

connection.

Order K69023-8M for 8M or K69023-15M for 15M or

K69023-30M for 30M.

WELDING CABLE WITH ELECTRODE HOLDER

Order K60077-50-3M for 3M, or K60077-50-15M for 15M,

or K60077-50-30M for 30M.

WORK CABLE WITH CLAMP

Order K60076-50-3M for 3M.

TIG TORCH WITH TWIST-MATE

Order K60078-1 for 4M.

C-1TROUBLESHOOTING C-1

INVERTEC®CC400-S/-S PLUS

Rev.01

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 Lincoln Electric

Field Service Facility for technical assistance.

Observe all Safety Guidelines detailed in the beginning and throughout this manual.

Problems (Symptoms)

Possible Areas of Misadjustment(s)

Recommended Course of Action

Output Problems

Major physical or electrical

damage is evident when the

sheet metal covers are removed.

None

Contact your local authorized

Lincoln Electric Field Service

facility for technical assistance.

Input breaker keeps tripping

1. Make certain that fuses or

breakers are properly sized.

See Installation section of this

manual for recommended

fuse and breaker sizes.

2. Welding procedure is drawing

too much output current, or duty

cycle is too high. Reduce

output current, duty cycle, or

both.

3. There is internal damage to

the power source.

If there is internal damage,

contact an authorized Lincoln

Electric Service facility for

technical assistance.

Machine will not power up

(no lights, no fan, etc.)

1. Make certain that the power to

the CC400-S/-S PLUS is

energized and is within the

CC400-S/-S PLUS operating

range.

In a typical installation the

main power switch on the

controller is the power switch.

Thermal LED is lit.

1. Check for proper fan operation.

(Fan should run whenever

output power is on.) Check for

material blocking intake or

exhaust louvers, or for

excessive dirt clogging cooling

channels in machine.

2. Machine may have been

operated above it’s duty

cycle..

Clear obstruction or repair fan

After machine has cooled,

reduce load, duty cycle, or

both

Machine won’t weld, can’t get any

output.

1. The ALARM light is lit, input

voltage is too low or too high.

Make certain that input voltage

is proper, according to the

Rating Plate.

2. If the Thermal LED is also lit, see

Thermal LED is Lit section.

Contact your local authorized

Lincoln Electric Field Service

facility for technical assistance.

Machine won’t produce full

output.

1. Input voltage may be too low,

limiting output capability of the

power source. Make certain

that the input voltage is proper,

according to the Rating Plate.

2. Current or voltage display

meter is not properly

calibrated.

3. Maybe the welding cable and

work cable are too long, or

their across area art too small.

Correct input voltage level.

Contact your local authorized

Lincoln Electric Field Service

facility for technical assistance.

Please shorten welding cable

and work cable, or use bigger

size cables for reducing the

voltage drop on cables.

General degradation of the weld

performance

1. Check for electrode holding

problems, bad connections,

excessive loops in cabling, etc.

2. Verify weld mode is correct for

If the machine need

calibration, contact an

authorized Lincoln Electric

Service facility for technical

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