Lincoln Electric POWERTEC i400S Manual de usuario

IM3132

04/2020

REV00

POWERTEC®i400S

OPERATOR’S MANUAL

ENGLISH

Lincoln Electric Bester Sp. z o.o.

ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland

www.lincolnelectric.eu

English English

12/05

THANKS! For having choosen the QUALITY of the Lincoln Electric products.

Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified

immediately to the dealer.

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

Number can be found on the machine rating plate.

Model Name:

………………...…………………………….…………………………………………………………………………………………..

Code & Serial number:

………………….……………………………………………….. …………………………………………………….……………..

Date & Where Purchased:

…………………………………………………………………... ……………………….…………………………………………..

ENGLISH INDEX

Technical Specifications...................................................................................................................................................... 1

Electromagnetic Compatibility (EMC).................................................................................................................................. 2

Safety.................................................................................................................................................................................. 3

Intoduction........................................................................................................................................................................... 5

Installation and Operator Instructions.................................................................................................................................. 5

WEEE ................................................................................................................................................................................. 9

Spare Parts ......................................................................................................................................................................... 9

REACh ................................................................................................................................................................................ 9

Authorized Service Shops Location .................................................................................................................................... 9

Electrical Schematic............................................................................................................................................................ 9

Accessories Suggested..................................................................................................................................................... 10

Connection configuration................................................................................................................................................... 11

English English

Technical Specifications

NAME INDEX

POWERTEC®i400S K14241-1

INPUT

Input Voltage U1EMC Class Frequency

400V ± 15% 3-phase A 50/60Hz

Input Power at Rated Cycle Input Amperes I1max PF

15 kVA @ 50% Duty Cycle (40°C) 21A 0,90

Efficiency Idle Power

85% 35W

RATED OUTPUT

Open Circuit Voltage

Duty Cycle 40°C

(based on a 10 min.

period)

Output Current Output Voltage

U0peak = 54Vdc

U0rms = 54Vdc

GMAW

50% 350A 31,5Vdc

60% 340A 31,0Vdc

100% 300A 29,0Vdc

FCAW

50% 350A 31,5Vdc

60% 340A 31,0Vdc

100% 300A 29,0Vdc

SMAW

30% 350A 34,0Vdc

60% 320A 32,8Vdc

100% 275A 31,0Vdc

WELDING CURRENT RANGE

GMAW FCAW SMAW

20A÷350A 20A÷350A 10A÷350A

WELDING VOLTAGE REGULATION RANGE

GMAW FCAW

15V÷ 33,5V 15V÷ 33,5V

RECOMMENDED INPUT CABLE AND FUSE SIZES

Fuse Type: Time-Delay or Circuit Breaker Type D Power Lead

400V

25A 4 Conductor, 2,5mm2

DIMENSION

Weight Height Width Length

68kg 932 mm 560 mm 925 mm

Protection Rating Operating Humidity (t=20°C) Operating Temperature Storage Temperature

IP23 ≤90 % from -10 ºC to +40 ºC from -25 ºC to +55 ºC

English English

Electromagnetic Compatibility (EMC)

01/11

This machine has been designed in accordance with all relevant directives and standards. However, it may still generate

electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or

other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand this

section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.

This machine has been designed to operate in an industrial area. The operator must install and operate this

equipment as described in this manual. If any electromagnetic disturbances are detected the operator must put

in place corrective actions to eliminate these disturbances with, if necessary, assistance from Lincoln Electric.

WARNING

Provided that the public low voltage system impedance at the point of common coupling is lower than:

105 mΩfor the POWERTEC®i400S

This equipment is compliant with IEC 61000-3-11 and IEC 61000-3-12 and can be connected to public lowvoltage systems.

It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network

operator if necessary, that the system impedance complies with the impedance restrictions.

Before installing the machine, the operator must check the work area for any devices that may malfunction because of

electromagnetic disturbances. Consider the following.

Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the machine.

Radio and/or television transmitters and receivers. Computers or computer controlled equipment.

Safety and control equipment for industrial processes. Equipment for calibration and measurement.

Personal medical devices like pacemakers and hearing aids.

Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure that

all equipment in the area is compatible. This may require additional protection measures.

The dimensions of the work area to consider will depend on the construction of the area and other activities that are

taking place.

Consider the following guidelines to reduce electromagnetic emissions from the machine.

Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take

additional precautions such as filtering the input supply.

The output cables should be kept as short as possible and should be positioned together. If possible connect the work

piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting the work

piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.

Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special

applications.

WARNING

The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public

low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,

due to conducted as well as radio-frequency disturbances.

English English

Safety

11/04

WARNING

This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair

procedures are performed only by qualified person. Read and understand this manual before operating this equipment.

Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this equipment.

Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages

caused by improper installation, improper care or abnormal operation.

WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,

loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or

death.

READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating this

equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could cause

serious personal injury, loss of life, or damage to this equipment.

ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the electrode,

work clamp, or connected work pieces when this equipment is on. Insulate yourself from the electrode,

work clamp and connected work pieces.

ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the fuse

box before working on this equipment. Ground this equipment in accordance with local electrical

regulations.

ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp

cables. If any insulation damage exists replace the cable immediately. Do not place the electrode holder

directly on the welding table or any other surface in contact with the work clamp to avoid the risk of

accidental arc ignition.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any

conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some pacemakers

and welders having a pacemaker shall consult their physician before operating this equipment.

CE COMPLIANCE: This equipment complies with the European Community Directives.

ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and EN

12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal Protective

Equipment (PPE) having filter with a protection degree up to a maximum of 15, as required by EN169

Standard.

FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to

health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use enough

ventilation or exhaust to keep fumes and gases away from the breathing zone.

ARC RAYS CAN BURN: 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. Use suitable clothing made from durable

flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel with

suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to the arc.

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding area

and have a fire extinguisher readily available. Welding sparks and hot materials from the welding process

can easily go through small cracks and openings to adjacent areas. Do not weld on any tanks, drums,

containers, or material until the proper steps have been taken to insure that no flammable or toxic vapors

will be present. Never operate this equipment when flammable gases, vapors or liquid combustibles are

present.

WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and

materials in work area can cause serious burns. Use gloves and pliers when touching or moving

materials in the work area.

English English

CYLINDER MAY EXPLODE IF DAMAGED: 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. Always keep cylinders in an upright position securely chained to a fixed support. Do not move or

transport gas cylinders with the protection cap removed. Do not allow the electrode, electrode holder,

work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders must be located away

from areas where they may be subjected to physical damage or the welding process including sparks

and heat sources.

SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an

environment with increased hazard of electric shock.

The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time

the operator’s manual.

English English

Intoduction

POWERTEC®i400S inverter source have to be

connected with wire feeder LF52Ds. Signal from the

power source will be displayed on wire feeders user

interface. For communication, inverter source-wire

feeder is used CAN protocol.

Inverter source-wire feed configuration allows the

welding:

GMAW (MIG/MAG);

FCAW;

SMAW (MMA).

The complete packaging includes the following items:

Inverter source;

USB with Operator’s Manual;

Work lead - 3m;

Slow-blow fuse – 2A (2 units);

Gas hose -2m;

Chain.

Recommended equipment, which can be bought by the

user, was mentioned in the chapter "Accessories

Suggested".

Installation and Operator Instructions

Read this entire section before installation or operation

of the machine.

Location and Environment

This machine can be operate in harsh environment.

However, it is important to use simple preventative

measures, which provide long life and reliable operation.

Do not place or operate this machine on a surface with

an incline higher than 15° from horizontal.

Do not use this machine for pipe thawing.

This machine must be located in a place where there

is free circulation of clean air without restrictions for air

movement to and from the air vents. Do not cover the

machine with paper, cloth or rags when switched on.

Keep awaz from dirt and dust that can be drawn into

the machine should be kept to a minimum.

This machine has a protection rating of IP23. Keep it

dry when possible and do not place it on a wet ground

or in puddles.

Locate the machine away from radio controlled

machinery. Normal operation may adversely affect the

operation of nearby radio controlled machinery, which

may result in injury or equipment damage. Read the

section on electromagnetic compatibility in this

manual.

Do not operate in areas with an ambient temperature

higher than 40°C.

Duty cycle and Overheating

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.

Example: 60% duty cycle

Welding for 6 minutes. Break for 4 minutes.

Excessive extension of the duty cycle will cause the

thermal protection circuit to activate.

Minutes or decrease

duty cycle

Input Supply Connection

WARNING

Only a qualified electrician can connect the welding

machine to the supply network. Installation the outlet plug

to power lead and connecting the welding machine had to

be made in accordance with the appropriate National

Electrical Code and local regulations.

Check the input voltage, phases, and frequency supplied

to this machine before turning it on. Verify the

connection of grounding wires from the machine to the

input power source. POWERTEC®i400S can only be

connected to a mating grounded receptacle.

Input voltages is 3x400V 50/60Hz. For more information

about input supply please refer to the technical

specification section of this manual and to the rating

plate of the machine.

Make sure that the amount of mains power available

from the input supply is adequate for normal operation of

the machine. The type of protection and cable sizes are

indicated in the technical specification section of this

manual.

WARNING

The welding machine can be supplied from a power

generator of output power at least 30% larger than input

power of the welding machine.

See "Technical Specifications" chapter.

WARNING

In case of powering welder from a generator make sure to

turn off welding machine first, before generator is shut

down, in order to prevent damage to welding machine!

Output Connections

Refer to points [2], [3] and [4] of the figures below.

English English

Controls and Operational Features

Figure 1.

1. Power Switch ON/OFF (I/O): Controls the input

power. Make sure the power source is properly

connected to the mains supply before turning power

on ("I").

2. Negative Output Socket for the Welding

Circuit: Depending on the configuration of

power source, for connecting a work lead,

the electrode holder with lead or the source/wire

feeder welding cable.

3. Positive Output Socket for the Welding

Circuit: Depending on the configuration of

power source, for connecting a work lead,

the electrode holder with lead or the source/wire

feeder welding cable.

4. Control Receptacle: 5 pins receptacle for

wire feeder or remote controller

connection. To communication wire

feeder or remote controller with power

source is used CAN protocol.

5. Gas Connector: For connection a gas hose from

interconnecting cable.

Figure 2.

6. Supply Plug: for gas heater kit (see “Accessories

Suggested” chapter).

7. Power Lead (5m): Connect the supply plug to the

existing input cable that is rated for the machine as

indicated in this manual, and conforms to all

applicable standards. This connection shall be

performed by a qualified person only.

8. Gas Connector: For connection a gas hose from

cylinder.

9. Top Chain: To protect gas bottle.

10. Bottom chain: For properly securing the gas cylinder

WARNING

Not using both chains at the same time to secure the gas

cylinder may result in damage to the cylinder, the device

and personal injury.

11. Gas hose: For connection between the cylinder and

machine.

12. Mass welding cable

13. Cover bracket: To install the welding and control

sockets on the rear panel of the device (see chapter

"Accessories Suggested") to connect the wire feeder.

English English

Figure 3.

14. Fuse F1: Use the 2A/400V (6,3x32mm) low blow

fuse.

Welding Cables Connection

Insert the plug of the work lead into the socket [2]. The

other end of this lead connect to the work piece with the

work clamp.

Connect the wire feeder to the power source:

Insert the positive welding cable into the output socket

[3].

Insert the wire feeder control cable into the socket [4]

(see "Accessories Suggested" chapter).

Use the possible shortest cable lengths.

Machine and Circuit Protection

Power Source is protected against overheating, overload

and accidental short-circuits.

If the machine is overheated, the thermal protection circuit

will decrease the output current to 0. This information will

be shown by wire feeder user interface. Please refer to

wire feeder user manual.

Transport & Lifting

WARNING

Falling equipment can cause injury and

damage to unit.

POWERTEC i400S

Figure 4.

During transportation and lifting with a crane, adhere to

the following rules:

The device contains elements adapted for transport.

For lifting a suitable lifting equipment capacity.

For lifting and transport use minimum four belts.

Lift and transport only power source without gas

cylinder, cooler and wire feeder, or/and any other

accessories.

English English

Maintenance

WARNING

For any repair operations, modifications or maintenances,

it is recommended to contact the nearest Technical

Service Center or Lincoln Electric. Repairs and

modifications performed by unauthorized service or

personnel will cause, that the manufacturer’s warranty will

be lost.

Any noticeable damage should be reported immediately

and repaired.

Routine maintenance (everyday)

Check condition of insulation and connections of the

work leads and insulation of power lead. If any

insulation damage exists replace the lead

immediately.

Remove the spatters from the welding gun nozzle.

Spatters could interfere with the shielding gas flow to

the arc.

Check the welding gun condition: replace it, if

necessary.

Check condition and operation of the cooling fan.

Keep clean its airflow slots.

Periodic maintenance (every 200 working hours, but

at list once a year)

Perform the routine maintenance and, in addition:

Keep the machine clean. Using a dry (and low

pressure) airflow, remove the dust from the external

case and from the cabinet inside.

If it is required, clean and tighten all weld terminals.

The frequency of the maintenance operations may vary

according to the working environment where the

machine is placed.

WARNING

Do not touch electrically live parts.

WARNING

Before the case of welding machine will be removed, the

welding machine has to be turned off and the power lead

had to be disconnected from mains socket.

WARNING

Mains supply network must be disconnected from the

machine before each maintenance and service. After

each repair, perform proper tests to ensure safety.

Customer Assistance Policy

The business of The Lincoln Electric Company is

manufacturing and selling high quality welding

equipment, consumables, and cutting equipment. Our

challenge is to meet the needs of our customers and to

exceed their expectations. On occasion, purchasers may

ask Lincoln Electric for advice or information about their

use of our products. We respond to our customers

based on the best information in our possession at that

time. Lincoln Electric is not in a position to warrant or

guarantee such advice, and assumes no liability, with

respect to such information or advice. We expressly

disclaim any warranty of any kind, including any

warranty of fitness for any customer’s particular purpose,

with respect to such information or advice. As a matter of

practical consideration, we also cannot assume any

responsibility for updating or correcting any such

information or advice once it has been given, nor does

the provision of information or advice create, expand or

alter any warranty with respect to the sale of our

products

Lincoln Electric is a responsive manufacturer, but the

selection and use of specific products sold by Lincoln

Electric is solely within the control of, and remains the

sole responsibility of the customer. Many variables

beyond the control of Lincoln Electric affect the results

obtained in applying these types of fabrication methods

and service requirements.

Subject to Change – This information is accurate to the

best of our knowledge at the time of printing. Please

refer to www.lincolnelectric.com for any updated

information.

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