Lincoln Electric SPEEDTEC 400S Bedienungsanleitung

IM3020

01/2012

Rev. 6

SPEEDTEC 400S & 500S

OPERATOR’S MANUAL

MANUALE OPERATIVO

BEDIENUNGSANLEITUNG

MANUAL DE INSTRUCCIONES

MANUEL D'UTILISATION

BRUKSANVISNING OG DELELISTE

GEBRUIKSAANWIJZING

BRUKSANVISNING

INSTRUKCJA OBSŁUGI

KÄYTTÖOHJE

MANUAL DE INSTRUÇÕES

ИНСТРУКЦИЯ ПО ЭКСПЛУАТАЦИИ

Lincoln Electric Bester Sp. z o.o.

ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland

www.lincolnelectric.eu

English English

Declaration of conformity

Lincoln Electric Bester Sp. z o.o.

Declares that the welding machine:

SPEEDTEC 400S

SPEEDTEC 500S

conforms to the following directives:

2006/95/CEE, 2004/108/CEE

and has been designed in compliance with the

following standards:

EN 60974-1, EN 60974-10

(2009)

Paweł Lipiski

Operations Director

Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland

12/05

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

Safety ..............................................................................................................................................................................1

Installation and Operator Instructions..............................................................................................................................2

Electromagnetic Compatibility (EMC) ..............................................................................................................................5

Technical Specifications .................................................................................................................................................. 5

WEEE..............................................................................................................................................................................6

Spare Parts......................................................................................................................................................................6

Electrical Schematic ........................................................................................................................................................6

Accessories .....................................................................................................................................................................6

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.

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.

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

an environment with increased hazard of electric shock.

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.

Installation and Operator Instructions

Read this entire section before installation or operation

of the machine.

Location and Environment

This machine will operate in harsh environments.

However, it is important that simple preventative

measures are followed to assure long life and reliable

operation:

•Do not place or operate this machine on a surface

with an incline greater than 15°from horizontal.

•Do not use this machine for pipe thawing.

•This machine must be located 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.

•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 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 greater 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

Installation and mains outlet socket shall be made and

protected according to appropriate rules.

Check the input voltage, phase, and frequency supplied

to this machine before turning it on. Verify the

connection of grounding wires from the machine to the

input source. The allowable input voltages is 3x400V

50/60Hz. For more information about input supply refer

to the technical specification section of this manual and

to the rating plate of the machine.

WARNING

This machine is not designed to operate on engine

driven generators. Operation of this machine with engine

driven generators may damage the machine.

Make sure that the amount of mains power available

from the input supply (connection) is adequate for

normal operation of the machine. The necessary fuse

(or circuit breaker) and cable sizes are indicated in the

technical specification section of this manual.

Refer to points [1] and [12] of the images below.

Output Connections

Refer to points [4], [5] and [6] of the images below.

Controls and Operational Features

1. Power Switch ON/OFF (O/I): It controls the

machine power input. Be sure the power source is

connected to the mains supply before turning power

on ("I").

2. Status Light: A two color light that indicates system

errors. Normal operation is steady green light. Error

conditions are indicated, per TABLE 1.

NOTE: The status light will flash green, and

sometimes red and green, for up to one minute

English English

when the machine is first turned on. This is a

normal situation as the machine goes through a self

test at power up.

TABLE 1

Light Condition Meaning

Steady Green System O.K. Power source

comunicating normaly with wire

feeder.

Blinking Green Occurs during a reset, and indicates

the power source is mapping

(identyfying) each component in the

systems. Normal for first 1-10

seconds after power is turned on, or

if the system configuration is

changed during operation.

Alternating

Green and Red

Non-recoverable system fault. If the

PS status light is flashing any

combination of red and green, errors

are present in power source.

Individual code digits are flashed in

red with a long pause between digits.

If more then one code is present, the

codes will be separated by green

light. Read the error code before the

machine is turned off.

If occurs, to clear the error try to turn

Off the machine, wait for a few

seconds, then turn ON again. If the

error remains, a maintenance is

required. Please contact the nearest

technical service center or Lincoln

Electric and report the error code

readed.

Steady Red Non recoverable hardware fault.

Generally indicates nothing is

connected to the power source wire

feeder receptacle.

Blinking Red Not applicable.

3. Thermal Indicator Light: It indicates that the

machine is overloaded or that the cooling is not

sufficient.

4. Negative Output Socket: For connecting the return

welding cable.

5. Control Socket: 5 pins receptacle for wire feeder or

remote controller connection. To communication

wire feeder with power source is used ArcLink

protocol.

6. Positive Output Socket: Allows the connection, with

the power cable, to the wire feeder.

7. Gas Heater Socket: U

sup

= 24VAC, P

max

= 80W.

8. Fuse Socket F3: The recommended fuse

12,5A/400V (6,3x32mm).

WARNING

You have to use fuses with technical specifications

given by the producer.

9. Fuse Socket F4: The recommended fuse

6,3A/400V (6,3x32mm).

WARNING

You have to use fuses with technical specifications

given by the producer.

10. Fuse Socket F1: The recommended fuse 2A/400V

(6,3x32mm).

WARNING

You have to use fuses with technical specifications

given by the producer.

11. Fuse Socket F2: The recommended fuse 2A/400V

(6,3x32mm).

WARNING

You have to use fuses with technical specifications

given by the producer.

12. Power Input Cable: Connect the proper plug to the

input cable then into the rated output according to

appropriate rules. Only qualified personnel shall

connect this plug.

13. Diagnostic Connector (RS232): female 9 pins D-Sub

receptacle for connecting the the personal

computer.

English English

14. Cooler Power Supply Socket: The socket has an

output of 400VAC to supplying water cooler (it is

protected by the circuit breaker [10]).

WARNING

Read and understand the cooler manual before

connecting it to the machine.

Welding Cables Connections

Insert the plug of the work cable into the socket [4]. The

other end of this cable connects to the work piece with

the work clamp.

Connect the wire feeder LF 45 to the power source:

•Insert the positive welding cable into the output

socket [6].

•Insert the wire feeder control cable into the socket

[5] (see Accessories, Source/wire feeder cable

K10349-PG-xM or K10349-PGW-xM).

Use the shortest possible cable lengths.

Water Cooler Connections

Connect the water cooler Coolarc 45 to the power

source:

•Remove the rubber grommet from the bottom panel.

•Remove the jumper from the cooler power supply

socket [13].

•Thread the water cooler supply plug through the

rubber grommet.

•Insert the water cooler cable into the socket [13].

•Instert the rubber grommet into the bottom panel

hole.

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. The thermal

protection indicator [3] will turn on.

The Power Source is also electronically protected

against overload and accidental short-circuit. The

overload and short-circuit protection circuit automatically

reduces the output current to a safe value when it

detects an overload.

Maintenance

WARNING

For any maintenance or repair operations it is

recommended to contact the nearest technical service

center or Lincoln Electric. Maintenance or repairs

performed by unauthorized service centers or personnel

will null and void the manufacturers warranty.

The frequency of the maintenance operations may vary

in accordance with the working environment where the

machine is placed.

Any noticeable damage should be reported immediately.

Routine maintenance (everyday)

•Check cables and connections integrity. Replace, if

necessary.

•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.

English English

Periodic maintenance (every 200 working hours

but not more rarely than once a year)

Perform the routine maintenance and, in addition:

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

pressure) airflow, remove the dust from the external

case and from inside of the cabinet.

•Check and tighten all screws.

WARNING

Mains supply network must be disconnected from the

machine before each maintenance and service. After

each repair, perform proper tests to ensure safety.

Electromagnetic Compatibility (EMC)

11/04

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.

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.

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

EMC classification of this product is class A in accordance with electromagnetic compatibility standard EN 60974-10 and

therefore the product is designed to be used in an industrial environment only.

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 may be potential difficulties in ensuring electromagnetic compatibility in those

locations, due to conducted as well as radiated disturbances.

Technical Specifications

INPUT

Input Power at Rated Output

SMAW 17.1 kVA @ 80% duty cycle

GTAW-DC 12.8 kVA @ 80% duty cycle

400S:

GMAW 16.2 kVA @ 80% duty cycle

SMAW 24.0 kVA @ 60% duty cycle

GTAW-DC 18.4 kVA @ 60% duty cycle

Input Voltage

400 V ±10%

Three Phase 500S:

GMAW 23.3 kVA @ 60% duty cycle

Frequency

50/60 Hz

RATED OUTPUT AT 40°C

Duty Cycle

(Based on a 10 min. period)

Output Current

Output Voltage

80% 400 A 36.0 Vdc

SMAW 100% 390 A 35.5 Vdc

80% 400 A 26.0 Vdc

400S:

GTAW-DC 100% 390 A 25.5 Vdc

English English

80% 400 A 34.0 Vdc

GMAW 100% 390 A 33.5 Vdc

60% 500 A 40.0 Vdc

SMAW 100% 390 A 35.5 Vdc

60% 500 A 30.0 Vdc

GTAW-DC 100% 390 A 25.5 Vdc

60% 500 A 39.0 Vdc

500S:

GMAW 100% 390 A 33.5 Vdc

OUTPUT RANGE

Welding Current Range Maximum Open Circuit Voltage

SMAW 5 A – 400 A

GTAW-DC 5 A – 400 A

400S: GMAW 20 A – 400 A

SMAW 5 A – 500 A

GTAW-DC 5 A – 500 A

500S: GMAW 20 A – 500 A

400S:

500S: 73 Vdc

RECOMMENDED INPUT CABLE AND FUSE SIZES

Fuse or Circuit Breaker Size Input Power Cable

400S: 25 A, Z curve recommended

500S: 40 A, Z curve recommended 400S:

500S: 4 x 4 mm

PHYSICAL DIMENSIONS

Height Width Length Weight

400S:

500S: 476 mm 305 mm 600 mm 50 kg

Operating Temperature

-10°C to +40°C Storage Temperature

-25°C to +55°C

WEEE

07/06

English

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE)

and its implementation in accordance with national law, electrical equipment that has reached the end of its

life must be collected separately and returned to an environmentally compatible recycling facility. As the

owner of the equipment, you should get information on approved collection systems from our local

representative.

By applying this European Directive you will protect the environment and human health!

Spare Parts

12/05

Part List reading instructions

•Do not use this part list for a machine if its code number is not listed. Contact the Lincoln Electric Service

Department for any code number not listed.

•Use the illustration of assembly page and the table below to determine where the part is located for your particular

code machine.

•Use only the parts marked "X" in the column under the heading number called for in the assembly page (# indicate

a change in this printing).

First, read the Part List reading instructions above, then refer to the "Spare Part" manual supplied with the machine, that

contains a picture-descriptive part number cross-reference.

Electrical Schematic

Refer to the "Spare Part" manual supplied with the machine.

Accessories

K10349-PG-XM Source wire/feeder cable (gas). Available in 5, 10,15, 20, 25 or 30m

K10349-PGW-XM Source wire/feeder cable (gas and water). Available in 5, 10,15, 20, 25 or 30m

K14067-1 Water cooler Coolarc 45

K14075-1 Assembly kit: Speedtec – Coolarc 45 (brackets)

K14074-1 Undercarriage with cylinder holder

K14033-1 Work cable

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