Lincoln Electric INVERTEC CC400-S User manual

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
Copyright © 2012 The Shanghai Lincoln Electric Company
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
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
1
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