Lincoln Electric RED-D-ARC FX650XL Operator's Manual
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Lincoln Electric RED-D-ARC FX650XL Operator's Manual

Lincoln Electric RED-D-ARC FX650XL Operator's Manual

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IM10391
RED-D-ARC
August 2017
FX650XL
For use with machines having Code Numbers: 12599
OPERATOR'S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This welder is designed and built with safety in mind.
However, your overall safety can be increased by proper installation
... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.
And, most importantly, think before you act and be careful.
1-800-245-3660
North America's Largest Fleet of Welding Equipment

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Summary of Contents for Lincoln Electric RED-D-ARC FX650XL

  • Page 1 OPERATOR’S MANUAL Red-D-Arc Spec-Built Welding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on You This welder is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
  • Page 4 S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Page Installation....................... Section A Technical Specifications....................... A-1, A-2 Safety Precautions........................A-3 VRD™ (Voltage Reduction Device)......................A-3 Select Suitable Location....................... A-3 Lifting...........................A-3 Stacking..........................A-3 Environmental Limitations....................A-3 Input and Grounding Connections..................A-3 High Frequency Protection....................A-3 High Temperature Operation......................A-3 Input Connection .........................A-4 Input Fuse and Supply Wire Considerations..................A-4 Input Voltage Selection.........................A-4 Cable Connections........................
  • Page 7 FX650XL INSTALLATION TECHNICAL SPECIFICATIONS - FX650XL POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Duty Cycle Input Voltage ± 10% Input Amperes Power Factor @ Idle Power Effective Rated Output 60% rating 61 / 50 / 40 230 MAX.( Fan On) K3437-1 380 / 460 / 575 / 3 / 50 / 60 100% rating 100 MAX.
  • Page 8 FX650XL INSTALLATION WELDING PROCESS OUTPUT RANGE (AMPERES) OCV (U OCV (U PROCESS GMAW (CV) 40-815 GTAW (CC) 10-815 SMAW (CC) 15-815 40-815 FCAW-G (CV) FCAW-S (CV) 40-815 SAW (CV) 40-815 PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT 165lbs (74.8kg)* 29.33 in (745 mm) K3437-1 21.8 in (554 mm) 16.14 in (410 mm)

  • Page 9: Installation

    FX650XL INSTALLATION INSTALLATION WARNING LIFTING The FX650XL has 2 lifting eyelets and 2 handles that can be used to lift the machine. Both handles or both eyelets should be used ELECTRIC SHOCK can kill. when lifting the FX650XL. • Only qualified personnel should When using a crane or overhead device to lift using the handles, a lifting strap should be connected to both handles.

  • Page 10: High Temperature Operation

    FX650XL INSTALLATION HIGH TEmPERATURE OPERATION INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS WELDER OUTPUT RATINGS AT 55°C Refer to Specification in this Installation Section for recommended ELEVATED TEMPERATURES fuse, wire sizes and type of the copper wires. Fuse the input AMPS Duty Cycle Volts Temperatures...

  • Page 11: Cable Connections

    FX650XL INSTALLATION CAbLE CONNECTIONS See FIGURE A.2 for locating 5, 12 and 14 pin connectors on the front of the FX650XL. FIGURE A.2 12-PIN ACCESSORY CONNECTIVITY Function Wiring A ArcLink CAN B ArcLink CAN C Remote potentiometer, common 12-pin remote D Remote potentiometer wiper control connector for...

  • Page 12: Output Cable Guidelines

    FX650XL INSTALLATION The following recommendations apply to all output polarities and weld modes: RECOmmENDED ELECTRODE AND WORk CAbLE • Select the appropriate size cables per the “Output Cable SIZES FOR ARC WELDING Guidelines” (See Table A.1). Excessive voltage drops General Guidelines caused by undersized welding cables and poor connections often result in unsatisfactory welding performance.

  • Page 13: Control Cable Connections, Paralleling

    FX650XL INSTALLATION CONTROL CAbLE CONNECTIONS Regarding cable placement, best results will be obtained when General Guidelines control cables are routed separate from the weld cables. This minimizes the possibility of interference between the high currents flowing through the weld cables, and the low level signals in the Genuine Lincoln control cables should be used at all times (except control cables.
  • Page 14 FX650XL INSTALLATION CONNECTING LF-72 AND LF-74 TO THE FX650XL WIRE FEEDER 14-PIN CONTROL CABLE K1797-XX LF-72 ELECTRODE LF-74 FX650XL WORK CONTROL SETTING WELD MODE CV, CV-INNERSHIELD WELD TERMINALS LOCAL REMOTE/LOCAL (REMOTE IF K2329-1 INSTALLED) VOLTMETER POLARITY PROCESS DEPENDENT...
  • Page 15 FX650XL INSTALLATION CONNECTING LN-10 AND DH-10 TO THE FX650XL WIRE FEEDER 14-PIN CONTROL CABLE K1501-XX LN-10 DH-10 FX650XL ELECTRODE WORK CONTROL SETTING WELD MODE CV, CV-INNERSHIELD WELD TERMINALS REMOTE/LOCAL REMOTE VOLTMETER POLARITY PROCESS DEPENDENT LN-10,DH-10 CONTROL SWITCH SETUP Setting the DIP Switches Initial set up of the LN-10, DH-10 control for the system components being used and for general operator preferences The DIP switches are each labeled with an “ON”...
  • Page 16 FX650XL INSTALLATION CONNECTING LN-25 PRO, LN-25 PIPE, ACTIV8 TO THE FX650XL WIRE FEEDER LN-25 PRO LN-25 PIPE FX650XL ELECTRODE ACTIV8 WORK CLIP WORK CONTROL SETTING WELD MODE CV, CV-INNERSHIELD WELD TERMINALS REMOTE/LOCAL LOCAL PROCESS DEPENDENT VOLTMETER POLARITY CONNECTING LN-25 PRO DUAL POWER TO THE FX650XL WIRE FEEDER CONTROL CABLE K1797-XX LN-25 PRO...
  • Page 17 FX650XL INSTALLATION CONNECTING LN-7 TO THE FX650XL WIRE FEEDER 14-PIN CONTROL CABLE K1818-XX LN-7 FX650XL ELECTRODE WORK CONTROL SETTING CV, CV-INNERSHIELD WELD MODE WELD TERMINALS REMOTE/LOCAL LOCAL VOLTMETER POLARITY PROCESS DEPENDENT CONNECTING LN-8 AND LN-9 TO THE FX650XL WIRE FEEDER 14-PIN CONTROL CABLE K1820-XX LN-8 LN-9...
  • Page 18 FX650XL INSTALLATION CONNECTING NA-3, NA-5 TO THE FX650XL WIRE FEEDER 14-PIN CONTROL CABLE K1820-XX NA-3 NA-5 FX650XL ELECTRODE WORK FOR NA-3, NA-4 WIRE FEEDERS ONLY: - MOVE JUMPER LEAD ON VARIABLE VOLTAGE BOARD TO "L" PIN. FOR NA-5 WIRE FEEDER ONLY: - MOVE "BLUE"...

  • Page 19: Operation

    FX650XL OPERATION OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. WARNING ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases.

  • Page 20: Graphic Symbols

    FX650XL OPERATION GRAPHIC SYmbOLS THAT APPEAR ON THIS mACHINE OR IN THIS mANUAL REDUCED OPEN INPUT POWER CIRCUIT VOLTAGE OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE HIGH TEMPERATURE INPUT CURRENT CIRCUIT BREAKER OUTPUT CURRENT PROTECTIVE WIRE FEEDER GROUND WARNING or CAUTION POSITIVE OUTPUT Read &...

  • Page 21: Product Description

    FX650XL OPERATION PRODUCT DESCRIPTION RECOmmENDED PROCESSES The FX650XL is a multi-process CC/CV DC inverter and is rated for The FX650XL is designed for CC-SMAW, CC-GTAW (lift tig), CV- 650 amps, 44 volts at a 100% duty cycle. The GMAW, CV-FCAW-S, CV-FCAW-G and CV-SAW welding processes. FX650XL is intended for both factory and field operation.
  • Page 22 FX650XL OPERATION 10. Wire Feeder Voltmeter polarity selection switch CASE FRONT CONTROL DESCRIPTIONS 11. 115V or 42V wire feeder selector switch (See Figure B.1) 1. Power Switch: Controls input power to the FX650XL 12. 14-pin wire feeder circular connector 2. Voltage Display Meter 13.

  • Page 23: Case Back Controls

    FX650XL OPERATION CASE bACk CONTROLS (See Figure B.2) 1. Input Power Cord Access Hole. 2. Access Panel – Allows access for connecting input power and configuring the machine. 3. Input Power Reconnect – Configures the machine for the input supply voltage. 4.

  • Page 24: Internal Controls

    FX650XL OPERATION Multi-Weld™ Mode INTERNAL CONTROLS - ENAbLING VRD, mULTI-WELD AND CURRENT/VOLTAGE When DIP switch # 3 is ON and the Multi-Weld™ mode is CALIbRATION selected, all knob settings on the case front are ignored. The Internal Controls Description machine is set to deliver maximum output (80VDC) and performance for use with Multi-Weld™...

  • Page 25: Power-Up Sequence

    Many variables beyond the control of The • Full range selection of arc control from -10 to +10. In CV Lincoln Electric Company affect the results obtained in mode, this control is an inductance control. In stick mode, applying these programs.
  • Page 26 FX650XL OPERATION Control - Local/Remote Toggle Switch bASIC mODES OF OPERATION • Set the switch to “local” to control output at the FX650XL via the Output Control dial. SMAW • Set the switch to “remote” to control output via a remote device (K857-2 hand amptrol or K870-2 foot amptrol) This weld mode is a constant current (CC) mode featuring connected to the 12-pin remote connector or a wire feeder...
  • Page 27 FX650XL OPERATION GTAW CV-Gas This weld mode is a constant current (CC) mode featuring This weld mode is a constant voltage (CV) mode featuring continuous control from 10 – 815 amps. It is intended for the continuous control from 10 to 45 volts. It is intended for the GTAW tig welding processes.
  • Page 28 FX650XL OPERATION Multi-Weld™ CV-SAW This weld mode automatically sets the machine to deliver This weld mode is a constant voltage (CV) mode featuring maximum output and performance for use with Multi-Weld™ continuous control from 10 to 45 volts. It is intended for the CV- equipment.
  • Page 29 FX650XL OPERATION Arc Link CrossLinc™ This weld mode is intended to unlock basic non-synergic and CrossLinc™ is a new welding system communication technology. synergic modes intended for use with compatible ArcLink wire When using a CrossLinc™ enabled power source such as the feeders.

  • Page 30: Accessories

    FX650XL ACCESSORIES OPTIONS / ACCESSORIES TIG Options General Options Pro-Torch™ TIG Torches – PTA-9, PTA- K2149-1 Work Lead Package. 17, PTA-26 – 2 piece power cord. Foot Amptrol - Provides 25 ft. (7.6 m) of K1842-10 10ft. Weld Power Cable (Lug to Lug). remote current control for TIG welding.

  • Page 31: Maintenance

    FX650XL MAINTENANCE MAINTENANCE PERIODIC  mAINTENANCE WARNING Safety Precautions Thermal Protection Thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of ELECTRIC SHOCK can kill. cooling air or operating the machine beyond the duty cycle and output rating.

  • Page 32: Voltage Calibration

    FX650XL MAINTENANCE VOLTAGE CALIbRATION TO RESTORE FACTORY CURRENT CALIbRATION 1. Connect a resistive load bank to the machine configured for 1. Connect the resistive load bank and test voltmeter to the 300A/20V (750A/50V equivalent). welding output terminals. 2. Connect a certified calibrated voltmeter to the output circuit. 2.

  • Page 33: How To Use Troubleshooting Guide

    FX650XL TROUBLESHOOTING TROUBLESHOOTING How to Use troUblesHooting gUide WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
  • Page 34 FX650XL TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION BASIC MACHINE PROBLEMS Major physical or electrical damage is 1. Contact your local authorized Lincoln evident when the sheet metal covers are Electric Field Service facility for technical removed.
  • Page 35 FX650XL TROUBLESHOOTING USING THE STATUS LED TO TROUbLESHOOT Included in this section is information about the fault codes SYSTEm PRObLEmS indicated on the status lights and some basic troubleshooting charts for both machine and weld performance. Errors are displayed on the amperage and voltage display meters. The status lights on the main control board and the switch pc In addition, there are status lights on the control pc board and the board are dual-color LED’s.
  • Page 36 FX650XL DIAGRAMS FRONT OF MACHINE...
  • Page 37 FX650XL DIAGRAMS...
  • Page 38 FX650XL - 12599...
  • Page 39 Index of Sub Assemblies - 12599 PART NUMBER DESCRIPTION P-1147-A INDEX OF SUB ASSEMBLIES P-1147-C CASE FRONT ASSEMBLY P-1147-D DIVIDER PANEL ASSEMBLY P-1147-E BASE ASSEMBLY P-1147-F CASE BACK ASSEMBLY P-1147-G COVERS ASSEMBLY FX650XL - 12599...
  • Page 40 Index of Sub Assemblies - 12599 P-1147-A.jpg FX650XL - 12599...
  • Page 41 Case Front Assembly PART NUMBER DESCRIPTION 9SG7035-10 CASE FRONT ASSEMBLY 9SG7061-4 CASE FRONT WELDED ASBLY 9SG9055 NAMEPLATE 9SG9055 NAMEPLATE 9SS16656-4 OUTPUT TERMINAL ASBLY 9SCF000371 #10-24X.50HHCS-FULL-GR2-3147 9SG6864 OUTPUT STUD COVER 9SS9225-100 SELF TAPPING SCREW 9SS9262-184 WASHER 9ST12287-20 CIRCUIT BREAKER-10A250VAC 9SS22061-3 SEALING BOOT 9ST12287-8 CIRCUIT BREAKER 9SS22061-2...
  • Page 42 Case Front Assembly PART NUMBER DESCRIPTION 9SM22778-1 KNOB 1.0" 9SM22778-2 KNOB 1.5" 9SM22778-3 KNOB 9SM22692-2 FRONT HANDLE SUPPORT 9SS9225-66 SELF TAPPING SCREW 9SS20030-1 LINE SWITCH 9SS25384-1 SWITCH COVER - WEATHER RESISTANT 9SCF000373 #10-32X.50PRHS-FULL-GR2-4265 9ST9695-1 LOCKWASHER 9SS28393-5 OUTPUT SNUBBER ASBLY 9SS9262-1 PLAIN WASHER 9SE106A-15 LOCKWASHER...
  • Page 43 Case Front Assembly P-1147-C.jpg FX650XL - 12599...
  • Page 44 Divider Panel Assembly PART NUMBER DESCRIPTION 9SG7033-4 DIVIDER PANEL ASSEMBLY 9SG7037-4 DIVIDER PANEL 9SCF000010 #10-24HN 9SE106A-1 LOCKWASHER 9ST13637-6 DIODE-BRIDGE35A400VF-W1-PH 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SM22062-3 INPUT RECTIFIER ASSEMBLY 9SS24574-1 INPUT HEATSINK 9SM15454-18 INPUT RECTIFIER MODULE 9SE106A-1 LOCKWASHER 9SS25930-5 TORX BUTTON HEAD SCREW #10-24X.62 9SS9262-98 PLAIN WASHER 9SE106A-2...
  • Page 45 Divider Panel Assembly PART NUMBER DESCRIPTION 9SL16423-1 40 V BUS PC BD ASBLY 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SS13490-157 CAPACITOR-ALEL24000100V+300/-10% 9SS11604-65 SET SCREW 9SS9262-23 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000198 1/4-28HN 9SS27974 CAPACITOR BRACKET 9SS22745-3 CAPACITOR INSULATION 9SE106A-2 LOCKWASHER 9SCF000017 1/4-20HN 9SS18504-6 CURRENT TRANSDUCER 9SS28515 TRANSDUCER SPACER 9SS9225-36...
  • Page 46 Divider Panel Assembly P-1147-D.jpg FX650XL - 12599...
  • Page 47 Base Assembly PART NUMBER DESCRIPTION 9SG7031-10 BASE ASSEMBLY 9SG7025-1 BASE 9SL13138 CORNER CAP 9SS9262-183 PLAIN WASHER 9SS9225-66 SELF TAPPING SCREW 9SM22557-2 MOUNTING BRACKET 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SS28070 QUICK LOCK FOOT 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000013 1/4-20X.625HHCS 9SS29204 SUPPORT PLATE 9SS9225-68 THREAD FORMING SCREW (CUTTING)
  • Page 48 Base Assembly PART NUMBER DESCRIPTION 9SCF000013 1/4-20X.625HHCS 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9ST11827-26 CARRIAGE BOLT 9SS9262-12 PLAIN WASHER 9SS28866 COPPER PLATE 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000060 1/4-28HJN 9ST13359-24 THERMOSTAT 9SS8025-113 SELF TAPPING SCREW 9SS9225-66 SELF TAPPING SCREW 9SG8746 SWITCHBOARD ASBLY 9SS9225-66 SELF TAPPING SCREW 9SS23224...
  • Page 49 Base Assembly P-1147-E.jpg FX650XL - 12599...
  • Page 50 Case Back Assembly PART NUMBER DESCRIPTION 9SG7032-6 CASE BACK ASSEMBLY 9SG7028-4 CASE BACK 9SS32099 RECEPTACLE 9SS21088 RECEPTACLEGASKET 9SM16996 RECEPTACLE COVER 9SS9225-63 THREAD FORMING SCREW (CUTTING) 9SS25793 DECAL 9SS18250-1105 PLUG AND LEAD ASBLY 9SM22071 9SS25930-14 M6 X 1.00 TBHS-FULL-4554 9SS19999-3 CORD GRIP CONNECTOR 9ST14370-6 CONDUIT LOCKNUT 9ST12287-22...
  • Page 51 Case Back Assembly P-1147-F.jpg FX650XL - 12599...
  • Page 52 Covers Assembly PART NUMBER DESCRIPTION 9SG7026-3 LEFT CASE SIDE 9ST10097-3 TINNERMAN SPEED GRIP NUT RETAINER 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SG9103 CASE SIDE DECAL 9SG7027-3 RIGHT CASE SIDE 9SG9103 CASE SIDE DECAL 9SG7030-1 CASE TOP WRAPAROUND 9SS9225-66 SELF TAPPING SCREW 9SG8737-1 WIRING DIAGRAM 9SL8064-1...
  • Page 53 Covers Assembly P-1147-G.jpg FX650XL - 12599...
  • Page 54 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 55 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 56 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.

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