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Multiprocess DC Power Source
For use with machines having Code Numbers 9814, 9836 and 9839 Only.
Safety Depends on You
Lincoln arc welding equipment 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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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DC-650 PRO
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
IM463-A
May, 2000
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Summary of Contents for Lincoln Electric DC-650 PRO IM463-A
- Page 1 DC-650 PRO Multiprocess DC Power Source For use with machines having Code Numbers 9814, 9836 and 9839 Only. Safety Depends on You Lincoln arc welding equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...
- Page 2 Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
- Page 3 4.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
- Page 4 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
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Page 5: Table Of Contents
TABLE OF CONTENTS GENERAL DESCRIPTION ...7 SPECIFICATIONS ...7 INSTALLATION...8-13 Location ...8 Minimizing Problems Due to High Frequency ...8 Input Connections...8 Output Connections...11 Wire Feeder Control Cable Connections...12 Connection of a K775 Remote Output Control ...13 Connection to Auxiliary Power...13 EXPLANATION OF CONTROLS ...13-14 OPERATING INSTRUCTIONS ...15-18 GMAW (MIG) Operation ...15 FCAW (Flux- Cored) Operation ...16... - Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...
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Page 7: General Description
GENERAL DESCRIPTION The DC-650 PRO is a multiprocess DC power source designed for the GMAW (MIG), FCAW, SMAW (Stick), and SAW (Sub-Arc) processes, with arc gouging capability as well. It features an international industrial rating of 700 amps, 44 volts at 100% duty cycle. -
Page 8: Installation
INSTALLATION WARNING ELECTRIC SHOCK can kill. • Turn the input power off at the disconnect switch before installing or servicing this machine. • Do not touch electrically “hot” parts such as output terminals or internal wiring. • Connect grounding screw earth ground. - Page 9 Figure 1 – –...
- Page 10 RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage / Input Ampere Rating Frequency on Nameplate 208V / 60 Hz 230V / 60 Hz 460V / 60 Hz 575V / 60 Hz 200V / 50/60 Hz 220V / 50/60 Hz 380V / 50/60 Hz 400V / 50/60 Hz 415V / 50/60 Hz 440V / 50/60 Hz...
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Page 11: Output Connections
Output Connections See Figure 2 for locations of the various case front connection points. Output Duty Cycle 700A 100% Output cable strain reliefs are built into the DC-650 PRO base. Feed the output cables up through the strain relief holes before connecting to the output studs. -
Page 12: Wire Feeder Control Cable Connections
Wire Feeder Control Cable Connections Lincoln wire feeders can be hooked up to either the 14-pin Wire Feeder Receptacle (#12, Figure 3), or to the terminal strip (behind #11, Figure 3). The Wire Feeder Receptacle is the preferred method, because it virtually eliminates accidental miswirings. -
Page 13: Connection Of A K775 Remote Output Control
Connection of a K775 Remote Output Control Feed the remote control cable through the box connector on the case front, to provide a strain relief for the cable. Connect the numbered leads in the control cable to the like numbered terminals on the right hand terminal strip (75 to 75, 76 to 76, and 77 to 77). - Page 14 Mode Switch This switch chooses the proper welding mode. Choose from GMAW (MIG), FCAW (flux-cored), SAW (submerged arc), or SMAW (stick). This switch electronically changes the welding characteristics depending on the mode setting. NOTE: The welding cables must also be attached to the proper output studs for best welding performance (See “Output Connections”...
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Page 15: Operating Instructions
OPERATING INSTRUCTIONS WARNING 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 GASES dangerous. • Keep your head out of fumes. •... -
Page 16: Fcaw (Flux-Cored) Operation
FCAW (Flux-Cored) Operation Properly connect a wire feeder control cable to either the terminal strip or to the Wire Feeder Receptacle. If welding electrode positive, connect the electrode to the “+” output studs, and connect the work cable to the “-” studs labeled “GMAW, FCAW”. If welding electrode negative, reverse the connections. -
Page 17: Smaw (Stick) Operation
SMAW (Stick) Operation If welding electrode positive connect the electrode cable to the “+” output studs, and connect the work cable to the “-” studs labeled “SMAW,SAW”. If welding electrode negative, reverse the connections. Do not make any connections to the center pair of output studs. -
Page 18: Cac-A (Arc Gouging) Operation
terminal strip. (See Figure 4). Instead, extend the wire feeder control cable 21 lead to the workpiece. Insulate the 21 lead connection with tape or other means to achieve 300V withstand capability. The LN-9 or NA-5 will now sense arc voltage through this work sense lead. -
Page 19: Overload Protection
Overload Protection The DC-650 PRO is protected from excessive output currents by phaseback circuitry on the Control PC board. If the output current exceeds approximately 850 amps, the output of the machine will phase back to a low value. It will remain at a low value until the load is removed. -
Page 20: Troubleshooting Guide
TROUBLE A. Input contactor chatters. B. Machine input contactor does not operate. C. Machine input contactor operates, but no output when trying to weld. D. Machine has high output and no control. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. - Page 21 TROUBLE E. Machine has low output and no control. F. Machine does not have maximum output. G. Machine will not shut off. H. Variable or sluggish welding arc. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 22 TROUBLE Output control not functioning on the machine. Output control not functioning on remote control. K. Digital meters do not light - or - Digital meter display is incorrect. Poor arc striking with semiautomatic wire feeders. TROUBLESHOOTING CAUSE Output control switch in wrong position.
- Page 23 TROUBLE M. Poor arc characteristics in GMAW mode. N. Ammeter displays “Err” and Voltmeter displays a number ACCESSORY TROUBLESHOOTING TROUBLE A. Output Control not functioning on Remote Control. B. Output Control not functioning on the machine. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 24 Observe all Safety Guidelines detailed througout this manual ERROR CODES DISPLAYED ON VOLTMETER WHEN AMMETER DISPLAYS “ERR” The DC-650 PRO Meter PC Board displays error codes when certain trouble conditions exist. The error codes, trouble conditions, and possible remedies are listed below. ERROR TROUBLE CODE...
- Page 25 If there is damage to the PC board or if replacing PC board corrects problem, return it to the local Lincoln Electric Field Service Shop. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 26 Protection PC Board The protection PC Board is located on the back of the control box. It protects the PC Board from electrical noise. Most of the circuits on the Protection board are straight through connections. The board can be checked out in the field with a continuity tester or an ohmmeter.
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Page 27: Wiring Diagram
307A 309A WHITE BLUE 304A 302A 320A 320A 375A – –... -
Page 28: Dimension Prints
DC-650 PRO WITH A K817 UNDERCARRIAGE N.A. - Optional K-842 Undercarriage also available. See next page. INCHES 38.00 (CM) (96.5) (51.4) (103.1) (12.1) (76.0) (99.2) UNITS DC-650 PRO WITH A K842 UNDERCARRIAGE INCHES 54.91 37.86 38.00 (CM) (139.5) (96.2) (96.5) (13.2) (51.4) (91.7) UNITS INCHES 7.11 20.00... - Page 29 This parts list is provided as an informative guide only. This information was accurate at the time of printing. However, since these pages are regularly updated in Lincoln Electric’s official Parts Book (BK-34), always check with your Lincoln parts supplier for the latest parts...
- Page 30 NOTES...
- Page 31 _______________________________________________ _______________________________________________ Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month Year BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Price Code $5.00 $15.00 $4.50 $5.00...
- Page 32 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 33 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 34 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...