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Airgas RED-D-ARC WELDERENTALS FX650 Operator's Manual

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RED-D-ARC
FX650
For use with machines having Code Numbers:
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.
North America's Largest Fleet of Welding Equipment
12622
IM10364
July 2016
(

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Summary of Contents for Airgas RED-D-ARC WELDERENTALS FX650

  • Page 1 RED-D-ARC IM10364 July 2016 FX650 12622 For use with machines having Code Numbers: 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 S FETY SECTION A: 1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away WARNINGS from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
  • 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 Welding Process, Physical Dimensions..............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...

  • Page 7: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - FX650 POWER SOURCE-INPUT VOLTAGE AND CURRENT Duty Cycle Input Voltage ± 10% Model Input Amperes Power Factor @ Idle Power Rated Output 60% rating 45/40/32 230 MAX.( Fan On) K4051-1 380 / 460 / 575 / 3 / 50 / 60 100% rating 100 MAX.
  • Page 8 INSTALLATION WELDING PROCESS OCV (U PROCESS OUTPUT RANGE (AMPERES) OCV (U GMAW (CV) 40-800 10-800 GTAW (CC) SMAW (CC) 15-800 40-800 FCAW-GS (CV) FCAW-SS (CV) 40-800 SAW (CV) 40-800 PHySICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 21.8 in (554 mm) 29.33 in (745 mm) 165lbs (74.8kg)* 16.14 in (410 mm) TEMPERATURE RANGES...

  • Page 9: Safety Precautions

    INSTALLATION SAFETy PRECAUTIONS LIFTING WARNING The FX650 has 2 lifting eyelets that can be used to lift the machine. Both eyelets should be used when lifting ELECTRIC SHOCk can kill. the FX650. ONLy QUALIFIED PERSONNEL Do not attempt to lift the FX650 with accessories attached to it.

  • Page 10: High Temperature Operation

    INSTALLATION INPUT FUSE AND SUPPLy WIRE HIGH TEMPERATURE OPERATION CONSIDERATIONS WELDER OUTPUT RATINGS AT 55°C ELEVATED TEMPERATURES Refer to Specification in this Installation Section for recommended fuse, wire sizes and type of the copper wires. Fuse the input circuit with the recommended AMPS DUTY CYCLE VOLTS...

  • Page 11: Cable Connections

    INSTALLATION CABLE CONNECTIONS See FIGURE A.2 for locating 3-pin and 14-pin con- nectors on the front of the FX650. 6-PIN REMOTE CONTROL CONNECTOR Function Wiring 3-pin remote 75 Remote potentiometer, common control con- 76 Remote potentiometer, wiper nector for 77 Remote potentiometer, 10K remote.

  • Page 12: Recommended Electrode And Work Cable For Arc Welding

    INSTALLATION RECOMMENDED ELECTRODE AND The following recommendations apply to all output WORk CABLE SIZES FOR ARC WELDING polarities and weld modes: • Select the appropriate size cables per the General Guidelines “Output Cable Guidelines” (See Table A.1). Connect the electrode and work cables between the Excessive voltage drops caused by undersized appropriate output studs of the FX650 per the follow- welding cables and poor connections often result in...

  • Page 13: Control Cable Connections, Paralleling

    INSTALLATION CONTROL CABLE CONNECTIONS Regarding cable placement, best results will be obtained when control cables are routed separate from the weld cables. This minimizes the possibility of General Guidelines interference between the high currents flowing Genuine Lincoln control cables should be used at all through the weld cables, and the low level signals in times (except where noted otherwise).
  • Page 14 INSTALLATION CONNECTING LF-72 AND LF-74 TO THE FX650 WIRE FEEDER 14-PIN CONTROL CABLE K1797-XX LF-72 FX650 LF-74 ELECTRODE WORK CONTROL SETTING WELD MODE CV-MIG, CV-INNERSHIELD WELD TERMINALS LOCAL REMOTE/LOCAL (REMOTE IF K2329-1 INSTALLED) VOLTMETER POLARITY PROCESS DEPENDENT FX650...
  • Page 15 INSTALLATION CONNECTING LN-10 AND DH-10 TO THE FX650 WIRE FEEDER 14-PIN CONTROL CABLE K1501-XX LN-10 FX650 DH-10 ELECTRODE WORK CONTROL SETTING WELD MODE CV-MIG, CV-INNERSHIELD WELD TERMINALS REMOTE/LOCAL REMOTE VOLTMETER POLARITY PROCESS DEPENDENT LN-10,DH-10 CONTROL SWITCH Setting the DIP Switches SETuP The DIP switches are each labeled with an “ON”...
  • Page 16 INSTALLATION A-10 A-10 CONNECTING LN-25 PRO, LN-25 PIPE, ACTIV8 TO THE FX650 WIRE FEEDER LN-25 PRO LN-25 PIPE FX650 ELECTRODE ACTIV8 WORK CLIP WORK CONTROL SETTING WELD MODE CV-MIG, CV-INNERSHIELD WELD TERMINALS REMOTE/LOCAL LOCAL VOLTMETER POLARITY PROCESS DEPENDENT CONNECTING LN-25 PRO DUAL POWER TO THE FX650 WIRE FEEDER CONTROL CABLE K1797-XX LN-25 PRO...
  • Page 17 INSTALLATION A-11 A-11 CONNECTING LN-7 TO THE FX650 WIRE FEEDER 14-PIN CONTROL CABLE K1818-XX LN-7 FX650 ELECTRODE WORK CONTROL SETTING CV-MIG, CV-INNERSHIELD WELD MODE WELD TERMINALS REMOTE/LOCAL LOCAL VOLTMETER POLARITY PROCESS DEPENDENT CONNECTING LN-8 AND LN-9 TO THE FX650 WIRE FEEDER 14-PIN CONTROL CABLE K1820-XX LN-8 LN-9...
  • Page 18 INSTALLATION A-12 A-12 CONNECTING NA-3, NA-5 TO THE FX650 WIRE FEEDER 14-PIN CONTROL CABLE K1820-XX NA-3 NA-5 FX650 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

    OPERATION GRAPHIC SyMBOLS THAT SAFETy PRECAUTIONS APPEAR ON THIS MACHINE Read this entire section of operating instructions OR IN THIS MANUAL before operating the machine. WARNING INPUT POWER 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...

  • Page 20: Product Description

    OPERATION GRAPHIC SyMBOLS THAT The FX650 is designed for the North America and APPEAR ON THIS MACHINE export markets and operates on 3 phase 380V, 460V, or 575V 50hz or 60hz power. OR IN THIS MANUAL DUTy CyCLE REDUCED OPEN CIRCUIT VOLTAGE The FX650 is capable of welding at a 100% duty cycle (continuous welding) at 650 amps rated output.

  • Page 21: Recommended Processes And Equipment

    OPERATION RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The FX650 is designed for CC-SMAW, CC-GTAW (lift tig), CV-GMAW, CV-FCAW-SS, CV-FCAW-GS and CV-SAW welding processes. CAG (arc gouging) is also supported. Weld Process Selector Process DC-TIG CC-GTAW (LIFT TIG) STICK CC-SMAW CV-MIG CV-GMAW CV-FCAW-GS MULTI-WELD™/...
  • Page 22 OPERATION CASE FRONT CONTROL DESCRIPTIONS 7. Output Control Dial: Sets the output current or voltage for the selected weld process. (See Figure B.1) 8. Local/Remote Selector Toggle Switch: Sets the control of the output to local or remote. 1. Power Switch: Controls input power to the FX650.

  • Page 23: Case Back Controls

    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

    OPERATION INTERNAL CONTROLS To Enter VRD™ Mode (VRD™ Enabled) a. For 380V input: Switch #5 in the “ON” Internal Controls Description Position. The Control PC Board has one bank of Dip Switches. As shipped from the factory VRD™ mode is disabled and Multi-Weld™...
  • Page 25 OPERATION To enable Multi-Weld™ Mode This product is equipped with a Multi-Weld™ mode and is shipped from the factory ready to be used in a Multi-Weld™ system. 1 2 3 4 5 6 7 8 DIP Switch #3 ON Enables Multi-Weld™ Mode. When DIP Switch #3 is ON and the Multi-Weld™...

  • Page 26: Power-Up Sequence

    OPERATION WELD CONTROLS AND DISPLAyS POWER-UP SEQUENCE Weld Process Selector Switch When power is applied to the FX650, the displays will 5 Position switch used to select the welding process. illuminate and display the voltage and/or amperage settings. Hot Start Control Dial COMMON WELDING PROCEDURES •...
  • Page 27 OPERATION Weld Terminals On/Remote Toggle Switch VRD™ (VOLTAGE REDUCTION DEVICE) • This switch determines the trigger location. INDICATOR LIGHT • When set to the “ON” position, the weld terminals are at OCV (open circuit voltage) and ready to weld. There are 2 indicator lights on the case front of the •...
  • Page 28 OPERATION B-10 B-10 Amperage Display Meter – This display will display Hot Start - The Hot Start control regulates the starting the pre-set welding current when the machine is in current at arc initiation. Hot Start can be set to “0” the idle state.
  • Page 29 OPERATION B-11 B-11 CV-Innershield Amperage Display Meter – This display will display three dashed lines when the machine is in the idle See the Internal Controls section to enable this mode. state. This indicates that amperage is not settable in This weld mode is a constant voltage (CV) mode fea- this weld mode.
  • Page 30 OPERATION B-12 B-12 CV-SAW This weld mode is a constant voltage (CV) mode fea- turing continuous control from 10 to 45 volts. It is intended for the CV-SAW submerged arc welding process. Hot Start – Not used for this welding process. Arc Control –...

  • Page 31: Accessories

    ACCESSORIES OPTIONS / ACCESSORIES GFCI kIT - Order k3157-1 Dual Cylinder Inverter and Wire General Options Feeder Cart - Rear-wheeled cart with front casters and dual gas bot- k2149-1 Work Lead Package. tle platform. Convenient handles allow for easy cable storage. Small footprint fits through 30in.

  • Page 32: Maintenance

    MAINTENANCE SAFETy PRECAUTIONS PERIODIC MAINTENANCE WARNING Thermal Protection Thermostats protect the machine from excessive ELECTRIC SHOCk can kill. operating temperatures. Excessive temperatures may • Only Qualified personnel should perform this maintenance. be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating.

  • Page 33: How To Use Troubleshooting Guide

    TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by 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. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 34 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SyMPTOMS) CAUSE COURSE OF ACTION Major physical or electrical damage 1. Contact your local authorized is evident when the sheet metal Field Service facility for technical covers are removed. assistance.
  • Page 35 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual USING THE STATUS LED TO TROUBLESHOOT SySTEM PROBLEMS Errors are displayed on the amperage and voltage display meters. In addition, there are status lights on the con- trol pc board and the switch pc board that contain error sequences. Included in this section is information about the fault codes indicated on the status lights and some basic trou- bleshooting charts for both machine and weld performance.

  • Page 36: Error Codes

    TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual FX650 Fault Codes Error Description Possible Cause Corrective Action Code# Input Power Misconnect. Verify the primary reconnect Occurs upon power up when the supply Supply Voltage is too high. is properly configured for the voltage to the switch pcb exceeded accept- able levels.
  • Page 37 NOTES Hold for G7148-6 FX650...
  • Page 38 DIMENSION PRINT FX650...
  • Page 39 NOTES FX650...
  • Page 42 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 43 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 44 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.

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