Lincoln Electric IM463-A Portable Generator User Manual
Contents
1. SE OA LAddi onalShipping Costs TOTAL 5 eee l WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa mojada Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v tements mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromfiihrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e electrodos com a pele ou roupa molhada Isole se da e terra OHBPOBARA XuiiHIIt 7 amp nfdcosn izucect NTUSHIELTFSU o 57 CUI TERRE ER ER 945 e i EC EUBEAIT HIER ecran SSE HE PSE uu HA axe Azle MSA gee ol jal Quali 3 alas 3993 a ursi st Al Yile Lo Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen2. eve ler re lve 3 we n Ro V80 lt at g 40 lt 1 vroe les 9 8 x a S A er ize ee 1 I VOLE A C X08 109109 H3SNNN 3100 NOWWOO V ONIAVH SIOHLNOO 40 HO SIN3NOdWOO 1OVY3 MOHS JON AVIA NVHOVIO SIHL 3131800 V 40 ALTIISV3ONVHOUSLNI 3H1 ONLLO AV LNOHLIM 39NVHO AYN V JO AHLINOHIO HO SIN3NOdOO 310N HOLIMS 10 u vdd GAMAIA ONIHIM HOLIMS TIV eui j sjeued eunsojoue y jo euo uo eui SNOLLO3NNOO YAWOLSNO amp of Ha 2 0311035 ASIMEBHLO 884 LLVW SWHO SHOLSIS3H 1 613 Wad SIOBNAS TYHAN3O ein eren Nid 9 eer Nid 9 gr AI war nre vee lt v vie r Nid 1 6 a sc ME 00000000 90000000 loooo looooo T MeL looo o 21 Fr T er quvog 9 d 30 301S IN3NOdWOO ALIAVO HOLO3NNOO 9 015 7 9 TOHLNOD HH ysaaay e 3dV1 e E ZHO9 A0 Z mala uva LNOAWT TWOISAHd T19YLd3034 081 pes ae a le sr tz 085 1 ceu Le oe Jl Ole 6 gt l 1 5 l Ze
3. ELECTRIC SHOCK can kill Have a qualified individual install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts Power Source Troubleshooting Most welding equipment problems particularly in new installations can be traced to incorrect installation or incorrect procedures Be sure that the DC 650 PRO is properly connected all accessories and wire feeders are working correctly and that valid welding procedures are being used Dec 95 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 TROUBLESHOOTING Faulty input contactor Low line voltage Pilot transformer T2 misconnected Supply line fuse blown Contactor power circuit dead Broken power lead Wrong input voltage Primary thermostats open Open input contactor coil Power On Off switch S1 not closing Electrode or work lead loose or broken Open main transformer T1 primary or secondary circuit Defective Control P C Boards Output terminals switch set wrong or faulty Secondary thermostat open Fault in leads 75 76 or 77 Open in feedback circuity CAUSE WHAT TO DO Refer to wiring diagram amp check related leads Check input power Check input connection instructions Rep
4. 650 PRO This voltage may be higher than that displayed on the LN 9 or NA 5 due to voltage drops in the cables and cable connection points The ammeter displays the actual welding current Connection of the Work Lead 21 In some applications very precise arc voltage sensing is required This requires that the wire feeder arc voltage sensing lead number 21 be extended directly to the workpiece Instructions follow for extending that lead When using the Wire Feeder Receptacle extend the 21 lead to the workpiece as follows 1 Turn the input power off 2 Open the terminal strip door When installing the wire feeder do not connect the lead marked 21 coming from the wire feeder control cable to the 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 The DC 650 PRO meters will continue to read the output stud voltage so there may be a difference between the DC 650 PRO voltmeter and the wire feeder voltmeter When using the terminal strip for wire feeder connection extend the 21 lead to the workpiece as follows 1 Turn the input power Off 2 Open the terminal strip door When installing the wire feeder do not connect the lead marked 21 coming from the wire feeder control cable to the terminal strip
5. AS1S 09v 062 ONY O9v 0 2 NIV JHL 3QvW SI NOLLO3NNOO LN3NVIWH3d SIHL silvia 33s TANvd 103NNOO3H DIMENSION PRINTS DC 650 PRO WITH A K817 UNDERCARRIAGE GAS CYLINDER SUPPORT AE 7 R N A Optional K 842 Undercarriage also available on INCHES 38 00 20 24 40 59 4 75 29 93 39 07 CM 96 5 51 4 103 1 12 1 76 0 99 2 UNITS A B G LOCATION OF 406 DIA MOUNTING HOLES INCHES 54 91 37 86 38 00 5 19 20 24 36 12 94 49 89 23 28 22 25 11 12 3 25 27 50 CM 139 5 96 2 96 5 13 2 51 4 91 7 2 4 126 7 59 1 56 5 28 2 8 2 69 9 INCHES 7 11 20 00 27 65 29 93 CM 18 1 50 8 70 2 76 0 P 223 P 223 PARTS LIST FOR DC 650 PRO AND DC 750 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 11 1 96 LINCOLN amp NOTES LINCOLN Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing
6. LL 1 GL Wey a 1606 181 3LON34 OVA OWA OWA M SI p CY SdIHLS 40 MIA LNOYS SNOILO3NNOO u3Woisno 580 mr ES 0 ov ao gt gt hd sk 299 Zz LE Bud 189 8 280 M MXN 1VISOWH3HL AHVONO93S Jl n H 0 d NOI19310Hd ele 6 21 zas 686 11 1e 606 6 Ole 486 8 ex 99 lt 9 59 9 29 q ce 19 lt 4 1 91 Io 71 cee 1 C s Tez veo e Ol Vase 4 6 QE 8 GIOHOL 626 8 9 er tee ac uo yt 0 98 6 985 12 HOLOW eh 1 9 002 93 1 90 sp 82 00 ea de nl Lye wens YOLONGNI HOW A0S Jn 000 LE by mooe s 99 001 09 QWNOB HOSS3HddnS ALOS V 008 1NNHS 4 10 S 541 310 ZH ZLVINSNI Quvog 02 AVISOWHSIHL A VNI Ed HILM H SINN INVH9VIG Old 099 AddNS OL ATNO S3NIHOVIA
7. When the secondary thermostat opens power will be removed from control transformer T3 causing the Control PC Board to lose power The meter displays will go off and there will be no output from the DC 650 PRO The pilot light will remain lit and the fan will continue to run When the machine cools down the thermostat will close automatically and normal operation will be restored 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 If the output is shorted in one of the constant voltage modes GMAW FCAW or SAW the output may phase back all the way to zero The short must be removed from the output and the protective circuits reset before welding can continue To reset them shut the DC 650 PRO off and then turn it back on again Routine Maintenance 1 The fan motor has sealed bearings which require no service 2 In extremely dusty locations dirt may clog the air channels causing the welder to run hot Blow out the machine at regular intervals 3 In extremely dusty locations dirt may accumulate on the remote control terminal strip Wipe or blow this terminal strip off at regular intervals This is particularly important in damp locations TROUBLESHOOTING WARNING
8. LN 7 K480 XX LN 8 LN 9 K595 XX NA 5 K597 XX Cables are available in various lengths Consult your welding equipment distributor for availability For connection to the terminal strip consult your Lincoln distributor for the appropriate wire feeder control cable Feed the control cable end 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 terminals on the terminal strip as depicted in Figure 4 For example for cables with leads A B and C connect A to 75 B to 76 and C to 77 connect lead 2 to terminal 2 lead 4 to terminal 4 etc Connect the green ground lead to the stud marked 777 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 Connect the green ground lead to the stud marked 777 e 42 V 115 V 115 V Connection to Auxiliary Power The DC 650 PRO has an extra 15 amps of 115 amp VAC auxiliary power above what is required for wire feed equipment This auxiliary supply is available on terminals 33 and 34 on the terminal strip This supply is protected by a 15 amp circuit breaker JON See 75 76 77 Ay 5
9. 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 The DC 650 PRO meters will continue to read the output stud voltage so there may be a difference between the DC 650 PRO voltmeter and the wire feeder voltmeter K317 DUAL PROCESS KIT FOR WIRE FEEDERS USING SAME POLARITY This kit permits the connection of two wire feeders to the DC650 PRO Both feeders will weld with the same electrode polarity When the trigger of the desired wire feeder is pressed the DC650 PRO output control leads 75 76 and 77 will be connected to that feeder and the procedure as set on its controls will be provided The other connected wire feeder will not be feeding wire but is electrically hot The kit mounts at the power source and is connected to the power source terminal strip with the supplied leads Installation instructions are included with the kit NOTE When using the DC650 PRO power source the K317 Dual Process Kit can only be used with two like wire feeders An LN 9 cannot be used with an LN 8 Only two LN 9 s may be used together or two LN 8 s together AC A Arc Gouging Operation Most arc gouging is done with constant voltage output Connect the electrode lead to the output studs and the work lead to the studs labeled G
10. changing and setting procedures The output current can be preset from the Output Control or from a remote control attached to the terminal strip Digital Voltmeter Displays the output voltage as measured on the output studs of the machine NOTE Due to voltage drops in the welding cables and at cable connection points the actual arc voltage may be lower than that displayed on the voltmeter Use welding cables of the proper capacity and make sure all connections are tight to minimize this effect If set to either the GMAW FCAW or SAW modes this meter can display the preset welding voltage when the secondary output contactor is open usually when the gun trigger is released By using this meter the output voltage can be set to a predetermined value before an arc is struck This permits repeatability when changing and setting procedures The output voltage can be preset from the Output Control or from a remote control attached to the terminal strip The only exception occurs when the DC 650 PRO is used with an LN 9 or NA 5 with those wire feeders the preset voltage can only be read on the wire feed unit The DC 650 PRO voltmeter will display when the LN 9 NA 5 mode see Operation with LN 9 or NA 5 Wire Feeder section OPERATING INSTRUCTIONS A WARNING ELECTRIC 5 can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and gr
11. itte 13 14 OPERATING INSTRUCTIONS inserer 15 18 GMAW MIG Operation ss sisi 15 FGAW Fl x Cored Operationerne aae latina ebur vo dada 16 SAW Submerged Arc Operation sisi 16 SMAW Stick Operation iii 17 Operation with an LN 9 or NA 5 Wire Feeder 17 S tup and Operation 17 Connection of the Work Lead 21 ire 17 CAC A Arc Gouging Operation sise 18 Installation with an NAFS 18 PROTECTIVE CIRCUITRY ii trnet rerit et Ea a Oo nente nennen 18 Thermostatic tee aini id 18 Overload Protection sise 19 ns einai 19 RR 19 24 Power Source Troubleshooting sn 19 Troubleshooting c LER 20 24 PC Board Troubleshooting Procedure 25 26 WIRING DIAGRAM 27 DIMENSION PRINTS cease cnet ces 28 PARTS PAGES DE Appendix Oct 96 for selecting a QUALITY product by Lincoln Electric We want you Thank You take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title
12. Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 students have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals M 1 700 00 lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only l IP rices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery l IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 For North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you atcost Outside U
13. S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders Name CHECKONE Address Please Invoice only if order is over 50 00 0 2 2 2 77007 I Check or Money Order Enclosed U S Funds only 1 11 1 1 1 1 1 1 _ Credit Card Ga Telephone LLL I m Signature as it appears on Charge LLLELLLLELLELLLLELLLL sese Lgl Smet on ctae card luse THIS FORM TO ORDER Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 sooks OR FREE INFORMATIVE CATALOGS Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 li incon Welding School Titles Price Code Quantity Cost I ED 80 New Lessons in Arc Welding 5 00 L Seminar Information Procedure Handbook Twelfth Edition 15 00 PH ED 45 How to Read Shop Drawings so H Educational Video Information Incentive Management 55 00 IM fJ J as A New Approach to ndusmsTEconomks 55 00 NA l Dames F Lincoln Arc Welding _____ The American centry 5500 AC Foundation Book Information Welding P reheat Calculator 3 00 wc a JFLF 518 PipeWeldingChats
14. Sie brennbarres Material e Mantenha inflam veis bem guardados e naedoe6008 HBMICL THEW ECA o Eia VA IEEE IF AT AS Aa A nig ap Jo ALD al gl pis Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und perschutz Use prote o para a vista ouvido e corpo HAUSHERMRELTT aU RRR ez 119 59 s ESSAI didi due Lily putes cl adi en e 3 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS DIE UNFALLVERH TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de respiraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci
15. faulty Fault in leads 75 76 or 77 Faulty Control P C Board Output control potentiometer circuit open lead 75 One input fuse blown One phase of main transformer open Faulty Control P C Board Output control potentiometer Output control potentiometer lead 75 open Defective main SCR bridge Input contactor contacts frozen Defective On Off switch S 1 Poor work or electrode connection Welding leads too small Welding current or voltage too low Leads or connections open in control circuit LN 9 NA 5 switch in wrong position CAUSE WHAT TO DO Check position of switch Check switch and replace if faulty Check wiring Replace See P C Board Troubleshooting Procedure Check and replace potentiometer if faulty Check wiring of lead 75 Check and replace if blown after checking for reason for blown fuse Check for open and repair Replace See P C Board Troubleshooting Procedure Check and replace if faulty Check and repair broken leads Check and replace if defective Check and replace if necessary Replace Check amp clean all connections Check table in instruction manual Check procedures for recommended settings Check amp replace if defective Only connect one pair of negative studs to the work CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Li
16. n para gases Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspirateur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRE OHRARV ER SBELTTFEL e 75 OF OF E fE n BE EERE HERTE 847A 247 AAs AS 715 44214 58718 dall oe ay EAU gaal jua si igi Jaial ge gaal au us Sas e Turn power off before servicing Desconectar el cable de alimentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entretien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten e opere com as tampas removidas Desligue a corrente antes de fazer servico e PRE 5 e OR 4 Alias Gb phd Qi uu 0 jui ail e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen
17. necessary Replace See P C Board Troubleshooting Procedure Replace See P C Board Troubleshooting Procedure Replace See P C Board Troubleshooting Procedure See Thermostatic Protection section Work connection must be adequate for application Adjust procedures for improved starting Replace See P C Board Troubleshooting Procedure TROUBLESHOOTING TROUBLE CAUSE WHAT TO DO M Poor arc characteristics in 1 Capacitor bank not switching in Check the Mode SCR SCR7 Should be on GMAW mode when in GMAW and FCAW modes Capacitor s in output circuit failed A failure Replace entire bank of capacitors Do not is indicated if the small vent plug on top of a replace individual capacitors capacitor is raised or blown out WARNING The liquid electrolyte in these capacitors is toxic Avoid contact with any portion of your body Clean up vented electrolyte using rubber gloves and a water dampened cloth Remove any electrolyte which gets on skin using soap and water N Ammeter displays Err and Anerror has been detected See Error code Troubleshooting Guide Voltmeter displays a number ACCESSORY TROUBLESHOOTING TROUBLE CAUSE WHAT TO DO A Output Control not functioning Output Control switch in wrong Place switch in Remote on Remote Control position Faulty Output Control switch Check amp replace if found faulty Faulty Remote Control Check amp replace if found fa
18. passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 Un coup d arc peut tre plus s v re qu un coup de soliel donc PR CAUTIONS DE S RET POU R a Utiliser un bon masque avec un verre filtrant appropri ainsi LES MACHINES SOUDER A qu un verre blanc afin de se prot ger les yeux du TRANSFORMATEUR ETA rayonnement de l arc et des projections quand on soude ou quand on regarde l arc REDR ESSEU R b Porter des v tements convenables afin de prot ger la peau Relier la terre le chassis du poste conformement au code de de soudeur et des aides contre le rayonnement de l arc eue p l lectricit et aux recommendations du fabricant Le dispo
19. pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir
20. 20248 Figure 4 EXPLANATION OF CONTROLS Refer to Figure 3 for placement of the DC 650 PRO controls 1 Output Control Potentiometer Controls the output of the machine Adjusts current when welding in the SMAW mode and adjusts voltage when welding in the GMAW FCAW and SAW modes The Output Control switch must be in the Local position for this control to be active 2 Output Control Switch This switch chooses whether the DC 650 PRO output is adjusted from the front panel or by remote control In the Local position the Output Control Potentiometer adjusts the output In the Remote position the output is adjusted by either a wire feeder or an optional remote control using an LN 9 or NA 5 see Operating with LN 9 or NA 5 Wire Feeder section 3 Arc Force Potentiometer Active only in the SMAW stick mode Adjusts the slope of the machine to give greater short circuit currents necessary when using certain manual electrodes When set to 0 there is no arc force action giving a soft buttery arc characteristic When adjusted towards 10 the higher arc force action gives the arc a digging characteristic which can help prevent the electrode from sticking to the work The setting of this control has no effect in any other mode 4 LN 9 NA 5 On Off Switch This switch is set to On only when used with LN 9 and NA 5 wire feed units For all other equipment this switch is to be set to Off For proper ope
21. 5V 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 500V 50 60 Hz 1 For a 600A 44V 100 duty cycle output in a 40 C ambient location Refer to your local or national electrical code for other conditions MAY 95 10 Output Connections See Figure 2 for locations of the various case front connection points The DC 650 PRO output studs are mounted in pairs The two studs in each pair are internally connected to each other with a buss bar The studs have a 1 2 13 thread Output cable lugs must have a hole large enough to clear a 1 2 inch stud Choose the cable size from the table Recommended Cable Sizes Lengths shown are the total cable length work cable length plus electrode cable length RECOMMENDED CABLE SIZES RUBBER COVERED COPPER RATED 75 C Cable Sizes for Combined Length of Work and Electrode Cables 200 250 1 60 75 Duty poss 0 100 ft 100 200 ft 0 30 m 30 60 m alt Mail 2 2 0 2 3 0 2 4 0 2 70 mm 2 95 mm 2 120 mm 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 This will prevent damage to the studs and the cables in the event the cables are pulled or stretched The positive connections can be made to the pair of studs on the lower r
22. American Welding Society P O Box 351040 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 ELECTRIC SHOCK can kill 1 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 hands 1 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 gratings 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also elect
23. IM463 A 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 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 This manual covers equipment which is obsolete and no longer in production by The Date of Purchase ____ Lincoln Electric Co Serial Number Specifications and availability of optional o MM features may have EE changed Where Purchased a ms OPERATOR S MANUAL LINCOLN 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 A WARNING 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 Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the
24. MAW FCAW Do not make any connections to the left hand pair of output studs Dec 95 Set the control panel switches as follows Output Local or Remote See Output Control Switch Wire Feeder Has no effect when arc gouging Voltmeter Output Terminals If using Local output control preset the desired voltage approximately 40 volts using the Output potentiometer and the volt meter If using Remote output control preset the voltage using a remote control Begin gouging and then adjust the output up or down as necessary Installation with an NA 3 As supplied from the factory the cold inch feature in the NA 3 will not work when used with a DC 650 PRO in negative polarity operation Contact the factory for information regarding an NA 3 modification procedure that will allow the cold inch feature to work with the DC 650 PRO under these conditions PROTECTIVE CIRCUITRY Thermostatic Protection The DC 650 PRO has a thermostat in both the primary and secondary circuits The primary thermostat located inside the right primary coil will open up if the main transformer overheats The machine will completely shut off when the primary thermostat opens The machine must be allowed to cool before it can be restarted The secondary thermostat located on the secondary common lead at the front of the main transformer will open if the output is overloaded the duty cycle is exceeded or if the flow of cooling air is blocked
25. RNING e ELECTRIC SHOCK can kill e Have a qualified individual install and service this equipment e Turn the power source input power off at the disconnect switch before working on this equipment Do not touch electrically hot parts Before replacing a PC board which is suspected of being defective visually inspect the PC board in question for any electrical or mechanical damage to any of its components and conductors on the back of the board a If there is no visible damage to the PC board install a new one and see if this remedies the problem If the problem is remedied reinstall the old PC board to see if the problem still exists If it does no longer exist with old PC board 1 Check the PC board harness connector pins for corrosion contamination or looseness 2 Check leads in the plug harness for loose or intermittent connection b If PC board is visibly damaged electrically before possibly subjecting the new PC board to the same cause of failure check for possible shorts opens or grounds caused by 1 Frayed or pinched lead insulation 2 Poor lead termination such as a poor contact or a short to adjacent connection or surface 3 Shorted or open motor leads or other external leads 4 Foreign matter or interference behind the PC boards c If PC board is visibly damaged mechanically inspect for cause then remedy before installing a replacement PC board If there is damage to the PC bo
26. an international industrial rating of 700 amps 44 volts at 10096 duty cycle It also has a dual rating of 600 amps 44 volts at 100 duty cycle in a 60 C ambient temperature environment TECHNICAL SPECIFICATIONS Ordering Product Input Rated Additional Dimensions Information Description Frequency Output Output amp Weight K1410 Multiprocess 700 Amps 600 Amps 27 50 0 x 22 25 x 38 in DC Power 44 Volts 44 Volts 698 x 565 x 965 mm Source 100 Duty 100 Duty 725 lbs Cycle Cycle 830 kg INPUT SPECIFICATIONS Input Input Currents 44 V Output Idle Idle Voltage 600 700A 9 750A Current Power 2 208 V 130A 146A 153A 1 5 kW 230 V 117A 132A 139A 1 5 kW 460 V 59A 6 69 A 1 5 kW 575 47A 53A 56A 1 5 kW OUTPUT SPECIFICATIONS Rated Output Additional DC Output Ratings Auxiliary Open Output Efficiency At 40 C At 60 C Outputs Circuit Current Power Factor 2 Ambient Ambient Voltage Range Temperature Temperature 700 Amps 600 Amps Two 115 Volts AC GMAW 15 45 80 750 Amps 600A 44V load 44 Volts 44 Volts 15 Amps FCAW 15 60 Eff 65 PF 88 100 100 SAW 10 60 Duty Cycle Duty Cycle 42 Volts AC SMAW 65 70 700A 44V load 750 Amps 750 Amps 10 Amps Eff 66 PF 90 44 Volts 44 Volts 60 35 750A 44V load Duty Cycle Duty Cycle Eff 67 PF 90 1 Overall height 30 75 in 781 mm including lift bale 2 Loaded readings are taken with a full auxiliary load No load ratin
27. ard or if replacing PC board corrects problem return it to the local Lincoln Electric Field Service Shop CAUTION 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 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 A copy of the DC 650 PRO wiring diagram is needed also All circuits should show continuity or nearly zero ohms resistance from input to output Inputs and outputs can be identified by the common lead number suffixes on the wires connected to the Protection PC Board For example lead 75 on the input side is common with lead 375A on the output side Lead 208 is common with 308 lead 209 is common with 309 and 309A etc Snubber PC Board The snubber PC Board is located on the main rectifier Circuits on this board protect the SCR s from high transient voltages Failures on this board should be very rare The only way to check the seven circuits on this board is to check each circuit one at a time using an ohmmeter preferably an analog ohmmeter on the X10 scale The first step is to connect one lea
28. d of the ohmmeter to the center plate of the rectifier assembly This is the cathode connection for SCR s 1 through 6 Next disconnect the Snubber board lead that goes to the anode of SCR1 Connect the other ohmmeter lead to this snubber lead The ohmmeter should show a low resistance initially then swing towards high resistance if the snubber is good Repeat this with SCR s 2 through 6 each time testing just one Snubber lead Lastly disconnect the snubber lead that goes to the cathode of SCR7 and perform the same test The ohmmeter action should be the same for each SCR on the bridge Output Bypass PC Boards One of these boards is mounted to each output terminal Each board prevents high frequency energy and electrical noise from entering the DC 650 PRO Again failures of these boards should be very rare The only way to inspect these boards is visually Inspect each board looking for burnt traces or components Control PC Board This board located inside the control box is the heart of the machine All welding output is controlled by this board The Meter boards receive their information from the Control board as well Very little external diagnostic work can be performed on this board If one control or function of the machine does not appear to be working it is best to trace out the wiring associated with that function switch or potentiometer all the way back to the Control board with an ohmmeter If all check out ther
29. e verify that the following voltages are present at the output of the auxiliary transformer T3 Auxiliary Transformer T3 Plug P8 Approximate Secondary Lead Color Locations Voltage Red to Red Red to White Yellow to Yellow Black to Black Orange to Orange Often replacement with a known good board is the best service method Remove the board that is suspected to be defective Carefully look over the board checking for burnt traces or components none are found install the known good board If the trouble goes away reinstall the suspected bad board to confirm that the board was indeed at fault If the problem is now gone with the original board installed the problem is probably with one of the leads or connectors going to the board Meter PC Board Both the Voltmeter and the Ammeter PC boards are identical They both operate as display boards displaying numbers sent to them by the Control PC board The Meter boards do not make voltage or current measurements the Control Board performs those functions If both meter boards are dark not lighted chances are that either the secondary thermostat is open see Thermostatic Protection section the auxiliary transformer T3 is defective see Control P C Board section or the Control board is defective If only one board is dark make sure the machine is in a mode where both boards are supposed to light There are certain modes where one board or the other is supp
30. e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas XxJAo25 SQRUALEEt e SER HGTBI BUSUR RE SERB eHdo Wel AE 2154 Aj Gals hil lin Jio Y e Ale Cut oi WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it ie BR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR ORR PRUOX A OHRBEEK RA ETBRLTF SL EE pap Af A UE a R 0 SSH AXBAE CS tL TRHORAMEI ETF EU E MRT LZ ARBRE e HA AUX ena 542 ETA Saal akal 91 Jub al gll clad Gail giall lasted gills LINCOLN e 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
31. gs are taken without auxiliary loads 7 m INSTALLATION A 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 to a good earth ground Do not operate with covers removed Turn power switch OFF before connecting or disconnecting cables or other equipment Only qualified personnel should install or service this equipment K Please read all of this section before starting installation Refer to Figure 1 during installation Location Place the welder where clean cooling air can freely circulate in through the front louvers and out through the rear louvers The presence of dirt dust or any foreign material that can be drawn in through the louvers should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and welder shutdowns due to thermal overload DC 650 PRO power sources can be stacked three high provided that the bottom machine is on a stable hard level surface Be sure that the two pins in the roof of the lower machine fit into the holes in the base of the DC 650 PRO above it Minimizing Problems Due to High Frequency This welder like all electrical equipment can be subject to interference from strong sources of high frequency energy Sources of high f
32. ight of the case front marked 5 Figure 2 Connection can be made to either or both of the studs Figure 2 There are two pairs of studs for the negative connection lt is important to use the correct pair of studs depending on the processes in use NOTE DO NOT CONNECT BOTH PAIRS OF NEGATIVE STUDS TOGETHER USE EITHER ONE PAIR OR THE OTHER BUT NEVER CONNECT BOTH PAIRS TO THE WORKPIECE AT THE SAME TIME Doing so will adversely affect the output characteristics of the machine giving poor welding performance Note that the center pair is labeled and GMAW FCAW 4 Figure 2 This pair is to be used for constant voltage processes requiring low output inductance such as gas metal arc welding and flux cored arc welding The left hand pair is labeled and SAW SMAW 3 Figure 2 This pair is to be used for constant current processes such as stick welding as well as for submerged arc welding on constant voltage 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 LINCOLN CEET Figure 3 For connection to the Wire Feeder Receptacle choose a control cable from the chart below Wire Feed Unit Current Capacity Duty Cycle Cable Type
33. ircuit Breakers These circuit breakers provide overload protection for the auxiliary circuits One 15 amp breaker is for the wire feeder 115V AC circuit 31 and 32 another 15 amp breaker is for the spare 115V AC auxiliary circuit 33 and 34 The 10 amp breaker is for the 42V AC wire feeder circuit 41 and 42 Strain Reliefs These strain reliefs are provided for control cables going to the terminal strips Terminal Strip Door This access door provides protection for the terminal strip connections Lead numbers shown for this panel in Figure 3 The door can be opened by turning the fastener one quarter turn counter clockwise Reverse this procedure to latch the door shut 12 Wire Feeder Receptacle This is the standard Lincoln 14 pin MS type amphenol receptacle See the DC 650 PRO wiring diagram for the pinout diagram of this receptacle Rating Plate This plate contains important information regarding the code number serial number input voltages input currents and output ratings of the DC 650 PRO Record the code and serial numbers in a safe place These numbers will be required if replacement parts are needed in the future Digital Ammeter Displays the output amperage when welding If set to the SMAW stick mode the ammeter displays the preset welding current when not welding By using this meter the output current can be set to a predetermined value before an arc is struck This permits repeatability when
34. ire feeder instruction manual When the gun trigger is pulled or the weld sequence is started and an arc is struck the voltmeter will display the welding voltage preset at the output studs of the DC 650 PRO and the ammeter will display the output current 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 Do not make any connections to the left hand pair of output studs Set the control panel switches as follows Mode FCAW Output Local or Remote See Output Control Control Switch LN 9 NA 5 Off unless an LN 9 or NA 5 is being used Wire Feeder Set to match the electrode polarity Voltmeter Output Terminals If using Local output control preset the desired welding voltage using the Output potentiometer and the voltmeter If using Remote Output control preset the welding voltage using a remote control or with the voltage control on the wire feeder If using an LN 9 and NA 5 see operation with LN 9 or NA 5 Wire Feeder section Set up the wire feeder according to the wire feeder instruction manual When the gun trigger is pulled or the weld sequence is started and an arc is struck the voltmeter will disp
35. lace if blown look for reason first Check pilot transformer T2 and associated leads Check input voltage at contactor Check voltage against instructions Check for overheating make sure fan is operating and there is no obstruction to free air flow Replaces faulty thermostat Replace coil Replace switch Repair connection Repair Replace See P C Board Troubleshooting Procedure Check setting operation of the Output Terminals switch Check for overheating make sure fan is operating and there is no obstruction to free air flow Replaces faulty thermostat Check wiring Check control and protection PC Baord wiring With input power off check for continuity between output stud and lead and 1J12 on the control board Also check for continuity between GMAW FCAW output stud and 3J12 on the control board Finally check for continuity between SMAW SAW output stud and 2J12 Repair if necessary CAUTION 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 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 TROUBLESHOOTING Output control Local Remote switch in wrong position Output control switch
36. lay the welding voltage present at the output studs of the DC 650 PRO and the ammeter will display the output current SAW Submerged Arc 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 cable to the output studs and connect the work cable to the studs labeled SMAW SAW welding electrode negative reverse the connections Do not make any connections to the center pair of output studs Set the control panel switches as follows Mode SAW Output Local or Remote See Output Control Control Switch LN 9 NA 5 Off unless an LN 9 or NA 5 is being used Wire Feeder Set to match the electrode polarity Voltmeter Output Terminals If using Local output control preset the desired welding voltage using the Output Potentiometer and the voltmeter If using Remote output control preset the welding voltage using a remote control or with the voltage control on the wire feed unit If using an LN 9 or NA 5 see Operation with LN 9 or NA 5 Wire Feeder section Set up the wire feed unit according to the wire feeder instruction manual When the gun trigger is pulled or the weld sequence is started and an arc is struck the voltmeter will display the welding voltage present at the output studs of the DC 650 PRO and the ammeter will display the output current SMAW Stick Operati
37. n filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other ev moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running To prevent accidentally starting gasoline engines while 8 b 8 c turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate d 7 h To avoid scalding do not remove the radiator pressure cap when the engine is hot ELECTRIC AND MAGNETIC FIELDS may be dangerous 8 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines a EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure
38. ncoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed TROUBLE I Output control not functioning on the machine J Output control not functioning on remote control Digital meters do not light Or Digital meter display is incorrect Poor arc striking with semiautomatic wire feeders TROUBLESHOOTING Output control switch in wrong position Faulty output control switch Faulty output control potentiometer Leads or connections open in control circuit LN 9 NA 5 switch in wrong position Faulty Control P C Board Output control switch in wrong position Faulty output control switch Faulty remote control potentiometer Leads or connections open in control circuit Faulty Control P C Board Faulty Meter P C Board Faulty Control P C Board Secondary thermostat is open Poor work connection Improper procedures Defective P C Board CAUSE WHAT TO DO Place switch in Local position Check amp replace if found faulty Check amp replace if found faulty Check lead continuity and connections for an open and repair if necessary Set to Off when not using an LN 9 NA 5 Replace See P C Board Troubleshooting Procedure Place switch in Output Control Remote Check amp replace if found faulty Check amp replace if found faulty Check all leads and connections internal or remote for continuity repair if
39. on 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 Set the control panel switches as follows Output Local or Remote See Output Control Switch Wire Feeder Has no effect in the SMAW mode Voltmeter Output Terminals On If using Local output control preset the desired welding voltage using the Output Potentiometer and the voltmeter If using Remote output control preset the welding voltage using a remote control Set the Arc Force potentiometer according to the arc characteristics desired With certain electrodes such as low hydrogen alloy electrodes it is beneficial to set the Arc Force to a high setting This gives a more forceful arc less prone to sticking and stubbing Setting this control too high can lead to excessive spatter It is often best to start stick welding with the Arc Force set to minimum and if sticking is a problem raise the setting until the electrode runs smoothly The output terminals will always be hot Before an arc is struck the ammeter will display the preset current When an arc is struck the ammeter will display the actual output current In the SMAW mode the voltmeter always displays the output voltage present at the output studs of the DC 650 PRO O
40. osed to be dark To check this place the mode switch in the SMAW mode and set the Output Control switch to On Both meters should be lit If one board is still dark that board may be defective The best way to check this is to switch the bad board with the other working Meter board right next to it Replace the defective board CAUTION 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 Jequunu epoo 1ueuudinbo y 10 9 HALINLIOA 430334 NO NMOHS S VN 6 NT NI NMOHS JOH1NOO LNdLNO jueujeoe dai e 104 914 ejqiBel si episui pajsed si epoo 104 ayy fenuew siy Aq 104 eq jou 108 WE V80 VEZE BIE 02 L rll W3I3ALTOA l 3008419373 300919313 eze 310W38 1ndino JOHINOO Induno dHvO8 0 d 7OH1NOO DEN co 12 v106X volen 808 16 eee 6 6 tie 19e r9 le 79 1 0064 Foie eo HE lt
41. ouch a cylinder Keep your head and face away from the cylinder valve outlet 5 f 5 0 when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 6 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National 7 a A Electrical Code and the manufacturer s recommendations FOR ENGINE powered equipment Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 T 7 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 7 7 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel whe
42. ound Always wear dry insulating gloves FUMES AND GASES can be 3 dangerous Keep your head out of fumes AR Use ventilation or exhaust to remove ES fumes from breathing zone WELDING SPARKS can cause fire or TE explosion p Keep flammable material away Do not weld on closed containers ARC RAYS can burn eyes and skin Wear eye ear and body LL protection See additional warning information at front of this operator s manual GMAW MIG 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 cable to the output studs Connect the work cable to the center output studs labeled GMAW FCAW Do not make any connections to the left hand pair of output studs Set the control panel switches as follows Mode GMAW Output Local or Remote See Output Control Control Switch LN 9 NA 5 Off unless an LN 9 or NA 5 is being used Wire Feeder Set to match the electrode polarity Voltmeter Output Terminals If using Local output control preset the desired welding voltage using the Output potentiometer and the voltmeter If using Remote Output control preset the welding voltage using a remote control or with the voltage control on the wire feeder If using an LN 9 see Operation with LN 9 or NA 5 Wire feeder section Set up the wire feeder according to the w
43. passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment GENERAL DESCRIPTION The DC 650 PRO is a multiprocess DC power source The DC 650 PRO is available from the factory in one designed for the GMAW MIG FCAW SMAW Stick model only with a choice of input voltages There are and SAW Sub Arc processes with arc gouging no factory installed options capability as well It features
44. peration with an LN 9 or NA 5 Wire Feeder NOTE Conversion Kits are required for LN 9 s and NA 5 s used with the DC 650 PRO For LN 9 and LN 9GMA model codes above 9100 order K442 1 For LN 9 models below code 9100 order K442 2 For NA 5 models below code 9100 order K442 3 For NA 5 models above code 9100 order K442 4 Setup and Operation These wire feeders are called presettable wire feeders The welding voltage is set on the wire feeder and then maintained throughout the weld by circuitry in the wire feeder It makes continuous adjustments during the weld to maintain the proper arc voltage Because the wire feeder takes control of the arc voltage the DC 650 PRO must be told that an LN 9 or NA 5 is in control This is done by setting the LN 9 NA 5 On Off switch to the On position To use an LN 9 or NA 5 the Output Control switch must be set to Remote Output voltage control is now done through the terminal strip or through the wire feeder receptacle rather than with the front panel Output potentiometer Additionally the LN 9 NA 5 switch must be set to On This tells the DC 650 PRO that an LN 9 or NA 5 is in control The DC 650 PRO Voltmeter will no longer display the preset welding voltage The preset welding voltage must be read at the LN 9 or NA 5 The DC 650 PRO Voltmeter will display when not welding When welding the Voltmeter displays the welding voltage as measured on the output studs of the DC
45. rating with LN 9 and NA 5 wire feed units the Output Control switch must be set to Remote and the LN 9 NA 5 switch must be set to On Mode Switch This switch chooses the proper welding mode Choose from GMAW MIG FCAW 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 10 11 the proper output studs for best welding performance See Output Connections section Wire Feeder Voltmeter Switch This switch changes the polarity of the wire feeder voltmeter sense lead if the wire feeder is so equipped Set to match the electrode polarity so that the wire feeder voltmeter can display the welding voltage This switch has no effect on the welding output polarity of the DC 650 PRO Output Terminals Switch This switch controls the solid state output contactor circuitry in the DC 650 PRO When set to the On position the output studs are hot all of the time When in the remote position the contactor circuitry is controlled by the equipment connected to terminals 2 and 4 usually a wire feeder Normally this switch is turned On only when stick welding arc gouging or when using an arc powered wire feeder such as an LN 25 Power Switch and Pilot Light Turns the DC 650 PRO on and off The red pilot light illuminates when the machine is turned On C
46. ree phase line The frame of the welder must be grounded A ground terminal 5 Fig 1 marked with the symbol is located on the bottom of the input box for this purpose Check local and national electrical codes for details on proper grounding methods On welders with multiple input voltages be sure that the reconnect panel is connected per the instructions that follow CAUTION FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE IMMEDIATE FAILURE OF COMPONENTS INSIDE THE WELDER Welders are shipped connected for the highest rated input voltage To change this to a lower voltage first reconnect the pilot transformer leads H2 H3 or H4 per the diagram attached to the inside of the reconnect door Next remove and reinstall the reconnect links according to the same diagram Fuse the input leads with the recommended size super lag fuses or delay type circuit breakers See Table 1 for the recommended fuse and or circuit breaker sizes Using fuses or breakers smaller than those recommended may result in nuisance tripping and possible damage to circuit breakers from welder inrush currents at turn on even if the machine is not used to weld at high currents Figure 1 Table 1 RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage Input Ampere Rating Type 75 C Cu Copper Grounding Wire Fuse Size Frequency on Nameplate Wire in Conduit Cu Copper Super Lag 208V 60 Hz 230V 60 Hz 460V 60 Hz 57
47. requency energy include but are not limited to TIG welders plasma cutters and two way radios To minimize the potential for such interference follow all of the installation instructions for equipment that will be installed in the same general area as the DC 650 PRO Pay particular attention to instructions on grounding The best preventative measure is to locate high frequency generating devices away from all other electrical equipment Also the input power lines going to those devices should be enclosed in solid metallic tubing or conduit Dec 95 Input Connections Be sure the voltage phase and frequency of the input power is as specified on the rating plate The rating plate is located on the front control panel of the DC 650 PRO An entry for the input power lines 1 Fig 1 is provided on the case back The knockout is 2 00 51 mm in diameter Access to the input panel connection area is gained by removing the two bolts which secure the Reconnect Door 2 Fig 1 and lifting the door upward Select the input lead wire sized according to local and national electrical codes A chart conforming to the U S National Electrical Code is provided as a reference Table 1 Have a qualified electrician connect the input leads to terminals L1 L2 and L3 on the reconnect panel 3 Fig 1 in accordance with all local and national electrical codes and with the diagram 4 Fig 1 located on the inside of the cover Use a th
48. rically hot 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 1 e Ground the work or metal to be welded to a good electrical earth ground 1 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 1 g Never dip the electrode in water for cooling 1 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 1 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 1 j Also see Items 4 c and 6 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 when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 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 Apr 93 2 FUMES AND GASES can be dangerous 3 a Welding may prod
49. rocedure Err 014 016 1 Faulty Control PC Board 1 Replace See PC Board Troubleshooting Procedure Err 023 Noisy line 1 Make sure machine frame is grounded See installation section on minimizing problems due to high frequency interference Faulty Control PC Board 2 Replace See PC Board Troubleshooting Procedure Err 030 Control transformer miswired 1 Swap leads 330 and 332A at Control Transformer T3 in the control box Main Transformer Auxiliary 2 Check leads 29 30B and 32B from main miswired transformer Repair if necessary Faulty Control PC Board 3 Replace See PC Board Troubleshooting Procedure Err 100 131 Mode Switch is set between two positions 1 Reposition mode switch Faulty Mode Switch 2 Check and replace if found faulty Mode Switch wiring bad 3 Check all leads for continuity Repair if necessary Faulty Control Board 4 Replace See PC Board Troubleshooting Procedure Err 200 206 Noisy input line 1 Make sure machine frame is grounded See installation section on minimizing problems due to high frequency interference Faulty Control PC Board 2 Replace See PC Board Troubleshooting Procedure CAUTION 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 Procedure for Troubleshooting PC Boards WA
50. see item 7b gt WELDING SPARKS gt cause fire or explosion 4 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 Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 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 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 substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 4 f Sparks and spatter are
51. sitif de montage ou la piece souder doit tre branch une c Prot ger l autre personnel travaillant proximit au ud bonne mise la terre soudage l aide d crans appropri s et non inflammables Autant que possible l installation et l entretien du poste seront Des gouttes de laitier en fusion sont mises de l arc de ue effectu s par un lectricien qualifi soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Toujours porter des lunettes de s curit dans la zone de m gt rder les couvercles et dispositifs de s ret leur place soudage Utiliser des lunettes avec crans lateraux dans les P 4 Mar 93 TABLE OF CONTENTS Page GENERAL DESCRIPTION ce aeritinite ze Ie argu teuer ele 7 SPEGIFIGATIONS rr ote tiq nen 7 INSTALLATION e 8 13 ocu PE 8 Minimizing Problems Due to High Frequency sr 8 Input 8 e nU 8 Output Connectlons 2 11 Wire Feeder Control Cable Connections ss 12 Connection of a K775 Remote Output Control ss 13 Connection to Auxiliary Power sise 13 EXPLANATION OF CONTROLS
52. 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 Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 4 h Also see item 7c 5 b 5 c CYLINDER may explode if damaged 5 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders 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 Never allow the electrode electrode holder or any other electrically hot parts to t
53. to EMF fields in welding may have other health effects which are now not known 8d All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 8 d 1 Route the electrode and work cables together Secure them with tape when possible 8 d 2 Never coil the electrode lead around your body 8 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 Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source Mar 93 PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch
54. uce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the 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 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 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 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 Also
55. ulty potentiometer Leads or connections open in Check all leads amp connections control circuit Faulty Control P C Board See P C Board Troubleshooting Procedure B Output Control not functioning Output Control switch in the Place switch in Local position on the machine wrong position Faulty Output Control switch Check amp replace if found faulty Faulty Output Control Check amp replace if found faulty potentiometer CAUTION 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 TROUBLESHOOTING 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 REMEDY CODE Err 000 Output overload Reduce output overload Shunt miswired or unconnected 2 Check shunt and wiring Repair if necessary Faulty Control PC Board 3 Replace See PC Board Troubleshooting Procedure Err 013 Missing Phase Signal 1 Check for 66 VAC 10 between leads 329 and 332 of J12 at control board Repair if necessary Faulty Control PC Board 2 Replace See PC Board Troubleshooting P
56. will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book must for all welders supervisors engineers and designers Many welding instructors will want to use the book as reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs
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