Lincoln Electric DC-650 PRO Operator'S Manual Download Page 1

DC-650  PRO

OPERATOR’S MANUAL

Multiprocess DC Power Source

For use with machines having Code Numbers 9814, 9836 and 9839 Only.

IM463-A

May, 2000

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.

• 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

• World's Leader in Welding and Cutting Products •

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

Summary of Contents for DC-650 PRO

Page 1: ...ion 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...

Page 2: ...lation 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 elec...

Page 3: ...fans and all other moving parts when starting operating or repairing equipment 7 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when ne...

Page 4: ...t non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons...

Page 5: ...15 18 GMAW MIG Operation 15 FCAW Flux Cored Operation 16 SAW Submerged Arc Operation 16 SMAW Stick Operation 17 Operation with an LN 9 or NA 5 Wire Feeder 17 Setup and Operation 17 Connection of the W...

Page 6: ...e the information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title pa...

Page 7: ...imensions Weight 27 50 1 x 22 25 x 38 in 698 x 565 x 965 mm 725 lbs 330 kg OUTPUT SPECIFICATIONS 700 Amps 44 Volts 100 Duty Cycle 750 Amps 44 Volts 60 Duty Cycle 600 Amps 44 Volts 100 Duty Cycle 750 A...

Page 8: ...r 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 referenc...

Page 9: ...9 Figure 1...

Page 10: ...2 0 1 0 4 4 4 4 6 6 6 8 8 4 6 6 8 8 8 8 200 175 100 75 225 200 125 100 100 100 75 Input Voltage Frequency Input Ampere Rating on Nameplate Type 75 C Cu Copper Wire in Conduit Grounding Wire Cu Copper...

Page 11: ...2 3 0 2 95 mm2 200 250 ft 60 75 m 2 4 0 2 120 mm2 Cable Sizes for Combined Length of Work and Electrode Cables RECOMMENDED CABLE SIZES RUBBER COVERED COPPER RATED 75 C Figure 2 Output Connections See...

Page 12: ...he Wire Feeder Receptacle choose a control cable from the chart below LN 7 LN 8 LN 9 NA 5 400A 600A 1000A 60 60 80 K480 XX K595 XX K597 XX Wire Feed Unit Current Capacity Duty Cycle Cable Type Cables...

Page 13: ...o 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 adjus...

Page 14: ...re feed unit The DC 650 PRO voltmeter will display when in the LN 9 NA 5 mode see Operation with LN 9 or NA 5 Wire Feeder section 14 5 Mode Switch This switch chooses the proper welding mode Choose fr...

Page 15: ...nect 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 R...

Page 16: ...voltage present 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 str...

Page 17: ...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 fe...

Page 18: ...ape 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...

Page 19: ...nnels 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 o...

Page 20: ...mer T2 and associated leads 3 Check input voltage at contactor 4 Check voltage against instructions 5 Check for overheating make sure fan is operating and there is no obstruction to free air flow Repl...

Page 21: ...switch in wrong position WHAT TO DO 1 Check position of switch 2 Check switch and replace if faulty 3 Check wiring 4 Replace See P C Board Troubleshooting Procedure 5 Check and replace potentiometer i...

Page 22: ...ary thermostat is open 1 Poor work connection 2 Improper procedures 3 Defective P C Board WHAT TO DO 1 Place switch in Local position 2 Check replace if found faulty 3 Check replace if found faulty 4...

Page 23: ...ING TROUBLE A Output Control not functioning on Remote Control B Output Control not functioning on the machine CAUSE 1 Output Control switch in wrong position 2 Faulty Output Control switch 3 Faulty R...

Page 24: ...C Board Troubleshooting Procedure 1 Check for 66 VAC 10 between leads 329 and 332 of J12 at control board Repair if necessary 2 Replace See PC Board Troubleshooting Procedure 1 Replace See PC Board Tr...

Page 25: ...on 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 sa...

Page 26: ...from the Control board as well Very little external diagnostic work can be performed on this board 26 If one control or function of the machine does not appear to be working it is best to trace out t...

Page 27: ...10 11 12 MODE SWITCH 366 361 362 363 364 VOLTMETER LN 9 NA 5 SHOWN ON OUTPUT CONTROL SHOWN IN LOCAL ON OFF 115 VAC 115 VAC 42 VAC 1 11 12 13 5 6 J4 G1 G2 G3 G4 G5 G6 300 310 311 312 313 1 2 3 4 5 6 7...

Page 28: ...ENSION PRINTS DC 650 PRO WITH A K817 UNDERCARRIAGE INCHES 38 00 20 24 40 59 4 75 29 93 39 07 94 N A CM 96 5 51 4 103 1 12 1 76 0 99 2 2 4 UNITS A B C E F G H NOTE INCHES 7 11 20 00 27 65 29 93 CM 18 1...

Page 29: ...ts 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 a...

Page 30: ...NOTES...

Page 31: ...383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to...

Page 32: ...ch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa mojada Aislese del trabajo y...

Page 33: ...Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el ca...

Page 34: ...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 World s Leader in Welding and Cutting Pr...

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