RETURN TO MAIN MENU DC-650 PRO IM463-A May, 2000 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.
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 & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974.
4.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area. 7.c.Do not add the fuel near an open flame welding arc or when the engine is running.
zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse.
TABLE OF CONTENTS Page GENERAL DESCRIPTION ..................................................................................................................7 SPECIFICATIONS ...............................................................................................................................7 INSTALLATION.................................................................................................................................8-13 Location .....................................................
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• 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 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.
GENERAL DESCRIPTION The DC-650 PRO is a multiprocess DC power source designed for the GMAW (MIG), FCAW, SMAW (Stick), and SAW (Sub-Arc) processes, with arc gouging capability as well. It features an international industrial rating of 700 amps, 44 volts at 100% duty cycle. It also has a dual rating of 600 amps, 44 volts at 100% duty cycle, in a 60°C ambient temperature environment. The DC-650 PRO is available from the factory in one model only with a choice of input voltages.
INSTALLATION Input Connections WARNING 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 DC650 PRO. 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.
Figure 1 –9–
Table 1 RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage / Frequency (1) Input Ampere Rating Type 75°C Cu (Copper) on Nameplate Wire in Conduit (1) Grounding Wire Cu (Copper) Fuse Size (Super Lag) 208V / 60 Hz 130 1/0 6 200 230V / 60 Hz 117 1/0 6 175 460V / 60 Hz 59 4 8 100 575V / 60 Hz 47 6 8 75 200V / 50/60 Hz 138 2/0 4 225 220V / 50/60 Hz 125 1/0 6 200 380V / 50/60 Hz 73 4 6 125 400V / 50/60 Hz 69 4 8 100 415V / 50/60 Hz 66 4 8 100 440V / 50/60 Hz 6
Output Connections 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. See Figure 2 for locations of the various case front connection points.
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.
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 . 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.
5. Mode Switch This switch chooses the proper welding mode. Choose from GMAW (MIG), FCAW (flux-cored), SAW (submerged arc), or SMAW (stick). This switch electronically changes the welding characteristics depending on the mode setting. NOTE: The welding cables must also be attached to the proper output studs for best welding performance (See “Output Connections” section). 6. 7.
OPERATING INSTRUCTIONS GMAW (MIG) Operation Properly connect a wire feeder control cable to either the terminal strip or to the Wire Feeder Receptacle. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. -----------------------------------------------------------------------FUMES AND GASES can be dangerous. • Keep your head out of fumes.
FCAW (Flux-Cored) Operation SAW (Submerged Arc) Operation Properly connect a wire feeder control cable to either the terminal strip or to the Wire Feeder Receptacle. 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.
SMAW (Stick) Operation Operation with an LN-9 or NA-5 Wire Feeder 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. NOTE: Conversion Kits are required for LN-9’s and NA-5’s used with the DC-650 PRO.
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.
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.
TROUBLESHOOTING TROUBLE CAUSE WHAT TO DO A. Input contactor chatters. 1. Faulty input contactor. 1. Refer to wiring diagram & check related leads. 2. Low line voltage. 2. Check input power. 3. Pilot transformer (T2) misconnected. 3. Check input connection 1. Supply line fuse blown. 1. Replace if blown-look for reason first. 2. Contactor power circuit dead. 2. Check pilot transformer T2 and associated leads. 3. Broken power lead. 3. Check input voltage at contactor. 4.
TROUBLESHOOTING TROUBLE CAUSE WHAT TO DO E. Machine has low output and no control. 1. Output control Local/Remote switch in wrong position. 1. 2. Output control switch faulty. 2. Check switch and replace if faulty. 3. Fault in leads 75,76, or 77. 3. Check wiring. 4. Faulty Control P.C. Board. 4. Replace. See P.C. Board Troubleshooting Procedure. 5. Output control potentiometer circuit open (lead 75). 5. Check and replace potentiometer if faulty. Check wiring of lead #75. 1.
TROUBLESHOOTING TROUBLE CAUSE WHAT TO DO I. 1. Output control switch in wrong position. 1. Place switch in “Local” position. 2. Faulty output control switch. 2. Check & replace if found faulty. 3. Faulty output control potentiometer. 3. Check & replace if found faulty. 4. Leads or connections open in control circuit. 4. Check lead continuity and connections for an open and repair if necessary. 5. LN-9/NA-5 switch in wrong position. 5. Set to “Off” when not using an LN-9/NA-5. 6.
TROUBLESHOOTING TROUBLE CAUSE WHAT TO DO M. Poor arc characteristics in GMAW mode. 1. Capacitor bank not switching in. 1. Check the Mode SCR (SCR7). Should be on when in GMAW and FCAW modes. 2. Capacitor(s) in output circuit failed. A failure is indicated if the small vent plug on top of a capacitor is raised or blown out. 2. Replace entire bank of capacitors. Do not replace individual capacitors. WARNING: The liquid electrolyte in these capacitors is toxic.
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 CODE Err 000 Err 013 Err 014-016 Err 023 Err 030 Err 100-131 Err 200-206 TROUBLE REMEDY 1. Output overload. 1. Reduce output overload. 2. Shunt miswired or unconnected. 2.
Procedure for Troubleshooting PC Boards WARNING ELECTRIC SHOCK can kill. • Have a qualified individual install and service this equipment. • Turn the power source input power off at the disconnect switch before working on this equipment. • Do not touch electrically hot parts.
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.
204 LINES L2 L3 L2 L1 L3 T1 T3 T2 GND L3 L2 L1 H3 H2 H1 9 8 7 L1 L2 L3 L2 L1 L3 11 10 12 T3 T2 T1 9 8 7 H3 H4 H2 5 4 6 11 10 12 T3 T2 T1 9 8 7 5 4 6 INSULATE WITH TAPE T1 T2 T3 A B C 4 5 6 C B A 6 5 4 INSULATE WITH TAPE T3 T2 T1 INSULATE WITH TAPE 460V/60HZ H1 H4 H3 H2 6 INSULATE WITH TAPE 575V/60HZ H1 4 5 INSULATE WITH TAPE 208V 50 / 60 HZ H2 H3 H1 6 5 4 S1 7 8 9 8 7 9 ON OFF INPUT LINES L3 L2 L1 203 POW
DIMENSION PRINTS DC-650 PRO WITH A K817 UNDERCARRIAGE G A 22.25 B 3.25 27.50 GAS CYLINDER SUPPORT 32.70 39.95 .406 DIA. MTG. HOLES 20.00 27.87 F H C N.A. - Optional K-842 Undercarriage also available. See next page. E 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 C E F G .94 (2.4) H N.A. NOTE DC-650 PRO WITH A K842 UNDERCARRIAGE L A C M D E P R FRONT OF WELDER S B W* H* U* J* V K * LOCATION OF .406 DIA. MOUNTING HOLES INCHES 54.
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.
NOTES
Now Available...12th Edition The Procedure Handbook of Arc Welding New Lessons in Arc Welding This printing will go fast so don’t delay. Place your order now using the coupon below. 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. Practice materials, exercises, questions and answers are suggested for each lesson.
WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de respiración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspirateur pour ôter les fumées des zones de travail.
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