Lincoln Electric IM463-A manual

DC-650 PRO OPERA TOR’S MANUAL Multiprocess DC P o w er 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[...]

– 2 – 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[...]

– 3 – FOR ENGINE powered equipment. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. --------------------------------------------------------------------------------------- 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ---[...]

-4- PR É CA UTIONS DE S Û RET É Pour votre propre protection lire et observer toutes les instructions et les pr é cautions de s û ret é specifiques qui parraissent dans ce manuel aussi bien que les pr é cautions de s û ret é g é n é rales suivantes: S û ret é Pour Soudage A L ’ Arc 1. Protegez-vous contre la secousse é lectrique: a.[...]

– 5 – T ABLE OF CONTENTS Page GENERAL DESCRIPTION ..................................................................................................................7 SPECIFICATIONS ...............................................................................................................................7 INSTALLATION .......................[...]

– 6 – 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick referenc[...]

– 7 – 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,[...]

INST ALLA TION 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 [...]

– 9 – Figure 1[...]

– 10 – Table 1 208V / 60 Hz 230V / 60 Hz 460V / 60 Hz 575V / 60 Hz 200V / 50/60 Hz 220V / 50/60 Hz 380V / 50/60 Hz 400V / 50/60 Hz 415V / 50/60 Hz 440V / 50/60 Hz 500V / 50/60 Hz 130 117 59 47 138 125 73 69 66 63 55 1/0 1/0 4 6 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 Ampe[...]

There are two pairs of studs for the negative connection. It 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 charac[...]

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 . – 12 – Wire Feeder Control Cab le 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[...]

– 13 – 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 t[...]

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. 13. 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[...]

– 15 – OPERA TING INSTRUCTIONS 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 [...]

SA W (Submerged Ar c) 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 ” . If welding electrode negative, reverse the [...]

SMA W (Stic k) Operation If welding electrode positive connect the electrode cable to the “ + ” output studs, and connect the work cable to the “ - ” studs labeled “ SMAW,SAW ” . If welding electrode negative, reverse the connections. Do not make any connections to the center pair of output studs. Set the control panel switches as follo[...]

Set the control panel switches as follows: ------------------------------------------------------------------------ Mode: GMAW ------------------------------------------------------------------------ Output Local or Remote (See “ Output Control Control: Switch ” ) ------------------------------------------------------------------------ LN-9/NA-[...]

– 19 – P ower Source T roubleshooting 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. TR OUBLESHOO TING [...]

– 20 – 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. CA USE 1. Faulty input contactor. 2. Low line voltage. 3. Pilot transformer (T2) misconnected. 1. Supply line fuse blown. 2. Contactor power c[...]

– 21 – TROUBLE E. Machine has low output and no control. F. Machine does not have maximum output. G. Machine will not shut off. H. Variable or sluggish welding arc. CA USE 1. Output control Local/Remote switch in wrong position. 2. Output control switch faulty. 3. Fault in leads 75,76, or 77. 4. Faulty Control P.C. Board. 5. Output control pote[...]

– 22 – TROUBLE I. Output control not functioning on the machine. J. Output control not functioning on remote control. K. Digital meters do not light - or - Digital meter display is incorrect. L. Poor arc striking with semiautomatic wire feeders. CA USE 1. Output control switch in wrong position. 2. Faulty output control switch. 3. Faulty output[...]

– 23 – TROUBLE M. Poor arc characteristics in GMAW mode. N. Ammeter displays “ Err ” and Voltmeter displays a number CA USE 1. Capacitor bank not switching in. 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. 1. An error has been detected. W H A TT OD O 1. [...]

– 24 – TR OUBLESHOO TING Observe all Safety Guidelines detailed througout this manual 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. CA UTION ERROR CODE TROUBLE[...]

– 25 – 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. CA UTION Procedure f or T r oubleshooting PC Boar ds Before replacing a PC board which is suspected of bei[...]

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 als[...]

– 27 – PL1 10/50W 50/100W 10K/2W 10K/2W S S 4-29-94C G REMOTE CONTROL RESISTORS = OHMS/WATT UNLESS OTHERWISE SPECIFIED ALL SWITCH WIRING VIEWED FROM REAR OF SWITCH (SEE DETAILS) RECONNECT PANEL T1 T2 T3 TO SUPPLY LINES (SEE DETAILS) RECONNECT PANEL GMAW, FCAW SMAW, SAW 216 209A 200A 324 320 319 318 317 361 362 363 366 364 TERMINAL STRIPS) (FRON[...]

– 28 – G A B 3.25 27.50 32.70 39.95 GAS CYLINDER SUPPORT .406 DIA. MTG. HOLES F C H E 22.25 20.00 27.87 N.A. - Optional K-842 Undercarriage also available. See next page. A C E D FRONT OF WELDER R P L M U* V * LOCATION OF .406 DIA. MOUNTING HOLES B S W* H* K J* DIMENSION PRINTS DC-650 PRO WITH A K817 UNDERCARRIA GE INCHES 38.00 20.24 40.59 4.75[...]

11-1-96 P-223 P-223 P AR TS LIST FOR DC-650 PR O AND DC-750 This par ts list is pr o vided as an informative guide onl y . This inf ormation was accurate at the time of printing. Howe ver , since these pages are regularly updated in Lincoln Electric ’ s official P ar ts Book (BK-34), alwa ys check with y our Lincoln par ts supplier for the latest[...]

NO TES[...]

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W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA [...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

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