Lincoln Electric Portable Generator IM463 A User Manual
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IM463-A  
May, 2000  
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.  
Date of Purchase:  
Serial Number:  
Code Number:  
Model:  
Where Purchased:  
OPERATOR’S MANUAL  
• 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  
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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. 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 when filling tank. If fuel is spilled, wipe it  
up and do not start engine until fumes have  
been eliminated.  
4.g. 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.  
---------------------------------------------------------------------------------------  
7.d. 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  
moving parts when starting, operating or  
repairing equipment.  
4.h. Also see item 7c.  
7.e. 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.  
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.  
7.f. 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.  
5.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
7.g. To prevent accidentally starting gasoline engines while  
turning the engine or welding generator during maintenance  
work, disconnect the spark plug wires, distributor cap or  
magneto wire as appropriate.  
5.c. 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.  
---------------------------------------------------------------------------------------  
5.d. Never allow the electrode, electrode holder or any other  
7.h. To avoid scalding, do not remove the  
radiator pressure cap when the engine is  
hot.  
electrically “hot” parts to touch a cylinder.  
5.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
5.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
ELECTRIC AND MAGNETIC FIELDS  
5.g. 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.  
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.  
FOR ELECTRICALLY  
powered equipment.  
8.b. EMF fields may interfere with some pacemakers, and  
welders having a pacemaker should consult their physician  
before welding.  
6.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
8.c. Exposure to EMF fields in welding may have other health  
effects which are now not known.  
6.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
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.  
6.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
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.  
FOR ENGINE  
powered equipment.  
7.a. Turn the engine off before troubleshooting and maintenance  
work unless the maintenance work requires it to be running.  
---------------------------------------------------------------------------------------  
8.d.4. Connect the work cable to the workpiece as close as  
possible to the area being welded.  
8.d.5. Do not work next to welding power source.  
7.b. Operate engines in open, well-ventilated  
areas or vent the engine exhaust fumes  
outdoors.  
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Mar. ‘93  
– 3 –  
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zones où l’on pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
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:  
prévenir tout risque d’incendie dû aux étincelles.  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
8. S’assurer que la masse est connectée le plus prés 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  
éloignés de la zone de travail, on augmente le risque de voir  
passer le courant de soudage par les chaines de levage,  
câbles de grue, ou autres circuits. Cela peut provoquer des  
risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue ou  
les vétements mouillés. Porter des gants secs et sans trous  
pour isoler les mains.  
b. Faire trés 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 couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état  
defonctionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le total  
de la tension à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie du  
corps.  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
a. Utiliser un bon masque avec un verre filtrant approprié ainsi  
qu’un verre blanc afin de se protéger les yeux du  
rayonnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
b. Porter des vêtements convenables afin de protéger la peau  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
de soudeur et des aides contre le rayonnement de l‘arc.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
2. Autant que possible, I’installation et l’entretien du poste seront  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse,  
pantalons sans revers, et chaussures montantes.  
effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la debrancher  
à l’interrupteur à la boite de fusibles.  
5. Toujours porter des lunettes de sécurité dans la zone de  
4. Garder tous les couvercles et dispositifs de sûreté à leur place.  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
-4-  
Mar. ‘93  
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TABLE OF CONTENTS  
Page  
GENERAL DESCRIPTION..................................................................................................................7  
SPECIFICATIONS...............................................................................................................................7  
INSTALLATION.................................................................................................................................8-13  
Location........................................................................................................................................8  
Minimizing Problems Due to High Frequency ..............................................................................8  
Input Connections.........................................................................................................................8  
Output Connections.....................................................................................................................11  
Wire Feeder Control Cable Connections.....................................................................................12  
Connection of a K775 Remote Output Control............................................................................13  
Connection to Auxiliary Power.....................................................................................................13  
EXPLANATION OF CONTROLS.....................................................................................................13-14  
OPERATING INSTRUCTIONS........................................................................................................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 Work Lead (21)...............................................................................................17  
CAC-A (Arc Gouging) Operation .................................................................................................18  
Installation with an NA-3..............................................................................................................18  
PROTECTIVE CIRCUITRY ................................................................................................................18  
Thermostatic Protection...............................................................................................................18  
Overload Protection.....................................................................................................................19  
MAINTENANCE..................................................................................................................................19  
TROUBLESHOOTING.....................................................................................................................19-24  
Power Source Troubleshooting ...................................................................................................19  
Troubleshooting Guide..............................................................................................................20-24  
PC Board Troubleshooting Procedure......................................................................................25-26  
WIRING DIAGRAM.............................................................................................................................27  
DIMENSION PRINTS .........................................................................................................................28  
PARTS PAGES.............................................................................................................................Appendix  
Oct 96  
– 5 –  
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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!  
Thank 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.  
Please record your equipment identification information below for future reference. This information can be  
found on your machine nameplate.  
Model Name & Number _____________________________________  
Code & 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:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or  
loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to  
this equipment.  
– 6 –  
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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. There are  
no factory installed options.  
TECHNICAL SPECIFICATIONS  
Ordering  
Information Description  
Product  
Input  
Frequency  
Rated  
Output  
Additional  
Output  
Dimensions  
& Weight  
27.50 (1) x 22.25 x 38 in  
(698 x 565 x 965 mm)  
K1410  
Multiprocess  
DC Power  
Source  
60 Hz  
700 Amps  
44 Volts  
600 Amps  
44 Volts  
725 lbs  
(330 kg)  
100% Duty  
Cycle  
100% Duty  
Cycle  
INPUT SPECIFICATIONS  
Input  
Voltage  
Input Currents - 44 V Output  
Idle  
Current  
Idle  
Power (2)  
@ 600 A @ 700 A  
@ 750 A  
12 A  
11 A  
6 A  
1.5 kW  
1.5 kW  
1.5 kW  
1.5 kW  
208 V  
230 V  
460 V  
575 V  
130 A  
117 A  
59 A  
146 A  
132 A  
66 A  
153 A  
139 A  
69 A  
5 A  
47 A  
53 A  
56 A  
OUTPUT SPECIFICATIONS  
Rated Output  
(DC)  
Additional  
Output Ratings  
At 60°C  
Auxiliary  
Outputs  
Open  
Circuit  
Voltage  
Output  
Current  
Range  
Efficiency  
Power Factor (2)  
At 40°C  
Ambient  
Ambient  
Temperature  
Temperature  
700 Amps  
44 Volts  
100%  
600 Amps  
44 Volts  
100%  
Two 115 Volts AC GMAW 15-45  
80-750 Amps  
@ 600A - 44V load:  
Eff= 65% PF= .88  
15 Amps  
FCAW 15-60  
SAW 10-60  
Duty Cycle  
Duty Cycle  
One 42 Volts AC SMAW 65-70  
@ 700A - 44V load:  
10 Amps  
Eff= 66% PF= .90  
750 Amps  
44 Volts  
60%  
750 Amps  
44 Volts  
35%  
@ 750A - 44V load:  
Eff= 67% PF= .90  
Duty Cycle  
Duty Cycle  
(1)  
Overall height 30.75 in (781 mm) including lift bale.  
(2) Loaded readings are taken with a full auxiliary load. No load ratings are taken without auxiliary loads.  
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Input Connections  
INSTALLATION  
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.  
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.  
• Connect grounding screw  
earth ground.  
to a good  
• 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.  
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 three phase line.  
-------------------------------------------------------------  
Please read all of this section before starting  
installation. Refer to Figure 1 during installation.  
Location  
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.  
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.  
On welders with multiple input voltages, be sure that  
the reconnect panel is connected per the instructions  
that follow.  
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.  
CAUTION  
FAILURE TO FOLLOW THESE INSTRUCTIONS  
CAN CAUSE IMMEDIATE FAILURE OF  
COMPONENTS INSIDE THE WELDER.  
Minimizing Problems Due to High  
Frequency  
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.  
This welder, like all electrical equipment, can be  
subject to interference from strong sources of high  
frequency energy. Sources of high frequency 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.  
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.  
Dec 95  
– 8 –  
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Figure 1  
– 9 –  
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Table 1  
(1)  
RECOMMENDED INPUT WIRE AND FUSE SIZES  
Input Voltage /  
Frequency  
Input Ampere Rating Type 75°C Cu (Copper)  
Grounding Wire  
Cu (Copper)  
Fuse Size  
(Super Lag)  
on Nameplate  
Wire in Conduit  
208V / 60 Hz  
230V / 60 Hz  
130  
1/0  
6
6
8
8
4
6
6
8
8
8
8
200  
175  
100  
75  
117  
59  
1/0  
4
460V / 60 Hz  
575V / 60 Hz  
47  
6
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  
138  
125  
73  
2/0  
1/0  
4
225  
200  
125  
100  
100  
100  
75  
69  
4
66  
4
63  
4
55  
6
(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  
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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.  
Output Connections  
See Figure 2 for locations of the various case front  
connection points.  
RECOMMENDED CABLE SIZES  
(RUBBER COVERED COPPER - RATED 75°C)  
Cable Sizes for Combined Length of Work and Electrode Cables  
Output  
700A  
Duty Cycle  
100%  
0 - 100 ft  
(0 - 30 m)  
100 - 200 ft  
(30 - 60 m)  
200 - 250 ft  
(60 - 75 m)  
2 - 2/0  
2 - 3/0  
2 - 4/0  
(2 - 70 mm2)  
(2 - 95 mm2)  
(2 - 120 mm2)  
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 right of the case front, marked “+”  
(#5, Figure 2). Connection can be made to either or  
both of the “+” studs.  
4
5
3
Figure 2  
There are two pairs of studs for the negative  
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.  
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 characteristics of  
the machine, giving poor welding performance.  
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.  
– 11 –  
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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.  
DC-650 PRO  
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 *  
LN-7  
400A  
60%  
K480-XX  
LN-8 / LN-9  
NA-5  
600A  
60%  
80%  
K595-XX  
K597-XX  
1000A  
* 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  
.
– 12 –  
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Connection of a K775 Remote Output  
Control  
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.  
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  
.
Figure 4  
EXPLANATION OF CONTROLS  
Refer to Figure 3 for placement of the DC-650 PRO  
controls.  
3. Arc Force Potentiometer  
1. Output Control 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.  
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. If  
using an LN-9 or NA-5 see “Operating with LN-9  
or NA-5 Wire Feeder” section.  
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 operating 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”.  
– 13 –  
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5. Mode Switch  
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.  
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.  
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 the code and serial  
numbers in a safe place. These numbers will be  
required if replacement parts are needed in the  
future.  
NOTE: The welding cables must also be attached to  
the proper output studs for best welding  
performance (See “Output Connections”  
section).  
6. 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.  
14. 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  
changing and setting procedures. The output  
current can be preset from the Output Control or  
from a remote control attached to the terminal  
strip.  
7. 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).  
15. 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.  
8. Power Switch and Pilot Light  
Turns the DC-650 PRO on and off. The red pilot  
light illuminates when the machine is turned “On”.  
9. Circuit 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).  
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 in the LN-9/NA-5 mode.  
(see “Operation with LN-9 or NA-5 Wire Feeder”  
section).  
10. Strain Reliefs  
These strain reliefs are provided for control cables  
going to the terminal strips.  
11. 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.  
– 14 –  
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OPERATING INSTRUCTIONS  
GMAW (MIG) Operation  
Properly connect a wire feeder control cable to either  
the terminal strip or to the Wire Feeder Receptacle.  
WARNING  
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.  
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.  
Set the control panel switches as follows:  
------------------------------------------------------------------------  
• Keep your head out of fumes.  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
Mode:  
GMAW  
------------------------------------------------------------------------  
WELDING SPARKS can cause fire or  
explosion.  
------------------------------------------------------------------------  
Output  
Local or Remote (See “Output Control  
• Keep flammable material away.  
• Do not weld on closed containers.  
Control:  
Switch”)  
------------------------------------------------------------------------  
------------------------------------------------------------------------  
ARC RAYS can burn eyes and skin.  
• Wear eye, ear and body  
LN-9/NA-5: Off, unless an LN-9 or NA-5 is being  
used.  
protection.  
------------------------------------------------------------------------  
------------------------------------------------------------  
Wire Feeder Set to match the electrode polarity.  
Voltmeter:  
See additional warning information at  
front of this operator’s manual.  
-----------------------------------------------------------  
------------------------------------------------------------------------  
Output  
Terminals:  
Remote  
------------------------------------------------------------------------  
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 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 preset at the output studs  
of the DC-650 PRO, and the ammeter will display the  
output current.  
– 15 –  
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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. Do not  
make any connections to the left hand pair of output  
studs.  
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:  
Set the control panel switches as follows:  
------------------------------------------------------------------------  
------------------------------------------------------------------------  
Mode:  
FCAW  
Mode:  
SAW  
------------------------------------------------------------------------  
------------------------------------------------------------------------  
Output  
Control:  
Local or Remote (See “Output Control  
Switch”)  
Output  
Control:  
Local or Remote (See “Output Control  
Switch”)  
------------------------------------------------------------------------  
------------------------------------------------------------------------  
LN-9/NA-5: Off, unless an LN-9 or NA-5 is being  
LN-9/NA-5: Off, unless an LN-9 or NA-5 is being  
used.  
used.  
------------------------------------------------------------------------  
------------------------------------------------------------------------  
Wire Feeder Set to match the electrode polarity.  
Voltmeter:  
Wire Feeder Set to match the electrode polarity.  
Voltmeter:  
------------------------------------------------------------------------  
------------------------------------------------------------------------  
Output  
Terminals:  
Output  
Terminals:  
Remote  
Remote  
------------------------------------------------------------------------  
------------------------------------------------------------------------  
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.  
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 feeder according to the wire feeder  
instruction manual.  
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.  
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.  
– 16 –  
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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.  
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.  
Set the control panel switches as follows:  
------------------------------------------------------------------------  
Setup and Operation  
Mode:  
SMAW  
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.  
------------------------------------------------------------------------  
Output  
Control:  
Local or Remote (See “Output Control  
Switch”)  
------------------------------------------------------------------------  
LN-9/NA-5: Off  
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.  
------------------------------------------------------------------------  
Wire Feeder Has no effect in the SMAW mode.  
Voltmeter:  
------------------------------------------------------------------------  
Output  
Terminals:  
On  
------------------------------------------------------------------------  
When welding, the Voltmeter displays the welding  
voltage, as measured on the output studs of the DC-  
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.  
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.  
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:  
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.  
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  
– 17 –  
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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.  
Set the control panel switches as follows:  
------------------------------------------------------------------------  
Mode:  
GMAW  
------------------------------------------------------------------------  
Output  
Control:  
Local or Remote (See “Output Control  
Switch”)  
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.  
------------------------------------------------------------------------  
LN-9/NA-5: Off  
------------------------------------------------------------------------  
Wire Feeder Has no effect when arc gouging.  
Voltmeter:  
When using the terminal strip for wire feeder  
connection, extend the 21 lead to the workpiece as  
follows:  
------------------------------------------------------------------------  
Output  
Terminals:  
On  
------------------------------------------------------------------------  
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  
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.  
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.  
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  
PROTECTIVE CIRCUITRY  
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.  
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.  
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.  
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  
“GMAW, FCAW”. Do not make any connections to  
the left hand pair of output studs.  
Dec 95  
– 18 –  
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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.  
TROUBLESHOOTING  
WARNING  
Routine Maintenance  
ELECTRIC SHOCK can kill.  
• Have a qualified individual install and  
service this equipment.  
1. The fan motor has sealed bearings which require  
no service.  
• Turn the input power off at the fuse  
box before working on equipment.  
• Do not touch electrically hot parts.  
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  
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  
– 19 –  
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TROUBLESHOOTING  
WHAT TO DO  
TROUBLE  
CAUSE  
1. Refer to wiring diagram &  
check related leads.  
A. Input contactor chatters.  
1. Faulty input contactor.  
2. Check input power.  
2. Low line voltage.  
3.  
1.  
Check input connection instructions  
Replace if blown-look for reason first.  
.
3.  
Pilot transformer (T2) misconnected.  
B. Machine input contactor does  
not operate.  
1. Supply line fuse blown.  
2. Check pilot transformer T2 and  
associated leads.  
2. Contactor power circuit dead.  
3.  
4.  
5.  
Check input voltage at contactor.  
Check voltage against instructions.  
3. Broken power lead.  
4. Wrong input voltage.  
5. Primary thermostats open.  
Check for overheating; make sure fan is  
operating and there is no obstruction to free  
air flow. Replaces faulty thermostat.  
6. Replace coil.  
6. Open input contactor coil.  
7. Replace switch.  
7. Power ”On/Off” switch (S1) not  
closing.  
1. Repair connection.  
2. Repair.  
C. Machine input contactor  
operates, but no output when  
trying to weld.  
1. Electrode or work lead loose or  
broken.  
2. Open main transformer (T1)  
primary or secondary circuit.  
3. Replace. See P.C. Board  
Troubleshooting Procedure.  
3. Defective Control P.C. Boards.  
4. Check setting/operation of the  
Output Terminals switch.  
4. Output terminals switch set  
wrong or faulty.  
5.  
Check for overheating; make sure fan is  
operating and there is no obstruction to free  
air flow. Replaces faulty thermostat.  
5. Secondary thermostat open.  
1. Check wiring.  
D. Machine has high output and  
no control.  
1. Fault in leads 75, 76, or 77.  
2. Open in feedback circuity.  
2.  
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.  
– 20 –  
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TROUBLESHOOTING  
WHAT TO DO  
TROUBLE  
CAUSE  
1. Check position of switch.  
E. Machine has low output and  
no control.  
1. Output control Local/Remote  
switch in wrong position.  
2. Check switch and replace if faulty.  
3. Check wiring.  
2. Output control switch faulty.  
3. Fault in leads 75,76, or 77.  
4. Faulty Control P.C. Board.  
4. Replace. See P.C. Board  
Troubleshooting Procedure.  
5. Check and replace  
potentiometer if faulty. Check  
wiring of lead #75.  
5. Output control potentiometer  
circuit open (lead 75).  
1. Check and replace if blown  
after checking for reason for  
blown fuse.  
F. Machine does not have  
maximum output.  
1. One input fuse blown.  
2. Check for open and repair.  
2. One phase of main transformer  
open.  
3. Replace. See P.C. Board  
Troubleshooting Procedure.  
3. Faulty Control P.C. Board.  
4. Output control potentiometer.  
4. Check and replace if faulty.  
5. Check and repair broken leads.  
5. Output control potentiometer  
lead 75 open.  
6. Check and replace if defective.  
6. Defective main SCR bridge.  
1. Input contactor contacts frozen.  
2. Defective On/Off switch, S-1.  
1. Check and replace if  
necessary.  
G. Machine will not shut off.  
2. Replace.  
1. Check & clean all connections.  
2. Check table in instruction manual.  
H. Variable or sluggish welding  
arc.  
1. Poor work or electrode  
connection.  
2. Welding leads too small.  
3. Check procedures for  
recommended settings.  
3. Welding current or voltage too  
low.  
4. Check & replace if defective.  
4. Leads or connections open in control  
circuit.  
5. Only connect one pair of  
negative studs to the work.  
5. LN-9/NA-5 switch in wrong position.  
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.  
– 21 –  
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TROUBLESHOOTING  
WHAT TO DO  
TROUBLE  
CAUSE  
1. Place switch in “Local” position.  
I. Output control not functioning  
on the machine.  
1. Output control switch in wrong  
position.  
2. Check & replace if found faulty.  
3. Check & replace if found faulty.  
2. Faulty output control switch.  
3. Faulty output control  
potentiometer.  
4. Check lead continuity and  
connections for an open and  
repair if necessary.  
4. Leads or connections open in  
control circuit.  
5. Set to “Off” when not using an  
5. LN-9/NA-5 switch in wrong  
position.  
LN-9/NA-5.  
6. Replace. See P.C. Board  
Troubleshooting Procedure.  
6. Faulty Control P.C. Board.  
1. Place switch in “Output Control  
J. Output control not functioning  
on remote control.  
1. Output control switch in wrong  
position.  
Remote”.  
2. Check & replace if found faulty.  
3. Check & replace if found faulty.  
2. Faulty output control switch.  
3. Faulty remote control  
potentiometer.  
4. Check all leads and  
connections, internal or remote,  
for continuity; repair if  
necessary.  
4. Leads or connections open in  
control circuit.  
5. Replace. See P.C. Board  
Troubleshooting Procedure.  
5. Faulty Control P.C. Board.  
1. Replace. See P.C. Board  
Troubleshooting Procedure.  
K. Digital meters do not light  
- or -  
1. Faulty Meter P.C. Board.  
2. Faulty Control P.C. Board.  
3. Secondary thermostat is open.  
2. Replace. See P.C. Board  
Troubleshooting Procedure.  
Digital meter display is  
incorrect.  
3. See “Thermostatic Protection”  
section.  
1. Work connection must be  
adequate for application.  
L. Poor arc striking with  
1. Poor work connection.  
2. Improper procedures.  
3. Defective P.C. Board.  
semiautomatic wire feeders.  
2. Adjust procedures for improved  
starting.  
3. Replace. See P.C. Board  
Troubleshooting Procedure.  
– 22 –  
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TROUBLESHOOTING  
WHAT TO DO  
TROUBLE  
CAUSE  
1.  
Check the Mode SCR (SCR7). Should be on  
when in GMAW and FCAW modes.  
M. Poor arc characteristics in  
GMAW mode.  
1. Capacitor bank not switching in.  
2.  
Replace entire bank of capacitors. Do not  
replace individual capacitors.  
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.  
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.  
1.  
See Error code Troubleshooting Guide.  
N. Ammeter displays “Err” and  
1. An error has been detected.  
Voltmeter displays a number  
ACCESSORY TROUBLESHOOTING  
WHAT TO DO  
TROUBLE  
CAUSE  
1. Place switch in “Remote”.  
A. Output Control not functioning  
on Remote Control.  
1. Output Control switch in wrong  
position.  
2. Check & replace if found faulty.  
3. Check & replace if found faulty.  
2. Faulty Output Control switch.  
3. Faulty Remote Control  
potentiometer.  
4. Check all leads & connections.  
4. Leads or connections open in  
control circuit.  
5. See P.C. Board  
5. Faulty Control P.C. Board.  
Troubleshooting Procedure.  
1. Place switch in “Local” position.  
B. Output Control not functioning  
on the machine.  
1. Output Control switch in the  
wrong position.  
2. Check & replace if found faulty.  
3. Check & replace if found faulty.  
2. Faulty Output Control switch.  
3. Faulty Output Control  
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.  
– 23 –  
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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  
TROUBLE  
REMEDY  
Err 000  
1. Output overload.  
1. Reduce output overload.  
2. Shunt miswired or unconnected.  
3. Faulty Control PC Board.  
1. Missing Phase Signal.  
2. Check shunt and wiring. Repair if necessary.  
3. Replace, See PC Board Troubleshooting Procedure.  
Err 013  
1. Check for 66 VAC ±10% between leads 329 and 332  
of J12 at control board. Repair if necessary.  
2. Faulty Control PC Board.  
1. Faulty Control PC Board.  
1. Noisy line.  
2. Replace. See PC Board Troubleshooting Procedure.  
1. Replace. See PC Board Troubleshooting Procedure.  
Err 014-016  
Err 023  
1. Make sure machine frame is grounded. See  
installation section on minimizing problems due to  
high frequency interference.  
2. Faulty Control PC Board.  
2. Replace. See PC Board Troubleshooting Procedure.  
Err 030  
1. Control transformer miswired.  
1. Swap leads 330 and 332A at Control Transformer T3  
in the control box.  
2. Main Transformer Auxiliary  
miswired.  
2. Check leads 29, 30B, and 32B from main  
transformer. Repair if necessary.  
3. Faulty Control PC Board.  
1. Mode Switch is set between two positions.  
2. Faulty Mode Switch.  
3. Replace. See PC Board Troubleshooting Procedure.  
1. Reposition mode switch.  
Err 100-131  
2. Check and replace if found faulty.  
3. Mode Switch wiring bad.  
4. Faulty Control Board.  
1. Noisy input line.  
3. Check all leads for continuity. Repair if necessary.  
4. Replace. See PC Board Troubleshooting Procedure.  
Err 200-206  
1. Make sure machine frame is grounded. See  
installation section on minimizing problems due to  
high frequency interference.  
2. 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.  
– 24 –  
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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.  
---------------------------------------------------------------------  
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 board 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.  
– 25 –  
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Protection PC 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 there, verify that the  
following voltages are present at the output of the  
auxiliary transformer, T3.  
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.  
Auxiliary Transformer (T3)  
Secondary Lead Color  
Plug P8  
Locations  
Approximate  
Voltage  
Red to Red  
Red to White  
7 to 9  
7 to 8  
1 to 2  
5 to 6  
3 to 4  
36V AC  
18V AC  
10V AC  
24V AC  
18V AC  
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. If  
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.  
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 lead 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.  
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.  
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.  
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 supposed 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.  
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.  
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.  
– 26 –  
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W
B
3 0 4 A  
3 0 2 A  
3 0 4  
3 0 2  
3 0 7 A  
3 0 9 A  
3 0 8  
3 6 4  
3 3 2  
3 6 3  
3 6 2  
3 2 9  
3 1 4  
3 6 1  
3 6 6  
G 1  
G 2  
G 3  
G 4  
G 5  
G 6  
3 1 5  
3 1 6  
3 2 0 A  
3 0 0  
3 1 0  
3 1 1  
3 2 0 A  
3 1 2  
3 1 3  
3 7 5  
3 7 5 A  
3 4 7  
4
3
3 4 3  
3 4 2  
3 4 1  
3 4 0  
4
3
3 4 6  
3 4 5  
2
1
2
3 4 4  
1
W H I T E  
B L U E  
– 27 –  
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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. 
E
INCHES 38.00 20.24 40.59 4.75 29.93 39.07  
.94  
N.A.  
NOTE  
(CM) (96.5) (51.4) (103.1) (12.1) (76.0) (99.2) (2.4)  
UNITS  
A
B
C
E
F
G
H
DC-650 PRO WITH A K842 UNDERCARRIAGE  
L
A
M
C
D
E
P
R
S
FRONT OF  
WELDER  
B
W*  
U*  
H*  
J*  
K
V
* 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)  
UNITS  
A
B
C
D
E
H
J
K
L
M
P
R
S
INCHES 7.11 20.00 27.65 29.93  
(CM) (18.1) (50.8) (70.2) (76.0)  
UNITS  
T
U
V
W
– 28 –  
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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  
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NOTES  
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Now Available...12th Edition  
New Lessons in Arc Welding  
The Procedure Handbook of Arc Welding  
Lessons, simply written, cover manipulatory techniques;  
machine and electrode characteristics; related subjects,  
such as distortion; and supplemental information on arc  
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exercises, questions and answers are suggested for each  
lesson.  
With over 500,000 copies of previous editions published  
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● Do not touch electrically live parts or  
electrode with skin or wet clothing.  
● Insulate yourself from work and  
ground.  
● Keep flammable materials away.  
● Wear eye, ear and body protection.  
WARNING  
SpanisAh VISO DE  
PRECAUCION  
French  
● No toque las partes o los electrodos ● Mantenga el material combustible  
● Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa  
mojada.  
● Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
● Ne laissez ni la peau ni des  
● Gardez à l’écart de tout matériel  
inflammable.  
● Protégez vos yeux, vos oreilles et  
votre corps.  
vêtements mouillés entrer en contact  
avec des pièces sous tension.  
ATTENTION  
● Isolez-vous du travail et de la terre.  
German  
● Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
● Isolieren Sie sich von den  
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
● Não toque partes elétricas e  
electrodos com a pele ou roupa  
molhada.  
● Mantenha inflamáveis bem  
guardados.  
● Use proteção para a vista, ouvido e  
corpo.  
ATENÇÃO  
● Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
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● Keep your head out of fumes.  
● Use ventilation or exhaust to  
remove fumes from breathing zone.  
● Turn power off before servicing.  
● Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
● Los humos fuera de la zona de  
respiración.  
● Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
● Desconectar el cable de  
alimentación de poder de la  
máquina antes de iniciar cualquier  
servicio.  
● No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
● N’opérez pas avec les panneaux  
ouverts ou avec les dispositifs de  
protection enlevés.  
● Gardez la tête à l’écart des fumées.  
● Utilisez un ventilateur ou un  
aspirateur pour ôter les fumées des  
zones de travail.  
● Débranchez le courant avant  
l’entretien.  
ATTENTION  
German  
● Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
● Vermeiden Sie das Einatmen von  
Schweibrauch!  
● Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
● Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig  
öffnen; Maschine anhalten!)  
WARNUNG  
Portuguese  
● Mantenha-se afastado das partes  
moventes.  
● Não opere com os paineis abertos  
ou guardas removidas.  
● Mantenha seu rosto da fumaça.  
● Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
● Não opere com as tampas removidas.  
● Desligue a corrente antes de fazer  
serviço.  
ATENÇÃO  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
• 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  
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