Lincoln Electric IM463 User Manual

Multiprocess DC Power Source

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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.

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.

DO NOT INSTALL,

IM463-A

May, 2000

DC-650 PRO

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: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

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. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

ELECTRIC SHOCK can
kill.

1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

1.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire)

Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically“hot”.

1.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

1.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

1.g. Never dip the electrode in water for cooling.

1.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

1.j. Also see Items 4.c. and 6.

ARC RAYS can burn.

2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

2.c. Protect other nearby personnel with suitable non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

3.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep your
head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

3.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.

3.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

3.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

3.e. Also see item 7b.

WELDING SPARKS can
cause fire or explosion.

4.a..Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

4.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

4.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

4.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned.” For information purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).

4.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Apr. ‘93

– 2 –

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.

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.

4.h. Also see item 7c.

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.

---------------------------------------------------------------------------------------

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.

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.

5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

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
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.

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.

FOR ELECTRICALLY
powered equipment.

6.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

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.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.

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.

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.

---------------------------------------------------------------------------------------

7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND MAGNETIC FIELDS

may be dangerous

8.a. Electric current flowing through any
conductor causes localized Electric and
Magnetic Fields (EMF). Welding current
creates EMF fields around welding cables
and welding machines.

8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

8d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

8.d.1. Route the electrode and work cables together - Secure
them with tape when possible.

8.d.2. Never coil the electrode lead around your body.

8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side,
the work cable should also be on your right side.

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.

---------------------------------------------------------------------------------------

– 3 –

Mar. ‘93

PRÉCAUTIONS DE SÛRETÉ

zones où l’on pique le laitier.

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 géné rales
suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

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 sû r état
defonctionnement.

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.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-é
soudage.

lectrode s’applicuent aussi au pistolet de

6. Eloigner les matériaux inflammables ou les recouvrir afin de
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.

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.

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.

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.

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:

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

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.

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 é paisse,
pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

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 branchéà une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
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.

4. Garder tous les couvercles et dispositifs de sûretéà leur place.

-4-

Mar. ‘93

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

– 5 –

Oct 96

for selecting a QUALITY product by Lincoln Electric. We want you

Thank 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.

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 –

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.

TECHNICAL SPECIFICATIONS

Ordering

Information

K1410 Multiprocess

Product

Description

DC Power

Source

Input

Frequency

60 Hz 700 Amps

Output

44 Volts

100% Duty

INPUT SPECIFICATIONS

Input

Voltage

Input Currents - 44 V Output

@ 600 A @ 700 A @ 750 A

Rated

Cycle

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.

Additional

Output

600 Amps

44 Volts

100% Duty

Cycle

Idle

Current

Idle

Power

Dimensions

& Weight

(1)

27.50
(698 x 565 x 965 mm)

x 22.25 x 38 in

725 lbs

(330 kg)

(2)

208 V
230 V
460 V
575 V

130 A 146 A 153 A
117 A 132 A 139 A

59 A 66 A 69 A
47 A 53 A 56 A

OUTPUT SPECIFICATIONS

Rated Output

(DC)

At 40°C

Ambient

Temperature

700 Amps

44 Volts

100%

Duty Cycle

750 Amps

44 Volts

60%

Duty Cycle

Additional

Output Ratings

At 60°C

Ambient

Temperature

600 Amps

44 Volts

100%

Duty Cycle

750 Amps

44 Volts

35%

Duty Cycle

Two 115 Volts AC

One 42 Volts AC

Auxiliary

Outputs

15 Amps

10 Amps

Open

Circuit

Voltage

GMAW 15-45
FCAW 15-60
SAW 10-60
SMAW 65-70

12 A
11 A

6 A
5 A

80-750 Amps

1.5 kW

1.5 kW

1.5 kW

1.5 kW

Output

Current

Range

Efficiency

Power Factor

@ 600A - 44V load:

Eff= 65% PF= .88

@ 700A - 44V load:

Eff= 66% PF= .90

@ 750A - 44V load:

Eff= 67% PF= .90

(2)

(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.

– 7 –

INSTALLATION

Input Connections

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power off at the
disconnect switch bef ore installing
or servicing this machine.

• Do not touch electrically “hot” parts such as
output terminals or internal wiring.

• Connect grounding screw to a good
earth ground.

• Do not operate with covers removed.

• Turn power switch “OFF” before connecting

or disconnecting cables or other equipment.

• Only qualified personnel should install or
service this equipment.

-------------------------------------------------------------

Please read all of this section before starting
installation. Refer to Figure 1 during installation.

Location

Place the welder where clean cooling air can freely
circulate in through the front louvers, and out through
the rear louvers. The presence of dirt, dust or any
foreign material that can be drawn in through the
louvers should be kept to a minimum. Failure to
observe these precautions can result in excessive
operating temperatures, and welder shutdowns due to
thermal overload.

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.

An entry for the input power lines (#1, Fig. 1) is
provided on the case back. The knockout is 2.00” (51
mm) in diameter. Access to the input panel
connection area is gained by removing the two bolts
which secure the Reconnect Door (#2, Fig. 1) and
lifting the door upward.

Select the input lead wire sized according to local and
national electrical codes. A chart conforming to the
U.S. National Electrical Code is provided as a
reference. (Table 1). Have a qualified electrician
connect the input leads to terminals L1, L2 and L3 on
the reconnect panel (#3, Fig. 1), in accordance with all
local and national electrical codes, and with the
diagram (#4, Fig. 1) located on the inside of the cover.
Use a three phase line.

The frame of the welder must be grounded. A ground
terminal (#5, Fig. 1) marked with the symbol
is located on the bottom of the input box for this
purpose. Check local and national electrical codes for
details on proper grounding methods.

On welders with multiple input voltages, be sure that
the reconnect panel is connected per the instructions
that follow.

DC-650 PRO power sources can be stacked three
high, provided that the bottom machine is on a stable,
hard, level surface. Be sure that the two pins in the
roof of the lower machine fit into the holes in the base
of the DC-650 PRO above it.

Minimizing Problems Due to High
Frequency

This welder, like all electrical equipment, can be
subject to interference from strong sources of high
frequency energy. Sources of high 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.

CAUTION

FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN CAUSE IMMEDIATE FAILURE OF
COMPONENTS INSIDE THE WELDER.

Welders are shipped connected for the highest rated
input voltage. To change this to a lower voltage, first
reconnect the pilot transformer leads H2, H3 or H4 per
the diagram attached to the inside of the reconnect
door. Next, remove and reinstall the reconnect links
according to the same diagram.

Fuse the input leads with the recommended size
super lag fuses or delay type circuit breakers. See
Table 1 for the recommended fuse and/or circuit
breaker sizes. Using fuses or breakers smaller than
those recommended may result in nuisance “tripping”,
and possible damage to circuit breakers from welder
inrush currents at turn on, even if the machine is not
used to weld at high currents.

Dec 95Dec 95

– 8 –– 8 –

Figure 1

– 9 –

Table 1

RECOMMENDED INPUT WIRE AND FUSE SIZES

(1)

Input Voltage /

Frequency

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

(1)

For a 600A / 44V / 100% duty cycle output in a 40°C ambient location. Refer to your local or national electrical

Input Ampere Rating

on Nameplate

130
117

59

47
138
125

73

69

66

63

55

Type 75°C Cu (Copper)

Wire in Conduit

1/0
1/0

4

6
2/0
1/0

4

4

4

4

6

Grounding Wire

Cu (Copper)

6
6
8
8
4
6
6
8
8
8
8

Fuse Size

(Super Lag)

200
175
100

75
225
200
125
100
100
100

75

code for other conditions.

MAY,95

– 10 –

3

4

5

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

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

700A

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.

Duty Cycle

100%

(2 - 70 mm

0 - 100 ft

(0 - 30 m)

2 - 2/0

100 - 200 ft

(30 - 60 m)

2

)

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.

2 - 3/0

(2 - 95 mm2)

200 - 250 ft

(60 - 75 m)

2 - 4/0

(2 - 120 mm2)

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 characteristics of
the machine, giving poor welding performance.

Figure 2

– 11 –

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 flux­cored arc welding.

The left hand pair is labeled “-” and “SAW, SMAW”
(#3, Figure 2). This pair is to be used for constant
current processes, such as stick welding, as well as
for submerged arc welding on constant voltage.