Lincoln Electric DC-655 User Manual

SVM142-A

September, 2002

Safety Depends on You

Lincoln arc welding and cutting
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.

SERVICE MANUAL

For use with machine code number 10501 thru 10510

IDEALARC ™DC-655

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

View Safety Info View Safety Info View Safety Info View Safety Info

RETURN TO MAIN INDEX

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Copyright © 2002 Lincoln Global Inc.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

SAFETY

i i

IDEALARC DC-655

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld-

ing 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.

____________________________________________________

1.d. Keep all equipment safety guards , cov ers and

devices in position and in good repair.Keep
hands, hair, clothing and tools away from V­belts, gears, fans and all other moving parts
when starting, operating or repairing equip­ment.

____________________________________________________

1.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.

___________________________________________________

1.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.

___________________________________________________

1.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.

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 saf ety highlights.For additional safety inf ormation, 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.

WARNING

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.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

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

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

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

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

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

2.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.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

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

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

SAFETY

ii ii

IDEALARC DC-655

ARC RAYS can burn.

4.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.

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

4.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.

ELECTRIC SHOCK can kill.

3.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.

3.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.

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

3.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.

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

3.f.

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

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

3.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.

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

3.j. Also see Items 6.c.and 8.

FUMES AND GASES
can be dangerous.

5.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.

5.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.

5.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.

5.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.

5.e. Also see item 1.b.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

SAFETY

iii iii

IDEALARC DC-655

FOR ELECTRICALLY
powered equipment.

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

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

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

CYLINDER may explode
if damaged.

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

7.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.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.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.

WELDING SPARKS can
cause fire or explosion.

6.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.

6.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.

6.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.

6.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).

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

6.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.

6.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.

6.h. Also see item 1.c.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

SAFETY

iv iv

IDEALARC DC-655

PRÉCAUTIONS DE SÛRETÉ

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:

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 sûr état
defonctionnement.

d. Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous ten-

sion 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.

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
enroule 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 rayonnementde
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 laiter en fusion sont émises de l’arc de
soudage. Se protéger avec es vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, 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
zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir ttout risque d’incendie dû 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 la 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 atres 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 fumées toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opéerations 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 roxique) ou autres produits irritants.

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 branché à
une bonne mise à la terre.

2. Autant que possible, l’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 dispostifis de sûreté à leur
place.

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

v v

IDEALARC DC-655

Page

Safety.................................................................................................................................................i-iv

Installation.............................................................................................................................Section A

Technical Specifications .............................................................................................................A-2

Safety Precautions......................................................................................................................A-4

Select Suitable Location (Stacking, Tilting, Lifting) ....................................................................A-4

Electrical Input Connections.......................................................................................................A-4

Reconnect Procedure .................................................................................................................A-5

Output Connections....................................................................................................................A-6

Operation...............................................................................................................................Section B

Safety Precautions......................................................................................................................B-2

General Description ....................................................................................................................B-3

Controls and Settings.................................................................................................................B-4

Case Back Connections.............................................................................................................B-6

Auxiliary Power ...........................................................................................................................B-6

Machine Protection.....................................................................................................................B-6

Welding Performance .................................................................................................................B-8

Accessories...........................................................................................................................Section C

Maintenance .........................................................................................................................Section D

Safety Precautions......................................................................................................................D-2

General Maintenance..................................................................................................................D-2

General Component Locations...................................................................................................D-3

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair.................................................................................................Section F

How to Use Troubleshooting Guide............................................................................................F-2

PC Board Troubleshooting Procedures ......................................................................................F-3

Troubleshooting Guide ................................................................................................................F-4

Test Procedures ........................................................................................................................F-13

Oscilloscope Waveforms ..........................................................................................................F-43

Replacement Procedures..........................................................................................................F-49

Retest After Repair....................................................................................................................F-57

Electrical Diagrams............................................................................................................. Section G

Parts Manual............................................................................................................................... P-317

RETURN TO MAIN INDEX

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

TABLE OF CONTENTS

- INSTALLATION SECTION -

Section A-1 Section A-1

IDEALARC DC-655

Installation .............................................................................................................................Section E

Technical Specifications - Idealarc DC-655 ...............................................................................A-2

Graphic Symbols that Appear on Rating Plate ..........................................................................A-3

Safety Precautions......................................................................................................................A-4

Select Suitable Location.............................................................................................................A-4

Stacking................................................................................................................................A-4

Tilting ....................................................................................................................................A-4

Electrical Input Connections.......................................................................................................A-4

Fuse and Wire Sizes.............................................................................................................A-4

Ground Connection..............................................................................................................A-4

Input Power Supply Connections ........................................................................................A-5

Reconnect Procedure.................................................................................................................A-5

Output Connections ...................................................................................................................A-6

Electrode and Work Cables..................................................................................................A-6

Auxiliary Power and Control Connections ...........................................................................A-7

Auxiliary Power Table.....................................................................................................A-7

115VAC Duplex Receptacle...........................................................................................A-7

230V Receptacle............................................................................................................A-7

14 Pin MS Type Receptacle...........................................................................................A-7

Terminal Strips ...............................................................................................................A-8

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

A-2 A-2

IDEALARC DC-655

INSTALLATION

TECHNICAL SPECIFICATIONS – DC-655

Volts at Rated Amperes

44
44

Amps

650
815

Auxiliary Power

See the OPERATION section for

Auxiliary Power

information by model

Maximum Open Circuit Voltage

46 CV Mode
68 CC Mode

Duty Cycle

100% Duty Cycle

NEMA Class I (100)*

60% Duty Cycle

INPUT - THREE PHASE ONLY

OUTPUT

* European models meet IEC974-1 standards.

1

Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.

RECOMMENDED INPUT WIRE AND FUSE SIZES

Standard

Voltage

230/460/60

230/460/575/60

208/416/60

460/60

575/60
230/400/50/60*
380/500/50/60*

440/50/60

200/400/50/60

415/50/60

Code

Number

10501
10502
10503
10504
10505
10506
10507
10508
10509
10510

100% Duty Cycle

122/61

122/61/49

135/67.5

61
49

122/70

74/56

64

140/70

68

60% Duty Cycle

150/75

150/75/60

166/83

75
60

150/86

90/69

78

172/86

83

Input Current at Rated Output

RATED OUTPUT

INPUT

VOLTAGE /

FREQUENCY

208
230
416
460
575
200
230
380
400
415
440
500

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

1

250 Amp
225 Amp
125 Amp
110 Amp

90 Amp
250 Amp
225 Amp
125 Amp
125 Amp
110 Amp
110 Amp
110 Amp

Copper

GROUND WIRE

IN CONDUIT

AWG(IEC-MM2) SIZES

4 (21)
4 (21)
6 (14)
6 (14)

8 (8.4)

4 (21)
4 (21)
6 (14)
6 (14)
6 (14)
6 (14)
6 (14)

TYPE 80°C

COPPER WIRE

IN CONDUIT
AWG(IEC-MM2) SIZES
40°C (104°F) Ambient

1 (43)
1 (43)
6 (14)
6 (14)

8 (8.4)

1/0 (54)

1 (43)
4 (21)
4 (21)
6 (14)
6 (14)
6 (14)

INPUT AMPERE

RATING ON

NAMEPLATE

135
122

67.5
61
49

140
122

74
70
68
64
56

HERTZ

60
60
60
60

60
50/60
50/60
50/60
50/60
50/60
50/60
50/60

PHYSICAL DIMENSIONS

HEIGHT

27.5 in

699 mm

WIDTH

22.2 in

564 mm

DEPTH

38.0 in

965 mm

WEIGHT

720 lbs.

326 kg.

Current Range

50-815

Voltage Range

13-44 DC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

INSTALLATION

A-3 A-3

IDEALARC DC-655

3 Phase transformer with
rectified DC output

INPUT POWER

THREE PHASE

Designates welder complies with
National Electrical Manufacturers
Association requirements EW 1
Class I with 100% duty cycle at
650Amps output. (Domestic,
Canadian, and Export models)

Designates welder complies with
both Underwriters Laboratories
(UL) standards and Canadian
Standards Association (CSA)
standards. (Canadian Model)

GMAW

FCAW

GRAPHIC SYMBOLS THAT APPEAR ON

RATING PLATE (LOCATED ON CASE BACK)

Constant Voltage Output
Characteristics

R

NEMA EW 1 (100%)

Designates welder complies with
International Electrotechnical
Commission requirements 974-1.
(European Models)

IEC 974-1

Designates welder complies with
low voltage directive and with
EMC directive.(European
models)

CE

Designates welder can be used
in environments with increased
hazard of electric shock.
(European models)

S

NRTL/C

Designates welder complies with
Underwriters Laboratories (UL)
standards. (Domestic Models)

R

NRTL

SMAW

SAW

Constant Current Output
Characteristics

Designates the degree of envi­ronmental protection provided by
the power sources enclosure.

IP-23

Open Circuit Output Voltage

U

o

Input Voltage Rating(s)

U

1

Input Current Rating(s)

I

1

Output Voltage Rating(s)

U

2

Output Duty Cycle Rating(s)

X

Output Current Rating(s)

I

2

Read this entire installation section
before you start installation.

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Only qualified personnel should
perform this installation.

•

Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.

• Turn the Power Switch on the DC-655 “OFF” before
connecting or disconnecting output cables, wire
feeder or remote connections, or other equipment.

• Do not touch electrically hot parts.

• Always connect the Idealarc DC-655 grounding ter­minal (located on the welder near the reconnect
panel) to a good electrical earth ground.

SELECT SUITABLE LOCATION

Place the welder where clean cooling air can freely cir­culate in through the front louvers and out through the
rear louvers. Dirt, dust or any foreign material that can
be drawn into the welder should be kept at a mini­mum. Failure to observe these precautions can result
in excessive operating temperatures and nuisance
shut-downs.

STACKING

The DC-655 may be stacked three-high provided the
bottom machine is on a stable, hard, level surface. Be
sure that the two pins in the roof fit into the slots in the
base of the DC-655 above it.

TILTING

Do not place the machine on a surface that is inclined
enough to create a risk of the machine falling over.

ELECTRICAL
INPUT CONNECTIONS

Before installing the machine check that the input sup­ply voltage, phase, and frequency are the same as the
voltage, phase, and frequency as specified on the
welder nameplate.

Use input wire sizes that meet local electrical codes or
see the Technical Specifications page in this manual.

Input power supply entry is through the hole in the
Case Back Assembly. See Figure A.1 for the location
of the machine’s input cable entry opening, Input
Contactor (CR1), and reconnect panel.

FUSE AND WIRE SIZES

Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the Technical
Specifications page of this manual for the machine
being used. They are also called inverse time or ther­mal/magnetic circuit breakers.

DO NOT use fuses or circuit breakers with a lower amp
rating than recommended. This can result in “nui­sance” tripping caused by inrush current even when
machine is not being used for welding at high output
currents.

GROUND CONNECTION

Ground the frame of the machine. A ground
terminal marked with the symbol is located inside
the case back of the machine near the input contactor.
Access to the input box assembly is at the upper rear
of the machine. See your local and national electrical
codes for proper grounding methods. Use grounding
wire sizes that meet local electrical codes or see the
Technical Specifications page in this manual.

INSTALLATION

A-4 A-4

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

WARNING

FIGURE A.1 - ELECTRICAL INPUT CONNECTIONS

INPUT

CONTACTOR (CR1)

INPUT POWER SUPPLY
CABLE WITH BUSHING

OR BOX CONNECTOR

RECONNECT

PANEL ASSEMBLY

INPUT POWER SUPPLY CONNECTIONS

A qualified electrician should connect the input power
supply leads.

1. Follow all national and local electrical codes.

2. Use a three-phase line.

3. Remove the input access door at upper rear of the

machine.

4. Follow input supply connection diagram located

on the inside of the door.

5. Connect the three-phase AC power supply leads

L1, L2, and L3 to the input contactor
terminals in the input box assembly. See Figure

A.1.

RECONNECT PROCEDURE

Electric Shock Can Kill

• Disconnect input power before per­forming this procedure.

Multiple voltage machines are shipped connected to
the highest input voltage listed on the machine’s rating
plate. Before installing the machine, check that the
reconnect panel in the input box assembly is connect­ed for the proper voltage.

Failure to follow these instructions can cause immedi­ate failure of components within the machine.

To reconnect a multiple voltage machine to a different
voltage, remove input power and follow the input con­nection diagram located on the inside of case back
input access door.

1. For dual voltage sample machine reconnect
instructions, see Figure A.2.

INSTALLATION

A-5 A-5

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

WARNING

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.

H2

GND

5. MOUNT THE LINKS IN THE POSITIONS SHOWN. CONNECT THE FLEX LEAD AS SHOWN;

LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.

L1

LINES

4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC

2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.

CODES.

INSTALL AND TIGHTEN ALL OF THE HEX NUTS.

POSITIONING THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS.

D-UF

INPUT

3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H2 CONTROL TRANSFORMER

W

CR1

V

L3

U

H3

CONTACTOR

L2
L1

W

V

GND

CR1

L3
L2

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.

2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION.

ALL OF THE HEX NUTS.

4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC
CODES.

5. MOUNT THE LINKS IN THE POSITIONS SHOWN; DOUBLE OR TRIPLE STACK THE LINKS
IN THREE POSITIONS. LOOP THE FLEX LEAD IN THE POSITION SHOWN; POSITIONING
THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN

DUAL VOLTAGE MACHINE

INPUT SUPPLY CONNECTION DIAGRAM

IMPORTANT: CHANGE LINK POSITIONS AND CONTROL TRANSFORMER CONNECTIONS.

NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS

Do not touch electrically live parts

Only qualified persons should install,

use or service this equipment

Do not operate with covers
removed

Disconnect input power before

LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.

TRANSF.

CONTROL

TRANSF.

CONTROL

3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H3 CONTROL TRANSFORMER

CONNECTION FOR HIGHEST RATING PLATE VOLTAGE

servicing

M18225

INPUT

CONTACTOR

CONNECTION FOR LOWEST RATING PLATE VOLTAGE

H2

H1

LINKS

LINES

THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.

LINKS

U

H1

H3

FIGURE A.2 - DUAL VOLTAGE MACHINE RECONNECTION PROCEDURE

CAUTION

OUTPUT CONNECTIONS

ELECTRODE AND WORK CABLES

Use the shortest possible cable lengths. See Table A.1
for recommended cable sizes based on length.

The output terminals are located at the lower front of
the welder behind a hinged door. Refer to Figure A.3.
Route the welding cables through the slotted strain
reliefs of the base to the welding terminals.

LOW INDUCTANCE TERMINAL

On the DC-655, the inside right Negative (-) output ter­minal is lower choke inductance. This terminal is
presently only recommended for CV mode welding
with NR203Ni 1% negative polarity procedures.. All
other processes are to be welded using the outside
right Negative (-) output terminal with higher choke
inductance. CC mode processes must use high
inductance.

For Positive Polarity:

1. Connect the work cable to the high inductance (-)
terminal (marked " ").

2. Connect the electrode cable to the positive terminal
marked “+”.

3. Remove the terminal strip access cover panel on
the lower case front. Refer to Figure A.3 for the
location.

4. Work Sense lead #21 from the 14 Pin MS-recepta­cle must be connected to “-21”on the terminal strip.

Note: This is how the DC-655 is shipped from the
factory.

5. Replace the terminal strip access cover panel.

For Negative Polarity:

1. Connect the electrode cable to the appropriate high
inductance (-) terminal (marked " ")
or to the low inductance (-) terminal (marked
" ") if using NR203Ni 1% electrode.

2. Connect the work cable to the positive terminal
marked “+”.

3.

Remove the terminal strip access cover panel on the
lower case front. Refer to Figure A.3 for the location.

4. Work Sense lead #21 from the 14 Pin MS-recepta­cle must be connected to “+21”on the terminal
strip.

5. Replace the terminal strip access cover panel.

INSTALLATION

A-6 A-6

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

TABLE A.1

Cable Sizes for Combined Lengths of Copper

Electrode and Work Cable

Cable Length

ft. (m)

Parallel Cables Cable Size

0 (0) to 100 (30.4)
100 (30.4) to 200 (60.8)
200 (60.8) to 250 (76.2)

2
2
2

2/0 ( 70mm2)
3/0 ( 95mm2)

4/0 (120mm2)

FIGURE A.3 - OUTPUT CONNECTIONS

POSITIVE
OUTPUT
TERMINAL

TERMINAL STRIP
COVER PANEL

14 PIN MS RECEPTACLE

LOW INDUCTANCE
NEGATIVE OUTPUT
TERMINAL

HIGH INDUCTANCE
NEGATIVE OUTPUT
TERMINAL

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

INSTALLATION

A-7 A-7

IDEALARC DC-655

AUXILIARY POWER AND
CONTROL CONNECTIONS

Located at the lower front of the welder behind a
hinged door is a 115 VAC duplex receptacle for auxil­iary power (Domestic and Canadian Models only) and
a 14-pin MS type receptacle for connection of auxiliary
equipment such as wire feeders. Also, terminal strips
with 115 VAC and connections for auxiliary equipment
are located behind the access panel on the lower case
of the welder. A 220 VAC receptacle for a water cooler
(European and Export Models only) is located on the
case back.

115 VAC DUPLEX RECEPTACLE (DOMESTIC AND
CANADIAN MODELS ONLY)

The 115 VAC duplex receptacle is protected by a cir­cuit breaker located below the receptacle (see
Auxiliary Power Table). Receptacle is a NEMA 5-20R
(protected by a 20 amp breaker) on Domestic Models
and a NEMA 5-15R (protected by a 15 amp breaker) on
Canadian Models.

230 VAC RECEPTACLE (EUROPEAN AND EXPORT
MODELS ONLY)

A Continental European receptacle is located on the
rear panel for supplying 220 VAC to a water cooler. The
receptacle has a protective cover to prevent acciden­tal contact and is a Schuko type. The circuit is pro­tected by a 2 amp circuit breaker also located on the
rear panel. This circuit is electrically isolated from all
other circuits, but on the European Models one line is
connected to chassis ground.

14-PIN MS TYPE RECEPTACLE

(For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32)

Refer to the Figure A.4 for the available circuits in the
14-pin receptacle.

42 VAC is available at receptacle pins I and K. A 10
amp circuit breaker protects this circuit.

115 VAC is available at receptacle pins A and J
(Domestic, Canadian and Export Models). This circuit
is protected by a circuit breaker (see Auxiliary Power
Table). Note that the 42 VAC and 115 VAC circuits are
electrically isolated from each other. However, on the
European model one line of the 115 VAC is connected
to chassis ground.

AUXILIARY POWER TABLE

Voltage and Circuit Breaker Ratings at Auxiliary Power

Connections for Various Models

Auxiliary Domestic Canadian European Export

Power Models Model Models Models

Connections (60Hz)

(230/460/575V/60 Hz)

(50/60 Hz) (50/60 Hz)

At Duplex 115V 20A 115V 15A No Duplex No Duplex

Receptacle

Terminal strip 115V 20A 115V 15A 115V 15A 115V 15A

terminals 31 & 32

MS-Receptacle 115V 20A 115V 15A

Open Circuit

115V 15A

pins A & J

MS-Receptacle 42V 10A 42V 10A 42V 10A 42V 10A

pins I & K

At 220V

No Receptacle No Receptacle 220V 2A 220V 2A

Receptacle

FIGURE A.4 - FRONT VIEW OF 14-PIN
CONNECTOR RECEPTACLE

PIN LEAD NO. FUNCTION

A 32 115 VAC
B GND Chassis Connection
C 2 Trigger Circuit
D 4 Trigger Circuit
E 77 Output Control
F 76 Output Control
G 75 Output Control

H 21 Work Sense Connection

2

I 41 42 VAC
J 31 115 VAC

1.

K 42 42 VAC
L --- --­M --- --­N --- ---

1.

115VAC circuit is not present in the 14-pin connector on IEC 974­1 European models.

2.

As shipped from the factory Lead #21 from the 14-pin connector is
connected to “-21”on the terminal strip. This is the configuration for
positive welding. If welding negative polarity, connect lead #21 to
the “+21”connection point on the ter minal strip.

K=42

A=32

B=GND

L N

C=2

D=4

E=77

J=31

I=41

H=21

G=75

F=76

M

TERMINAL STRIPS

Terminal strips are available behind the cover panel on
the lower case front to connect wire feeder control
cables that do not have a 14-Pin MS-type connector.
Refer to Figure A.3 for the location of this cover panel.
These terminals supply the connections as shown in
the following Terminal Strip charts. See Auxiliary
Power Table for rating of circuit breaker in 115 VAC cir­cuit. Remove a plug button from the terminal strip
cover and install an appropriate strain relief clamp for
the cable being used. NOTE: There are two work
sense lead connection points on the terminal strip.
Connect both the work sense lead #21 from the 14-pin
connector and #21 lead of the control cable to “-21”
when welding positive polarity or to “+21” when weld­ing negative polarity.

TERMINAL STRIP 1 (T.S.1)

TERMINAL STRIP 2 (T.S.2)

INSTALLATION

A-8 A-8

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Lead No. Function

75 Output Control
76 Output Control
77 Output Control

1

115 VAC circuit is also present on IEC 974-1 European models.

2

If connecting a feeder cable directly to the terminal strip, Lead #21
from the cable is connected to “-21”on the terminal strip for positive
welding. If welding negative polarity, connect lead #21 to the “+21”
connection point on the terminal strip.

Lead No. Function

+21 Work Connection

-21 Work Connection

2

41 42 VAC
4 Trigger Circuit
2 (42 VAC) Trigger Circuit (42 VAC)
31 115 VAC

1

32 115 VAC

1

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Section B-1 Section B-1

IDEALARC DC-655

TABLE OF CONTENTS

- OPERATION SECTION -

Operation...............................................................................................................................Section B

Safety Precautions......................................................................................................................B-2

General Description ....................................................................................................................B-3

Recommended Processes and Equipment .........................................................................B-3

Design Features and Advantages ........................................................................................B-3

Welding Capability................................................................................................................B-3

Controls and Settings.................................................................................................................B-4

Case Back Connections .............................................................................................................B-6

220 VAC Auxiliary Receptacle..............................................................................................B-6

220 VAC 2 Amp Circuit Breaker...........................................................................................B-6

Auxiliary Power ...........................................................................................................................B-6

Machine Protection.....................................................................................................................B-6

Thermal Fan Control.............................................................................................................B-6

Fan Motor Fuse ....................................................................................................................B-6

Machine Shutdown ..............................................................................................................B-6

Thermal Shutdown ...............................................................................................................B-7

Over Current Protection Shutdown......................................................................................B-7

Remote Control Leads Fault Protection Shutdown.............................................................B-7

Shorted Rectifier Fault Protection........................................................................................B-7

Idle Shutdown Timer ............................................................................................................B-7

Welding Performance .................................................................................................................B-8

Low Inductance Terminal .....................................................................................................B-8

CV Mode Current Limiting....................................................................................................B-8

CC Mode Arc Force .............................................................................................................B-8

CC Mode Hot Start ..............................................................................................................B-8

CC Mode Arc Gouging.........................................................................................................B-8

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

B-2

B-2

IDEALARC DC-655

OPERATING INSTRUCTIONS

Read and understand this entire section of operating
instructions before operating the machine.

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrodes with your skin or wet cloth­ing.

• Insulate yourself from the work and ground.

• Always wear dry, insulating gloves.

FUMES AND GASES can be
dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from
breathing zone.

CUTTING SPARKS can cause
fire or explosion.

• Keep flammable material away.

• Do not cut containers that have held combustibles.

ARC RAYS
can burn.

• Wear eye, ear, and body protection.

Observe additional Safety Guidelines detailed in
the beginning of this manual.

WARNING

OPERATION

GENERAL DESCRIPTION

The DC-655 is an energy efficient constant voltage DC
power source that produces outstanding arc charac­teristics for multiple CV or CC welding processes.

Four models are available:

Domestic - all 60 Hertz models except

230/460/575v.
NEMA Class 1 rated

Canadian - 230/460/575v 60 Hertz

NEMA Class 1 rated

European - 50/60 Hertz models “CE” qualified

and rated for IEC 974-1

Export - 50/60 Hertz models NEMA Class 1 rated

RECOMMENDED PROCESSES AND
EQUIPMENT

The DC-655 is designed for CV or CC processes.

CV processes include: GMAW (MIG) and FCAW (flux­cored) welding, plus the capability of CV submerged
arc welding and air carbon arc gouging. It produces
outstanding welding performance with a single range
full output control knob.

CC processes include stick welding, CC submerged
arc and superior air carbon arc gouging with up to 3/8”
(10 mm) diameter carbons. The same single range full
output control knob is used and paralleling capability
is provided.

The DC-655 is recommended for use with Lincoln’s
DH-10 or LN-10 as well as the LN-7*, LN-7 GMA*, LN­742, LN-8*, LN-9*, LN-9 GMA*, LN-23P and LN-25
semiautomatic wire feeders. It is also recommended
for use with the NA-3, NA-5 and NA-5R automatic
feeders. “Cold starting” for sub-arc or across arc
“touch-sensing” can be used.

* The 14-pin MS receptacle on the European models

does not provide 115 VAC for these feeders; 115
VAC must be obtained from terminal strip.

Two DC-655’s may be paralleled in a “master” and
“slave” interconnection using the K1611-1 Paralleling
kit.

DESIGN FEATURES AND
ADVANTAGES

• Separate output terminals for selecting high or low
inductance as recommended for the welding
process.

• Power on/off switch with pilot light and thermostat
tripped indicator light.

• Full range output voltage (CV mode) and current (CC
mode) control for easy operation.

• Panel switches behind a latched front panel for
remote or local output control, output on or remote
selection, and CC, CV Sub-arc or CV MIG mode
selection.

• Panel knob settable CC arc force control with built­in adjustable “Hot Start”.

• High efficiency output, and selectable “sleep mode”
idle mode timer which shuts down input power if not
used for extra energy conservation.

• Fan as needed (F.A.N.). Solid state thermally con­trolled fan operates cooling fan only when required.
Minimizes power consumption, operating noise and
dust intake.

• Hinged cover to protect output terminals and auxil­iary connections.

• Electronic and thermostatic protection for current
overload and excessive temperatures.

• 42 VAC, 10 amp auxiliary power available for the wire
feeder; circuit breaker protected.

• 115 VAC, auxiliary power available for the wire feed­er; circuit breaker protected. 20 amp breaker on
Domestic model and 15 amp breaker on Canadian,
European, and Export Models.

• 115 VAC duplex plug receptacle available on
Domestic and Canadian Models. 20 amp breaker on
Domestic Models and 15 amp breaker on Canadian
Model.

• 220 VAC receptacle on European and Export models
for connecting to a water cooler. Protected by 2 amp
breaker.

• Single MS-type (14-pin) connection for wire feeder.

• Optional Field Installed Digital or Analog Voltmeter/
Ammeter kits are available.

• Optional dual feeder kit for like polarity connection of
two wire feeders. Easy panel installation.

• Optional Dual Process Switch for two processes
with polarity change and electrical isolation.

WELDING CAPABILITY

The DC-655 has the following Output and Duty Cycle
based on operation for a 10 minute period:

650 Amps, 44 Volts at 100%

815 Amps, 44 Volts at 60%

OPERATION

B-3 B-3

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

1. INPUT POWER ON/OFF SWITCH - This tog-

gle switch turns the machine on or off. Putting the
switch in the ON position energizes the
machine’s input contactor applying input power to
the machine. Switching the switch to the OFF

position de-energizes the input contactor. This
switch is also used to reset a machine shutdown.
(See Machine Shutdown section)

2. PILOT LIGHT - When the power switch is in the

ON position the machine’s white pilot light will illu­minate. If the input contactor de-energizes the
machine in a shutdown situation, the pilot will still
illuminate. In this situation it will be necessary to
reset the machine by switching the power switch to
the OFF then ON position. (See Machine
Shutdown section)

3. OUTPUT CONTROL - This control provides

continuous control of the machine’s output from
minimum to maximum as it is rotated clockwise.
The CV mode voltage range of control is 13 to 44V.
The CC mode current range of control is 50 to
815A.

4. OUTPUT TERMINALS ON/REMOTE - When this

switch is in the REMOTE position, the DC-655’s
output terminals will be electrically “cold” until a

remote device such as a wire feeder closes the #2 and
#4 circuit in the MS-receptacle or terminal strip. When
this switch is in the ON position the machine’s output
terminals will be electrically energized all the time.

5. LOCAL/REMOTE CONTROL SWITCH - When

this switch is set to the LOCAL position, con­trol of the output voltage is via the output control
on the DC-655’s control panel. When this switch is
set to the remote position, control is through a
remote source such as a wire feeder via the #75,
#76, and #77 leads in the MS-receptacle or termi­nal strip.

6.

CC STICK/CV SUBARC/CV MIG MODE SWITCH -

This switch selects the proper welding characteris­tics for the process being used:

CC Stick provides a constant current output
characteristic through the 50 to 815 amp
range. The current is adjusted within this
range by the Output Control dial. The open
circuit (no load) voltage will be about 68 volts
in this mode.

This mode is used for stick welding (SMAW)
and CC air carbon-arc gouging, and employs
a “Hot Start” feature and an Arc Force Control.

OPERATION

B-4 B-4

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

CONTROLS AND SETTINGS

All operator controls and adjustments are located on the case front of the DC-655. Refer to Figures B.1, and B.2
and corresponding explanations.

FIGURE B.1 CONTROL PANEL CONTROLS

DC-655

5

4

8

1

9

2

3

6

7

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

OPERATION

B-5 B-5

IDEALARC DC-655

CC mode may also be used for CC submerged arc
with appropriate arc-sensing CC(VV) wire feeders
if arc force is set high enough. Refer to Welding
Performance section.

CV MIG provides a constant voltage output char­acteristic through the 13 to 44 volt range. The volt­age is adjusted within this range by the Output
Control dial.

The dynamic characteristics of this mode are ideal
for open arc processes including, MIG/MAG
(GMAW), Innershield®, and other cored wire
(FCAW) processes. Faster travel submerged arc
processes and CV air carbon-arc gouging may
also use this mode. Refer to the Welding
Performance section.

CV Sub-Arc provides the same constant voltage
output control range as CV MIG, but the dynamic
characteristics of this mode make possible
improved CV (constant wire speed) submerged arc
welding. This improved process is most notice­able on high deposition slow travel speed welds.
Fast travel, narrow bead subarc welds will have
better performance in CV MIG mode.

7. ARC FORCE CONTROL - This control is only func-

tional in CC Stick mode. It prevents “stubbing” of
the electrode by providing the extra weld current
that linearly increases as the welding voltage
decreases below a level determined by the setting
of the constant current control.

The Arc Force control knob, located behind the
latched cover, adjusts arc force from “Min” (no cur­rent increase) to “Max” (higher short circuit current).
The “mid” position (#5) is recommended for most
CC welding. Refer to the Welding Performance
Section.

8. OPTIONAL VOLTMETER & AMMETER - Digital or

analog meter kits are available as field installed
options. Refer to the Accessories Section of this
manual.

9. THERMAL PROTECTION LIGHT - If the

machine overheats due to lack of proper air flow
through the machine or due to exceeding the
machine’s duty cycle, thermostats will disable the
welding output and this light will illuminate. Input
power is still applied to the machine and the cool­ing fan will continue to run. When the machine
cools the welding output will resume.

FIGURE B.2 LOWER CASE FRONT CONTROLS & CONNECTIONS

7

6

5

4

3

1 2

1. 115 VAC DUPLEX RECEPTACLE (Domestic and
Canadian Models) This receptacle provides up to

20 amps of 115 VAC auxiliary power on the
Domestic Models and up to 15 amps on the
Canadian Model.

2. 115 VAC CIRCUIT BREAKER - This breaker

protects the 115 VAC auxiliary circuits located in
the duplex receptacle, terminal strip and MS­receptacle. Breaker is rated 20 amps on Domestic
Models and 15 amps on all other models.

3. 42 VAC 10 AMP CIRCUIT BREAKER - This
breaker protects the 42 VAC auxiliary circuits locat­ed in the terminal strip and MS-receptacle.

4. 14-PIN MS-RECEPTACLE - This connector pro­vides easy connection for a wire feeder control
cable. It provides connections for auxiliary power,
output switching, remote output control, wire feed­er voltmeter sense lead and ground. Refer to 14-
Pin MS Type Receptacle in the Installation
Section of this manual for information about the cir­cuits made available at this receptacle.

5. TERMINAL STRIP COVER PANEL - Remove this
panel to gain access to the circuits made available
at the terminal strip and the 4-pin receptacle for the
optional paralleling kit. This terminal strip contains
the same circuits as the 14-pin MS-receptacle.
The cover also provides for installation of cable
strain relief clamps.

6. POSITIVE OUTPUT TERMINAL - This output ter­minal is for connecting a welding cable. To change
welding polarity and for proper welding cable size
refer to Electrode and Work Cables in the
Installation Section of this manual.

7. NEGATIVE OUTPUT TERMINALS - These output
terminals are for connecting a welding cable to
either the High Inductance or Low Inductance
Terminal for desired arc characteristics. To change
welding polarity and for proper welding cable size
refer to Electrode and Work Cables in the
Installation Section of this manual.

CASE BACK CONNECTIONS

220 VAC AUXILIARY RECEPTACLE

(European and Export Models)

This receptacle provides up to 2 amps of 220 VAC
auxiliary power for a water cooler.

220 VAC 2 AMP CIRCUIT BREAKER

(European and Export Models)

This breaker protects the 220 VAC auxiliary circuit
located in the 220 VAC receptacle.

AUXILIARY POWER

42 volt AC auxiliary power, as required for some wire
feeders, is available through the wire feeder recepta­cle. A 10 amp circuit breaker protects the 42 volt cir­cuit from overloads.

DC-655 machines can also supply 115 volt AC auxil­iary power through the wire feeder receptacle. A 20
amp circuit breaker on the Domestic model, and a 15
amp on the Canadian and Export models protects the
115 volt circuit from overloads. 115 VAC is not avail­able in the MS-receptacle on the European models.

Note that some types of equipment, especially pumps
and large motors, have starting currents which are sig­nificantly higher than their running current. These high­er starting currents may cause the circuit breaker to
open. If this situation occurs, the user should refrain
from using the DC-655 auxiliary power for that equip­ment.

MACHINE PROTECTION

THERMAL FAN CONTROL

The machine’s cooling fan remains off when the tem­perature of the rectifiers and windings inside the
machine are below that requiring air flow cooling, as
determined by electronic monitoring of several thermal
sensors and the welding current of the machine.
Depending upon the operating temperature of the
machine, the fan may remain off while welding but
once the fan is activated, it will remain on for at least 5
minutes to assure proper cooling. This feature saves
energy and also minimizes the amount of dirt and
other air borne particles being drawn into the machine.

FAN MOTOR FUSE
(European Model)

A 10 amp slow blow fuse protects the fan motor cir­cuit. This fuse is located inside the DC-655 mounted
on the fan motor bracket.

MACHINE SHUTDOWN

The DC-655 provides shutdown modes for thermal
over-heating, excessive load currents and faults. It
also provides an idle timer shutdown feature for addi­tional operating economy.

OPERATION

B-6 B-6

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

CAUTION

THERMAL SHUTDOWN

This welder has thermostatic protection from exces­sive duty cycles, overloads, loss of cooling, and high
ambient temperature. When the welder is subjected to
an overload or loss of cooling, a thermostat will open.
This condition will be indicated by the illumination of
the yellow Thermostatic Protection Light on the case
front (see Figure B.1). The fan will continue to run to
cool the power source. No welding is possible until the
machine is allowed to cool and the Thermostatic
Protection Light goes out.

OVER CURRENT PROTECTION
SHUTDOWN

Average Current Shutdown

To protect the SCR’s , the DC-655 will shut down to
essentially no output if the output current averages
over 900 amps for about 5-6 seconds, and in less than

0.3 seconds if averaging over 1200 amps (shorter time

for higher current). Control PC board LED4, shutdown
light, will turn on.

This average current shut down can only be reset by
opening the feeder gun trigger, or switching the DC­655 Output/Remote switch out of the “on” position.

Peak Current Shutdown

To protect the SCRs, the DC-655 will shut down imme­diately to essentially no output if the peak output cur­rent exceeds 2500 amps (about 1800A average).
Control PC board LED4, shutdown light, will turn on.

This peak current shut down can be reset by turning
the DC-655 input power off, then on.

REMOTE CONTROL LEADS FAULT
PROTECTION SHUTDOWN

1

The remote control leads from the 14-pin receptacle or
terminal strip are protected against high voltage faults
to the electrode circuit or auxiliary voltage supplies. If
such a fault occurs, the DC-655 will shut down the
input primary voltage to the transformer to prevent the
fault output. Control PC board LED3, input shutdown
light, turns on.

If this input shutdown occurs the input power pilot
light remains lit, since the power switch is ON and
control power is still present. Welding output or auxil­iary supply output will not be present.

This input shut down is reset by turning the DC-655
input power off, then on. If the fault is not corrected
however, the shutdown will re-occur when turning on
the input power.

1

Note on earlier machines: LED4 will turn on and output will be
disabled if this fault occurs.

SHORTED RECTIFIER FAULT PROTECTION

If a short occurs across one of the silicon controlled
rectifiers of the DC-655, a potentially hazardous AC
voltage could appear across the welding output termi­nals, even in idle mode when no output should be pre­sent. If such a fault occurs, the DC-655 will shut down
the input primary voltage to the transformer to prevent
the fault output. Control PC board LED3, input shut­down light, turns on.

If this input shutdown occurs the input power pilot
light remains lit, since the power switch is ON and
control power is still present. Welding output or auxil­iary supply output will not be present.

This input shut down is reset by turning the DC-655
input power off, then on. If the fault is not corrected
however, the shutdown will re-occur when turning on
the input power.

IDLE SHUTDOWN TIMER

For additional operating economy, the DC-655 can be
set up to automatically shut off the primary input
power to the main transformer after a selectable time
(1/2 or 2 hr.) has expired without welding. The unex­pired timer is reset with each weld.

The idle mode timer is activated by setting Switch #1
(left most) of the DIP Switch located on the lower-cen­ter of the DC-655 Control PC board. from the down
(Off) position to the up (On) position. Setting Switch
#2 of the DIP switch to up (On) sets the shutdown time
to 2 hours. Setting Switch #2 of the DIP switch to
down (Off) sets the shutdown time to 1/2 hour.
Shutdown is reset by turning the DC-655 input power
off, then on.

OPERATION

B-7 B-7

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Switch #1 Timer On/Off
(UP=ON, Down=OFF)

1 2 3 4

DIP Switch

Switch #2 Time selection
(UP=2 hours, Down=1/2 hour)

See Weld Performance section

Note:

for use of switch #3 and #4.

WELDING PERFORMANCE

LOW INDUCTANCE TERMINAL

The inside right Negative (-) terminal is lower choke
inductance and presently is only recommended for
welding with NR203Ni 1% procedures. All other
processes are to be welded using the outside right
Negative (-) terminal with higher choke inductance.

CV MODE CURRENT-LIMITING

CV MIG and CV Sub-Arc modes employ electronic
current limiting to limit excessive short circuit output
current which can result in undesirable arc character­istics or nuisance over current protection shutdown
(see Machine Protection section).

As shipped, the DC-655 is set for “Hi” current limiting,
which maintains constant voltage until the welding
current exceeds a level proportional to the voltage set­ting, then falls off linearly at about 10 volts per 100
amps to a limited short circuit current. “Lo” current
limiting provides the same short circuit current, but the
arc voltage begins to linearly fall off at lower current, at
about 5 volts per 100 amps.

“Hi” is recommended for all CV processes, especially
for CV subarc and CV arc gouging, but “Lo” tends to
“soften” the arc more when welding NR203Ni 1% on
the Low Inductance (-) terminal. If “Lo” is desired,
switch #4(right-most) of the DIP switch located on the
lower-center of the DC-655 Control PC board needs to
be switched from up (Hi) position to down (Lo) posi­tion.

CC MODE ARC FORCE

Arc Force provides extra weld current which linearly
increases as the welding voltage decreases below a
level determined by the constant current setting. The
Arc Force control knob, located behind the latched
cover, adjust Arc Force from “Min” (no current
increase) to “Max” (about 9A/V increase).

As a general guideline for CC welding, set Arc Force to
“Mid” position and increase (typically to no more than
#7) as necessary to prevent “stubbing” or “pop-outs”
while welding. This higher arc force is recommended
especially for low end 6010 stick welding.

CC MODE HOT START

Hot start is built-in for CC mode stick and carbon arc
starting. Hot Start provides an extra weld current
“boost” at the arc strike which increases with higher
current settings. This Hot Start level exponentially
decays to the weld current setting in a few seconds.

Adjustment of the Hot Start shouldn’t be necessary,
but an unsealed trimmer (R81) is provided on the DC­655 Control PC Board to adjust hot start. Full counter­clockwise adjustment will reduce Hot Start to zero.

CC MODE ARC GOUGING

The DC-655 is rated for air carbon arc gouging with up
to 3/8” (10mm) diameter carbons. CC mode gouging
is often preferred over CV mode for cutting control, but
some Arc Force may be required to avoid carbon stub­bing.

OPERATION

B-8 B-8

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

VOLTS

OCV

Hot Start

Max. Arc Force

AMPS

Low
Setting

Min. Arc Force

Hi
Setting

CC OUTPUT

VOLTS

High
Setting

Low
Setting

"Lo" Current Limit

CV OUTPUT

"HI" Current Limit

AMPS

Switch #3 is for test
purposes. Keep down.

DIP Switch

1 2 3 4

Switch #4 "Hi"CV Current
Limit (as shown)

(as shown)

See Machine Shutdown section

Note:

for use of switch #1 and #2.

CC Hot Start
Trimmer

DC-655 Control PC Board

TABLE OF CONTENTS

- ACCESSORIES -

Accessories...........................................................................................................................Section C

Field Installed Options................................................................................................................C-2

Connection of Lincoln Electric Automatic or Semiautomatic Wire Feeders..............................C-3

Automatic Wire Feeders.......................................................................................................C-3

NA-3 or LT-7 (Terminal Strip) .........................................................................................C-3

NA-5 or NA-5R (Terminal Strip) .....................................................................................C-4

Semiautomatic Wire Feeders...............................................................................................C-6

LN-7 (14-Pin MS Receptacle)........................................................................................C-6

LN-7 (Terminal Strip)......................................................................................................C-7

LN-8 or LN-9 (Terminal Strip) ........................................................................................C-8

LN-8 or LN-9 (14-Pin MS Receptacle) ..........................................................................C-9

DH-10 (14-Pin MS Receptacle) .....................................................................................C-9

Section C-1 Section C-1

IDEALARC DC-655

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

FIELD INSTALLED OPTIONS

K1482-1 Digital Ammeter/Voltmeter Kit - Installs

easily to the front control panel and provides digital
display of actual welding voltage and amperage while
welding. (Installation instructions are included with the
kit).

K1483-1 Analog Ammeter/Voltmeter Kit - Installs
easily to the front control panel and provides analog
display of actual welding voltage and amperage while
welding. (Installation instructions are included with the
kit).

K1484-1 Dual Feeder Kit - This kit replaces the 14­Pin MS-receptacle panel on the lower case front of the
DC-655. It provides two 14-Pin MS-receptacles and a
built in transfer circuit for connecting and operating
two like-polarity wire feeders. European DC-655 mod­els can only use 42V feeders with this kit. (Installation
instructions are included with the kit).

K1485-1 Cable Hanger Bracket - Mounts over stan­dard lift bale of the DC-655 and provides a cable
hanger on both sides of the power source, each side
capable of holding up to 100 ft. of weld cable.
(Installation instructions are included with the kit).

K1486-1 Air Filter Kit - Removable metal filter easily
slides in and out of a bracket which mounts to the
front of the DC-655. Filter is designed to trap 80% of
entering particles which are 5 microns, or larger, in
size. (Installation instructions are included with the kit).
Cannot be used with K1528-1 Dual process switch.

NOTE: A dirty air filter may cause the thermal protec­tion of the DC-655 to prematurely activate. Remove
and blow out, or wash and dry, the filter every two
months, or less if in extremely dirty conditions.
Replace if necessary.

Undercarriage (K817P, K842) - The DC-655 is
designed for use with the Lincoln K817P or K842
Undercarriage. Complete installation instructions are
included with each undercarriage. When any of the
undercarriages are installed, the DC-655 lift bail is no
longer functional. Do not attempt to lift the machine
with the undercarriage attached. The undercarriage is
designed for moving the machine by hand only.
Mechanized towing can lead to injury and /or damage
to the DC-655.

REMOTE OUTPUT CONTROL
(K775 OR K857 WITH K864 ADAPTER)

An optional “remote output control” is available. This is
the same remote control that is used on other Lincoln
power sources (K775). The K775 consists of a control
box with 28 ft (8.5m) of four conductor cable. This
connects to terminals 75, 76, and 77 on the terminal
strip and the case grounding screw so marked with the
symbol on the machine. These terminals are locat­ed behind the cover panel on the lower connection
panel of the DC-655. This control will give the same
control as the output control on the machine.

The K857 has a 6-pin MS-style connector. The K857
requires a K864 adapter cable which connects to the
14-pin connector on the DC-655.

REMOTE CONTROL ADAPTER CABLE (K864)

A “V” cable 12” (.30m) long to connect a K857 Remote
Control (6 pin connector) with a wire-feeder (14-pin
connector) and the machine (14-pin connector). If a
remote control is used alone the wire-feeder connec­tion is then not used.

K1528-1 Dual Process Switch - (Cannot be used with
K1486-1 Air Filter Kit) The Dual-Process Switch
mounts easily to the front of the machine and is
designed to provide a selection between left and right
side output terminals. Each pair of output terminals
can be switched to either the DC-655, high or low
inductance terminals as desired. Wire feed unit cables
and air carbon arc cables can be connected to either
or both sides of the box and with proper connection
can provide polarity change with just a switch change.
Selecting one side only energizes those output studs
and opens the other side. Installation instructions are
included with the switch.)

K1611-1 Paralleling Kit - Provides interconnection of
two DC-655 machines in parallel for doubling the cur­rent capacity of one machine. This “master” and
“slave” connection configuration allows the “master”
to control the balanced output of both machines.
Individual protection circuits of both machines func­tion normally. (Installation instructions are included
with the switch.)

ACCESSORIES

C-2 C-2

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

STRAIGHT PLUG (14 PIN)
TO POWER SOURCE

CABLE RECEPTACLE (6 SOCKET)

TO: K857 REMOTE CONTROL

CABLE RECEPTACLE (14 SOCKET)

TO: LN-7 WIRE FEEDERS

The DC-655 can be used to power any of
the following Lincoln Wire feeders:

SEMI-AUTOMATIC WIRE FEEDERS

• DH-10 • LN-9*

• LN-10 • LN-9 GMA*

• LN-7 GMA* • LN-23P

• LN-742 • LN-25

• LN-7* • LN-8*

AUTOMATIC WIRE FEEDERS*

• NA-3 • NA-5R

• NA-5 • LT-7 Tractor

* European DC-655 models only provide 115VAC for these feeders at the ter-

minal strip (TS2)

CONNECTION OF LINCOLN ELECTRIC
AUTOMATIC OR SEMIAUTOMATIC WIRE
FEEDERS

ELECTRIC SHOCK can kill.

• Only qualified personnel should per­form this installation.

• Turn the input power OFF at the dis-

connect switch or fuse box before working on this
equipment.

• Do not touch electrically hot parts.

Auxiliary power for wire feeder operation is available at
both a 14-pin MS receptacle and at terminal strips
with screw-type connections located on the front of
the machine. Refer to the Installation section for
pinouts and lead designations. The two circuits are
isolated, and each is protected by a circuit breaker.

The following descriptions show how to connect the
wire feeders using either the 14-pin MS receptacle or
the terminal strip.

AUTOMATIC WIRE FEEDERS

CONNECTING THE NA-3 OR LT-7 TO THE
IDEALARC DC-655 (TERMINAL STRIP)

1. Set Idealarc DC-655 POWER toggle switch to the
OFF (0) position.

2. Disconnect main AC input power to the Idealarc
DC-655.

3. Connect the wire feeder control cable leads to the
Idealarc DC-655 terminal strip as shown in Figure
C.1.

4. Connect the wire feeder control cable ground lead
to the frame terminal marked .

NOTE: The Idealarc DC-655 must be properly

grounded.

FIGURE C.1 – NA-3 OR LT-7 WIRE FEEDER

CONNECTION TO THE IDEALARC DC-655

5. Extend wire feeder control cable lead #21 so it can
be connected directly to the work piece.

a. Make a bolted connection using AWG #14 or

larger insulated wire. Tape the bolted connec­tion with insulating tape.

b. An S-16586- X remote voltage sensing work

lead is available for this purpose.

c. Keep the #21 lead electrically separate from

the work cable circuit and connection.

d. Tape the #21 lead to work cable for ease of

use.

ACCESSORIES

C-3 C-3

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

WARNING

NEGATIVE

POSITIVE

32
31
2
4

GND

21

ELECTRODE CABLE

TO WORK

POWER SOURCE

CONTROL BOX

21

FOR CONTROL CABLE
WITH 14 PIN MS-TYPE
PLUG CONNECTOR

OR

FOR CONTROL CABLE
WITH TERMINAL STRIP
LEAD CONNECTORS

CONTROL CABLE

14-PIN

RECEPTACLE

75

76

77

TO AUTOMATIC

EQUIPMENT

TO AUTOMATIC

CONTROL CABLE

41

4 2 31

32

75 76

77

21-21

+

REMOTE VOLTAGE SENSING LEAD

NOTE: The connection diagram shown in Figure C.1

shows the electrode connected for positive
polarity. To change polarity:

a. Set the Idealarc DC-655 POWER toggle

switch to the OFF (0) position.

b. Move the electrode cable to the negative (-)

output terminal. (High inductance or low
inductance, as needed).

c. Move the work cable to the positive (+) output

terminal.

d. If connecting lead #21 to the terminal strip,

connect it to the +21 terminal (to match work
polarity). If work polarity changes back to
negative, lead #21 must be connected to the

-21 terminal.

e. Reverse the leads on the back of the ammeter

and voltmeter in the automatic control box.

f. If the automatic controls include a variable

voltage board, connect its jumper lead to pin
“L”. This will permit the inch down button to
operate. However, the jumper also disables
the cold starting/autostop feature of the auto­matic controls. Only hot starting will be avail­able.

6. Set the DC-655 OUTPUT CONTROL switch to the
“Remote” position and the OUTPUT TERMINALS
switch in the “Remote” position.

CONNECTING THE NA-5/-5R TO THE
IDEALARC DC-655 (TERMINAL STRIP)

1. Set the Idealarc DC-655 POWER toggle switch to
the OFF (0) position.

2. Disconnect main AC input power to the Idealarc
DC-655.

3. Connect the wire feeder control cable leads to the
Idealarc DC-655 terminal strip as shown in Figure
C.2.

FIGURE C.2 – NA-5/-5R WIRE FEEDER

CONNECTION TO THE IDEALARC DC-655

4. Connect the wire feeder control cable ground lead
to the frame terminal marked .

NOTE: The Idealarc DC-655 must be properly

grounded.

5. Extend wire feeder control cable lead #21 so it can
be connected directly to the work piece.

a. Make a bolted connection using AWG #14 or

larger insulated wire. Tape the bolted connec­tion with insulating tape.

b. An S-16586-X remote voltage sensing work

lead is available for this purpose.

c. Keep the #21 lead electrically separate from

the work cable circuit and connection.

d. Tape the #21 lead to work cable for ease of

use.

ACCESSORIES

C-4 C-4

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

14-PIN

POWER SOURCE

+

21-21

NEGATIVE

41

4 2 31

21

32

POSITIVE

RECEPTACLE

CONTROL CABLE

75 76

77

BOLT TO CABLES FROM NA-5/-5R
WIRE CONTACT AS'BLY

REMOTE VOLTAGE SENSING LEAD

TO NA-5/-5R
INPUT CABLE PLUG

TO WORK

CONTROL CABLE

C
B
A
32
31
2
4

GND

21

FOR CONTROL CABLE
WITH 14 PIN MS-TYPE
PLUG CONNECTOR

OR

FOR CONTROL CABLE
WITH TERMINAL STRIP
LEAD CONNECTORS

6. Connect NA-5/-5R wire feeder control jumpers on
Voltage Control Board. See NA-5/-5R Operator’s
Manual.

NOTE: The connection diagram shown in Figure C.2

shows the electrode connected for positive
polarity. To change polarity:

a. Set the Idealarc DC-655 POWER toggle

switch to the OFF (0) position.

b. Move the electrode cable to the negative (-)

output terminal. (High inductance or low
inductance as needed).

c. Move the work cable to the positive (+) output

terminal.

d. If connecting lead #21 to the terminal strip,

connect it to the +21 terminal (to match work
polarity). If work polarity changes back to
negative, lead #21 must be connected to the ­21 terminal.

NOTE: For proper NA-5 operation, the electrode

cables must be secured under the clamp bar
on the left side of the NA-5 Control Box.

7. Set the DC-655 OUTPUT CONTROL switch to the
“Remote” position and the OUTPUT TERMINALS
switch to the “Remote” position.

ACCESSORIES

C-5 C-5

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

SEMIAUTOMATIC WIRE FEEDERS

CONNECTING THE LN-7 TO THE IDEALARC
DC-655 (14-PIN MS RECEPTACLE)

1. Set the POWER toggle switch to the OFF (0) posi­tion.

2. Disconnect main AC input power to the Idealarc
DC-655.

3. Connect the electrode cable from the control
cable to the “+” terminal of the welder and to the
LN-7 wire feeder. Connect the work cable to the
“-” terminal of the welder (High inductance or low
inductance as needed). Reverse this hookup for
negative polarity.

NOTE: Welding cable must be sized for the current

and duty cycle of the application.

4. Connect control cable between the DC-655 and
the LN-7. See Figure C.3.

5. Set the MODE switch to a CV (constant voltage)
position at the welder.

6. Adjust wire feed speed at the LN-7 and set the
welding voltage with the output CONTROL.

NOTE: If optional remote control is used, place the

OUTPUT CONTROL and the OUTPUT TERMI­NALS switch in the “Remote” position.

ACCESSORIES

C-6 C-6

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

41

4231

32

75 76

77

NEGATIVE

POSITIVE

32
31
2
4

GND

21

ELECTRODE CABLE

TO WIRE FEED UNIT

TO WORK

}

POWER SOURCE

LN-7 TO INPUT

CABLE PLUG

LN-7 CONTROL
CABLE

21

-

21

21

+

REMOTE VOLTAGE SENSING LEAD

FIGURE C.3

IDEALARC DC-655/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM

CONNECTING THE LN-7 TO THE
IDEALARC DC-655 (TERMINAL STRIP)

1. Set the Idealarc DC-655 POWER toggle switch to
the OFF (0) position.

2. Disconnect main AC input power to the Idealarc
DC 655.

3. Connect the wire feeder control cable leads to the
Idealarc DC-655 terminal strip as shown in Figure

C.3.

4. Connect the wire feeder control cable ground lead
to the frame terminal marked .

NOTE: The Idealarc DC-655 must be properly

grounded.

5. PERFORM THIS STEP ONLY IF THE LN-7 IS
EQUIPPED WITH A METER KIT.

Extend wire feeder control cable lead #21 so it can
be connected directly to the work piece.

a. Make a bolted connection using AWG #14 or

larger insulated wire. Tape the bolted connec­tion with insulating tape.

NOTE: If the work cable length is less than 25 feet

and the connections to the work piece are
secure, then wire feeder control cable lead
#21 can be connected directly to the DC­655 terminal strip.

b. An S-16586-X remote voltage sensing work

lead is available for this purpose.

c. Keep the #21 lead electrically separate from

the work cable circuit and connection.

d. Tape the #21 lead to work cable for ease of

use.

NOTE: The connection diagram shown in Figure

C.3 shows the electrode connected for
positive polarity. To change polarity:

a. Set the IDEALARC DC-655 POWER toggle

switch to the OFF (0) position.

b. Move the electrode cable to the negative (-)

output terminal (High inductance or low induc­tance as needed).

c. Move the work cable to the positive (+) output

terminal.

d. Connect control cable lead #21 to “+21” on

the terminal strip.

ACCESSORIES

C-7 C-7

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

CONNECTING THE LN-8 OR LN-9 TO THE
IDEALARC DC-655 (TERMINAL STRIP)

1. Set the Idealarc DC-655 POWER toggle switch to
the OFF (0) position.

2. Disconnect main AC input power to the Idealarc
DC-655.

3. Connect the wire feeder control cable leads to the
Idealarc DC-655 terminal strip as shown in Figure
C.4.

4. Connect the wire feeder control cable ground lead
to the frame terminal marked .

5. Extend wire feeder control cable lead #21 so it can
be connected directly to the work piece.

a. Make a bolted connection using AWG #14 or

larger insulated wire. Tape the bolted connec­tion with insulating tape.

b. An S-16586- X remote voltage sensing work

lead is available for this purpose.

c. Keep the #21 lead electrically separate from

the work cable circuit and connection.

d. Tape the #21 lead to work cable for ease of

use.

6. Connect LN-9 wire feeder control jumpers on
Voltage Control board. See LN-9 Operator’s
Manual.

NOTE: The connection diagram shown in Figure C.4

shows the electrode connected for positive
polarity. To change polarity:

a. Set the Idealarc DC-655 POWER toggle

switch to the OFF (0) position.

b. Move the electrode cable to the negative (-)

output terminal (High inductance or low
inductance as needed).

c. Move the work cable to the positive (+) output

terminal.

d. Connect control cable lead #21 to “+21” on

the terminal strip.

7. Set the OUTPUT CONTROL switch to the
“Remote” position and the OUTPUT TERMINALS
switch to the “Remote” position.

ACCESSORIES

C-8 C-8

IDEALARC DC-655

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

FIGURE C.4 - LN-8 OR LN-9 WIRE FEEDER CONNECTION TO THE IDEALARC DC-655

NEGATIVE

POSITIVE

32
31
2
4

GND

21

ELECTRODE CABLE
TO WIRE FEED UNIT

TO WORK

}

POWER SOURCE

N.E.

CABLE

21

A

B

C

}

TO LN-8 OR LN-9

CONTROL

INPUT CABLE PLUG

41

4231

32

75 76

77

21-21

+

REMOTE VOLTAGE SENSING LEAD