Idealarc dc655 PDF

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SVM142-A
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September, 2002
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IDEALARC ™ DC-655
For use with machine code number 10501 thru 10510
Safety Depends on You

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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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
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SERVICE MANUAL
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Copyright © 2002 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
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 pur-
chase 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.
FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do
current creates EMF fields around welding cables and

not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and before welding.
devices in position and in good repair.Keep
hands, hair, clothing and tools away from V- 2.c. Exposure to EMF fields in welding may have other health
belts, gears, fans and all other moving parts effects which are now not known.
when starting, operating or repairing equip-
ment. 2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d.1. Route the electrode and work cables together - Secure
guards to perform required maintenance. Remove them with tape when possible.
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.2. Never coil the electrode lead around your body.
Always use the greatest care when working near moving
parts. 2.d.3. Do not place your body between the electrode and
___________________________________________________ work cables. If the electrode cable is on your right
1.f. Do not put your hands near the engine fan. Do not attempt to side, the work cable should also be on your right side.
override the governor or idler by pushing on the throttle con-
trol rods while the engine is running. 2.d.4. Connect the work cable to the workpiece as close as
___________________________________________________ possible to the area being welded.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance 2.d.5. Do not work next to welding power source.
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
IDEALARC DC-655

ii ii
Return to Master TOC SAFETY
ELECTRIC SHOCK can kill. ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot” when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot” parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
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 FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
• Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
3.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.g. Never dip the electrode in water for cooling.

form phosgene, a highly toxic gas, and other irritating
products.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
5.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
5.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.j. Also see Items 6.c. and 8.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.

IDEALARC DC-655

iii iii
WELDING SPARKS can CYLINDER may explode

cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can • A safe distance from arc welding or cutting operations and
cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
IDEALARC DC-655

iv iv
PRÉCAUTIONS DE SÛRETÉ 7. Quand on ne soude pas, poser la pince à une endroit isolé
de la masse. Un court-circuit accidental peut provoquer un
Pour votre propre protection lire et observer toutes les instructions échauffement et un risque d’incendie.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 8. S’assurer que la masse est connectée le plus prés possible
antes: 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
Sûreté Pour Soudage A L’Arc endroits éloignés de la zone de travail, on augmente le
risque de voir passer le courant de soudage par les chaines
1. Protegez-vous contre la secousse électrique: de levage, câbles de grue, ou atres circuits. Cela peut
a. Les circuits à l’électrode et à la piéce sont sous tension provoquer des risques d’incendie ou d’echauffement des
quand la machine à souder est en marche. Eviter tou- chaines et des câbles jusqu’à ce qu’ils se rompent.
jours tout contact entre les parties sous tension et la 9. Assurer une ventilation suffisante dans la zone de soudage.
peau nue ou les vétements mouillés. Porter des gants Ceci est particuliérement important pour le soudage de tôles
secs et sans trous pour isoler les mains. galvanisées plombées, ou cadmiées ou tout autre métal qui
b. Faire trés attention de bien s’isoler de la masse quand produit des fumées toxiques.
on soude dans des endroits humides, ou sur un planch- 10. Ne pas souder en présence de vapeurs de chlore provenant
er metallique ou des grilles metalliques, principalement d’opéerations de dégraissage, nettoyage ou pistolage. La
dans les positions assis ou couché pour lesquelles une chaleur ou les rayons de l’arc peuvent réagir avec les
grande partie du corps peut être en contact avec la vapeurs du solvant pour produire du phosgéne (gas forte-
masse. ment roxique) ou autres produits irritants.

c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
PRÉCAUTIONS DE SÛRETÉ POUR LES
d. Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir. MACHINES À SOUDER À TRANSFOR-
e. Ne jamais toucher simultanément les parties sous ten-
MATEUR ET À REDRESSEUR
sion des porte-électrodes connectés à deux machines à 1. Relier à la terre le chassis du poste conformement au code
souder parce que la tension entre les deux pinces peut de l’électricité et aux recommendations du fabricant. Le dis-
être le total de la tension à vide des deux machines. positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
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 2. Autant que possible, l’installation et l’entretien du poste
enroule le câble-électrode autour de n’importe quelle partie seront effectués par un électricien qualifié.
du corps.
3. Avant de faires des travaux à l’interieur de poste, la
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, debrancher à l’interrupteur à la boite de fusibles.
donc:
4. Garder tous les couvercles et dispostifis de sûreté à leur
a. Utiliser un bon masque avec un verre filtrant approprié place.
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-inflamma-
bles.
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, pan-
talons 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.
IDEALARC DC-655

v v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
RETURN TO MAIN INDEX

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
IDEALARC DC-655

Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
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
IDEALARC DC-655

A-2 A-2
INSTALLATION
Return to Section TOC
TECHNICAL SPECIFICATIONS – DC-655

INPUT - THREE PHASE ONLY
Standard Input Current at Rated Output Code
Voltage 100% Duty Cycle 60% Duty Cycle Number
230/460/60 122/61 150/75 10501

230/460/575/60 122/61/49 150/75/60 10502
208/416/60 135/67.5 166/83 10503
460/60 61 75 10504
575/60 49 60 10505
230/400/50/60* 122/70 150/86 10506
380/500/50/60* 74/56 90/69 10507
440/50/60 64 78 10508
200/400/50/60 140/70 172/86 10509
415/50/60 68 83 10510
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
100% Duty Cycle 650 44
NEMA Class I (100)*
60% Duty Cycle 815 44
OUTPUT
Voltage Range Current Range Maximum Open Circuit Voltage Auxiliary Power
46 CV Mode See the OPERATION section for
13-44 DC 50-815 68 CC Mode Auxiliary Power
information by model
RECOMMENDED INPUT WIRE AND FUSE SIZES
INPUT HERTZ INPUT AMPERE TYPE 80°C Copper
VOLTAGE / RATING ON COPPER WIRE GROUND WIRE (SUPER LAG)
FREQUENCY NAMEPLATE IN CONDUIT IN CONDUIT OR BREAKER
AWG(IEC-MM2) SIZES AWG(IEC-MM2) SIZES SIZE (AMPS)1

40°C (104°F) Ambient

208 60 135 1 (43) 4 (21) 250 Amp
230 60 122 1 (43) 4 (21) 225 Amp
416 60 67.5 6 (14) 6 (14) 125 Amp
460 60 61 6 (14) 6 (14) 110 Amp
575 60 49 8 (8.4) 8 (8.4) 90 Amp
200 50/60 140 1/0 (54) 4 (21) 250 Amp
230 50/60 122 1 (43) 4 (21) 225 Amp
380 50/60 74 4 (21) 6 (14) 125 Amp
400 50/60 70 4 (21) 6 (14) 125 Amp
415 50/60 68 6 (14) 6 (14) 110 Amp
440 50/60 64 6 (14) 6 (14) 110 Amp
500 50/60 56 6 (14) 6 (14) 110 Amp
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
27.5 in 22.2 in 38.0 in 720 lbs.

699 mm 564 mm 965 mm 326 kg.
* European models meet IEC974-1 standards.
1Also 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.
IDEALARC DC-655

A-3 A-3
INSTALLATION
GRAPHIC SYMBOLS THAT APPEAR ON
RATING PLATE (LOCATED ON CASE BACK)
3 Phase transformer with Constant Voltage Output

rectified DC output Characteristics
INPUT POWER GMAW
THREE PHASE FCAW
Designates welder complies with

Designates welder can be used

National Electrical Manufacturers
S in environments with increased
NEMA EW 1 (100%) Association requirements EW 1 hazard of electric shock.
Class I with 100% duty cycle at
(European models)
650Amps output. (Domestic,
Canadian, and Export models)
low voltage directive and with
CE
Designates welder complies with EMC directive. (European
International Electrotechnical models)
IEC 974-1
Commission requirements 974-1.
(European Models) Designates welder complies with
both Underwriters Laboratories
R
(UL) standards and Canadian

Standards Association (CSA)

Designates the degree of envi- NRTL/C

IP-23 ronmental protection provided by standards. (Canadian Model)
the power sources enclosure.

Constant Current Output R
Underwriters Laboratories (UL)

Characteristics standards. (Domestic Models)
NRTL
SMAW Uo Open Circuit Output Voltage
U1 Input Voltage Rating(s)

SAW
I1 Input Current Rating(s)
X Output Duty Cycle Rating(s)
U2 Output Voltage Rating(s)
I2 Output Current Rating(s)

IDEALARC DC-655

A-4 A-4
INSTALLATION
Read this entire installation section INPUT

before you start installation. CONTACTOR (CR1)
INPUT POWER SUPPLY

SAFETY PRECAUTIONS CABLE WITH BUSHING
RECONNECT
OR BOX CONNECTOR
PANEL ASSEMBL Y
WARNING
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 FIGURE A.1 - ELECTRICAL INPUT CONNECTIONS
feeder or remote connections, or other equipment.
• Do not touch electrically hot parts.
Use input wire sizes that meet local electrical codes or
• Always connect the Idealarc DC-655 grounding ter- see the Technical Specifications page in this manual.
minal (located on the welder near the reconnect
Input power supply entry is through the hole in the
panel) to a good electrical earth ground.
Case Back Assembly. See Figure A.1 for the location
of the machine’s input cable entry opening, Input
Contactor (CR1), and reconnect panel.
SELECT SUITABLE LOCATION
FUSE AND WIRE SIZES
Place the welder where clean cooling air can freely cir-
culate in through the front louvers and out through the Protect the input circuit with the super lag fuses or
rear louvers. Dirt, dust or any foreign material that can delay type circuit breakers listed on the Technical
be drawn into the welder should be kept at a mini- Specifications page of this manual for the machine
mum. Failure to observe these precautions can result being used. They are also called inverse time or ther-
in excessive operating temperatures and nuisance mal/magnetic circuit breakers.

shut-downs. DO NOT use fuses or circuit breakers with a lower amp
rating than recommended. This can result in “nui-
STACKING sance” tripping caused by inrush current even when
The DC-655 may be stacked three-high provided the machine is not being used for welding at high output
bottom machine is on a stable, hard, level surface. Be currents.
sure that the two pins in the roof fit into the slots in the
base of the DC-655 above it. GROUND CONNECTION
Ground the frame of the machine. A ground
TILTING terminal marked with the symbol is located inside
Do not place the machine on a surface that is inclined the case back of the machine near the input contactor.
enough to create a risk of the machine falling over. 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
ELECTRICAL wire sizes that meet local electrical codes or see the
Technical Specifications page in this manual.
INPUT CONNECTIONS
Before installing the machine check that the input sup-
ply voltage, phase, and frequency are the same as the
voltage, phase, and frequency as specified on the
welder nameplate.
IDEALARC DC-655

A-5 A-5
INSTALLATION
INPUT POWER SUPPLY CONNECTIONS RECONNECT PROCEDURE

A qualified electrician should connect the input power
supply leads.
WARNING
Electric Shock Can Kill
1. Follow all national and local electrical codes.
• Disconnect input power before per-
2. Use a three-phase line. forming this procedure.
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. Multiple voltage machines are shipped connected to
the highest input voltage listed on the machine’s rating
5. Connect the three-phase AC power supply leads plate. Before installing the machine, check that the
L1, L2, and L3 to the input contactor reconnect panel in the input box assembly is connect-
terminals in the input box assembly. See Figure ed for the proper voltage.
A.1.
CAUTION
Failure to follow these instructions can cause immedi-
ate failure of components within the machine.
To reconnect a multiple voltage machine to a different

voltage, remove input power and follow the input con-
nection diagram located on the inside of case back
input access door.
1. For dual voltage sample machine reconnect
instructions, see Figure A.2.
DUAL VOLTAGE MACHINE

Do not operate with covers
removed
Do not touch electrically live parts INPUT SUPPLY CONNECTION DIAGRAM
IMPORTANT: CHANGE LINK POSITIONS AND CONTROL TRANSFORMER CONNECTIONS.
Disconnect input power before Only qualified persons should install,
servicing use or service this equipment NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE

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

W CR1 LEAST 600 VOLT INSULATION.
L3
INPUT 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H3 CONTROL TRANSFORMER
L2 V
LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
LINES CONTACTOR
L1 U 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC

CODES.
GND H1 5. MOUNT THE LINKS IN THE POSITIONS SHOWN; DOUBLE OR TRIPLE STACK THE LINKS
H3 H2
IN THREE POSITIONS. LOOP THE FLEX LEAD IN THE POSITION SHOWN; POSITIONING
CONTROL THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN
TRANSF. ALL OF THE HEX NUTS.
LINKS
CONNECTION FOR LOWEST RATING PLATE VOLTAGE

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT

L3 W CR1 LEAST 600 VOLT INSULATION.
INPUT 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H1 & H2 CONTROL TRANSFORMER
L2 V
LINES CONTACTOR LEADS TO THE INPUT SIDE OF CR1 CONTACTOR AS SHOWN.
L1 U
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC
CODES.
H1
GND
H2 H3 5. MOUNT THE LINKS IN THE POSITIONS SHOWN. CONNECT THE FLEX LEAD AS SHOWN;
POSITIONING THE LUGS TO MAINTAIN MAXIMUM CLEARANCE TO THE LINKS.
CONTROL
INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
TRANSF.
D-UF
LINKS
THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A. M18225
FIGURE A.2 - DUAL VOLTAGE MACHINE RECONNECTION PROCEDURE
IDEALARC DC-655

A-6 A-6
INSTALLATION
OUTPUT CONNECTIONS 2. Connect the electrode cable to the positive terminal

marked “+”.
ELECTRODE AND WORK CABLES 3. Remove the terminal strip access cover panel on
Use the shortest possible cable lengths. See Table A.1 the lower case front. Refer to Figure A.3 for the
for recommended cable sizes based on length. location.
4. Work Sense lead #21 from the 14 Pin MS-recepta-
TABLE A.1
cle must be connected to “-21”on the terminal strip.
Cable Sizes for Combined Lengths of Copper
Note: This is how the DC-655 is shipped from the
Electrode and Work Cable
factory.
Cable Length Parallel Cables Cable Size
ft. (m) 5. Replace the terminal strip access cover panel.
0 (0) to 100 (30.4) 2 2/0 ( 70mm2)
100 (30.4) to 200 (60.8) 2 3/0 ( 95mm2)
200 (60.8) to 250 (76.2) 2 4/0 (120mm2)
For Negative Polarity:

The output terminals are located at the lower front of
the welder behind a hinged door. Refer to Figure A.3. 1. Connect the electrode cable to the appropriate high
Route the welding cables through the slotted strain inductance (-) terminal (marked " ")
reliefs of the base to the welding terminals. or to the low inductance (-) terminal (marked
" ") if using NR203Ni 1% electrode.
LOW INDUCTANCE TERMINAL 2. Connect the work cable to the positive terminal
On the DC-655, the inside right Negative (-) output ter- marked “+”.
minal is lower choke inductance. This terminal is
3. Remove the terminal strip access cover panel on the
presently only recommended for CV mode welding
lower case front. Refer to Figure A.3 for the location.
with NR203Ni 1% negative polarity procedures.. All
other processes are to be welded using the outside 4. Work Sense lead #21 from the 14 Pin MS-recepta-
right Negative (-) output terminal with higher choke cle must be connected to “+21”on the terminal
inductance. CC mode processes must use high strip.
inductance.
5. Replace the terminal strip access cover panel.
For Positive Polarity:

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

terminal (marked " ").
14 PIN MS RECEPTACLE
POSITIVE LOW INDUCTANCE

OUTPUT HIGH INDUCTANCE
NEGATIVE OUTPUT NEGATIVE OUTPUT
TERMINAL TERMINAL
TERMINAL STRIP TERMINAL
COVER PANEL
FIGURE A.3 - OUTPUT CONNECTIONS
IDEALARC DC-655

A-7 A-7
INSTALLATION
AUXILIARY POWER AND 14-PIN MS TYPE RECEPTACLE

CONTROL CONNECTIONS (For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32)
Located at the lower front of the welder behind a Refer to the Figure A.4 for the available circuits in the
hinged door is a 115 VAC duplex receptacle for auxil- 14-pin receptacle.
iary power (Domestic and Canadian Models only) and
a 14-pin MS type receptacle for connection of auxiliary 42 VAC is available at receptacle pins I and K. A 10
equipment such as wire feeders. Also, terminal strips amp circuit breaker protects this circuit.
with 115 VAC and connections for auxiliary equipment 115 VAC is available at receptacle pins A and J
are located behind the access panel on the lower case (Domestic, Canadian and Export Models). This circuit
of the welder. A 220 VAC receptacle for a water cooler is protected by a circuit breaker (see Auxiliary Power
(European and Export Models only) is located on the Table). Note that the 42 VAC and 115 VAC circuits are
case back. electrically isolated from each other. However, on the
European model one line of the 115 VAC is connected
AUXILIARY POWER TABLE to chassis ground.
Voltage and Circuit Breaker Ratings at Auxiliary Power
Connections for Various Models FIGURE A.4 - FRONT VIEW OF 14-PIN
Auxiliary Domestic Canadian European Export CONNECTOR RECEPTACLE

Power Models Model Models Models
Connections (60Hz) (230/460/575V/60 Hz) (50/60 Hz) (50/60 Hz)
K=42
At Duplex 115V 20A 115V 15A No Duplex No Duplex A=32 J=31
Receptacle
B=GND I=41
Terminal strip 115V 20A 115V 15A 115V 15A 115V 15A
terminals 31 & 32 L N
MS-Receptacle 115V 20A 115V 15A Open Circuit 115V 15A

C=2
pins A & J H=21
MS-Receptacle 42V 10A 42V 10A 42V 10A 42V 10A D=4
G=75
pins I & K
E=77 F=76
At 220V No Receptacle No Receptacle 220V 2A 220V 2A M
Receptacle
PIN LEAD NO. FUNCTION
A 32 115 VAC
115 VAC DUPLEX RECEPTACLE (DOMESTIC AND
B GND Chassis Connection

CANADIAN MODELS ONLY) C 2 Trigger Circuit
The 115 VAC duplex receptacle is protected by a cir- D 4 Trigger Circuit
cuit breaker located below the receptacle (see E 77 Output Control
Auxiliary Power Table). Receptacle is a NEMA 5-20R F 76 Output Control
(protected by a 20 amp breaker) on Domestic Models G 75 Output Control
and a NEMA 5-15R (protected by a 15 amp breaker) on H 21 Work Sense Connection
2
Canadian Models. I 41 42 VAC

1.
230 VAC RECEPTACLE (EUROPEAN AND EXPORT J 31 115 VAC
MODELS ONLY) K 42 42 VAC
L --- ---
A Continental European receptacle is located on the
M --- ---
rear panel for supplying 220 VAC to a water cooler. The
N --- ---
receptacle has a protective cover to prevent acciden-
1.
tal contact and is a Schuko type. The circuit is pro- 115VAC circuit is not present in the 14-pin connector on IEC 974-
tected by a 2 amp circuit breaker also located on the 1 European models.
rear panel. This circuit is electrically isolated from all
2.
As shipped from the factory Lead #21 from the 14-pin connector is
other circuits, but on the European Models one line is connected to “-21” on the terminal strip. This is the configuration for
connected to chassis ground. positive welding. If welding negative polarity, connect lead #21 to
the “+21” connection point on the terminal strip.
IDEALARC DC-655

A-8 A-8
INSTALLATION
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 cir-
cuit. 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 weld-

ing negative polarity.
TERMINAL STRIP 1 (T.S.1)

Lead No. Function
75 Output Control
76 Output Control
77 Output Control
TERMINAL STRIP 2 (T.S.2)

Lead No. Function
+21 Work Connection

-21 Work Connection2

41 42 VAC
4 Trigger Circuit
2 (42 VAC) Trigger Circuit (42 VAC)
31 115 VAC1
32 115 VAC1
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.
IDEALARC DC-655

Section B-1 Section B-1
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
IDEALARC DC-655

B-2 B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section of operating
instructions before operating the machine.
SAFETY PRECAUTIONS
WARNING

• Do not touch electrically live parts or
electrodes with your skin or wet cloth-
ing.
• 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.
IDEALARC DC-655

B-3 B-3
OPERATION
GENERAL DESCRIPTION • Power on/off switch with pilot light and thermostat
tripped indicator light.

The DC-655 is an energy efficient constant voltage DC
power source that produces outstanding arc charac- • Full range output voltage (CV mode) and current (CC
teristics for multiple CV or CC welding processes. mode) control for easy operation.
Four models are available: • Panel switches behind a latched front panel for
remote or local output control, output on or remote
Domestic - all 60 Hertz models except selection, and CC, CV Sub-arc or CV MIG mode
230/460/575v. selection.
NEMA Class 1 rated
• Panel knob settable CC arc force control with built-
Canadian - 230/460/575v 60 Hertz in adjustable “Hot Start”.
NEMA Class 1 rated
• High efficiency output, and selectable “sleep mode”
European - 50/60 Hertz models “CE” qualified idle mode timer which shuts down input power if not
and rated for IEC 974-1 used for extra energy conservation.
Export - 50/60 Hertz models NEMA Class 1 rated • Fan as needed (F.A.N.). Solid state thermally con-
trolled fan operates cooling fan only when required.
Minimizes power consumption, operating noise and

RECOMMENDED PROCESSES AND dust intake.
EQUIPMENT • Hinged cover to protect output terminals and auxil-
iary connections.
The DC-655 is designed for CV or CC processes.
• Electronic and thermostatic protection for current
CV processes include: GMAW (MIG) and FCAW (flux-
overload and excessive temperatures.
cored) welding, plus the capability of CV submerged
arc welding and air carbon arc gouging. It produces • 42 VAC, 10 amp auxiliary power available for the wire
outstanding welding performance with a single range feeder; circuit breaker protected.
full output control knob.
• 115 VAC, auxiliary power available for the wire feed-
CC processes include stick welding, CC submerged er; circuit breaker protected. 20 amp breaker on
arc and superior air carbon arc gouging with up to 3/8” Domestic model and 15 amp breaker on Canadian,
(10 mm) diameter carbons. The same single range full European, and Export Models.
output control knob is used and paralleling capability
• 115 VAC duplex plug receptacle available on
is provided.
Domestic and Canadian Models. 20 amp breaker on
The DC-655 is recommended for use with Lincoln’s Domestic Models and 15 amp breaker on Canadian
DH-10 or LN-10 as well as the LN-7*, LN-7 GMA*, LN- Model.
742, LN-8*, LN-9*, LN-9 GMA*, LN-23P and LN-25
• 220 VAC receptacle on European and Export models
semiautomatic wire feeders. It is also recommended
for connecting to a water cooler. Protected by 2 amp
for use with the NA-3, NA-5 and NA-5R automatic
breaker.
feeders. “Cold starting” for sub-arc or across arc
“touch-sensing” can be used. • Single MS-type (14-pin) connection for wire feeder.
* The 14-pin MS receptacle on the European models • Optional Field Installed Digital or Analog Voltmeter/
does not provide 115 VAC for these feeders; 115 Ammeter kits are available.
VAC must be obtained from terminal strip.
• Optional dual feeder kit for like polarity connection of
Two DC-655’s may be paralleled in a “master” and two wire feeders. Easy panel installation.
“slave” interconnection using the K1611-1 Paralleling
• Optional Dual Process Switch for two processes
kit.
with polarity change and electrical isolation.
DESIGN FEATURES AND

WELDING CAPABILITY
ADVANTAGES
The DC-655 has the following Output and Duty Cycle
• Separate output terminals for selecting high or low based on operation for a 10 minute period:
inductance as recommended for the welding
process. 650 Amps, 44 Volts at 100%
815 Amps, 44 Volts at 60%

IDEALARC DC-655

B-4 B-4
OPERATION
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.
8 2 9
3
1
DC-655
7 4 5 6
FIGURE B.1 CONTROL PANEL CONTROLS
1. INPUT POWER ON/OFF SWITCH - This tog- remote device such as a wire feeder closes the #2 and
gle switch turns the machine on or off. Putting the #4 circuit in the MS-receptacle or terminal strip. When
switch in the ON position energizes the this switch is in the ON position the machine’s output
machine’s input contactor applying input power to terminals will be electrically energized all the time.
the machine. Switching the switch to the OFF

5. LOCAL/REMOTE CONTROL SWITCH - When
position de-energizes the input contactor. This
this switch is set to the LOCAL position, con-
switch is also used to reset a machine shutdown.
trol of the output voltage is via the output control
(See Machine Shutdown section)
on the DC-655’s control panel. When this switch is
2. PILOT LIGHT - When the power switch is in the set to the remote position, control is through a
ON position the machine’s white pilot light will illu- remote source such as a wire feeder via the #75,
minate. If the input contactor de-energizes the #76, and #77 leads in the MS-receptacle or termi-
machine in a shutdown situation, the pilot will still nal strip.
illuminate. In this situation it will be necessary to
6. CC STICK/CV SUBARC/CV MIG MODE SWITCH -
reset the machine by switching the power switch to
This switch selects the proper welding characteris-
the OFF then ON position. (See Machine
tics for the process being used:
Shutdown section)
CC Stick provides a constant current output
3. OUTPUT CONTROL - This control provides
characteristic through the 50 to 815 amp
continuous control of the machine’s output from
range. The current is adjusted within this
minimum to maximum as it is rotated clockwise.
range by the Output Control dial. The open

The CV mode voltage range of control is 13 to 44V.

circuit (no load) voltage will be about 68 volts
The CC mode current range of control is 50 to
in this mode.
815A.
This mode is used for stick welding (SMAW)
4. OUTPUT TERMINALS ON/REMOTE - When this
and CC air carbon-arc gouging, and employs
switch is in the REMOTE position, the DC-655’s
a “Hot Start” feature and an Arc Force Control.
output terminals will be electrically “cold” until a
IDEALARC DC-655

B-5 B-5
OPERATION
CC mode may also be used for CC submerged arc 7. ARC FORCE CONTROL - This control is only func-
with appropriate arc-sensing CC(VV) wire feeders tional in CC Stick mode. It prevents “stubbing” of
if arc force is set high enough. Refer to Welding the electrode by providing the extra weld current
Performance section. that linearly increases as the welding voltage
decreases below a level determined by the setting
CV MIG provides a constant voltage output char-
of the constant current control.
acteristic through the 13 to 44 volt range. The volt-
age is adjusted within this range by the Output The Arc Force control knob, located behind the
Control dial. latched cover, adjusts arc force from “Min” (no cur-
rent increase) to “Max” (higher short circuit current).
The dynamic characteristics of this mode are ideal
The “mid” position (#5) is recommended for most
for open arc processes including, MIG/MAG
CC welding. Refer to the Welding Performance
(GMAW), Innershield®, and other cored wire
Section.
(FCAW) processes. Faster travel submerged arc
processes and CV air carbon-arc gouging may 8. OPTIONAL VOLTMETER & AMMETER - Digital or
also use this mode. Refer to the Welding analog meter kits are available as field installed
Performance section. options. Refer to the Accessories Section of this
manual.
CV Sub-Arc provides the same constant voltage
output control range as CV MIG, but the dynamic 9. THERMAL PROTECTION LIGHT - If the
characteristics of this mode make possible machine overheats due to lack of proper air flow
improved CV (constant wire speed) submerged arc through the machine or due to exceeding the
welding. This improved process is most notice- machine’s duty cycle, thermostats will disable the
able on high deposition slow travel speed welds. welding output and this light will illuminate. Input
Fast travel, narrow bead subarc welds will have power is still applied to the machine and the cool-
better performance in CV MIG mode. ing fan will continue to run. When the machine
cools the welding output will resume.
FIGURE B.2 LOWER CASE FRONT CONTROLS & CONNECTIONS
1 2 3
4
6 5 7
1. 115 VAC DUPLEX RECEPTACLE (Domestic and 2. 115 VAC CIRCUIT BREAKER - This breaker
Canadian Models) This receptacle provides up to protects the 115 VAC auxiliary circuits located in
20 amps of 115 VAC auxiliary power on the the duplex receptacle, terminal strip and MS-
Domestic Models and up to 15 amps on the receptacle. Breaker is rated 20 amps on Domestic
Canadian Model. Models and 15 amps on all other models.
IDEALARC DC-655

B-6 B-6
OPERATION
3. 42 VAC 10 AMP CIRCUIT BREAKER - This DC-655 machines can also supply 115 volt AC auxil-
breaker protects the 42 VAC auxiliary circuits locat- iary power through the wire feeder receptacle. A 20
ed in the terminal strip and MS-receptacle. amp circuit breaker on the Domestic model, and a 15
amp on the Canadian and Export models protects the
4. 14-PIN MS-RECEPTACLE - This connector pro-
115 volt circuit from overloads. 115 VAC is not avail-
vides easy connection for a wire feeder control
able in the MS-receptacle on the European models.
cable. It provides connections for auxiliary power,
output switching, remote output control, wire feed-
er voltmeter sense lead and ground. Refer to 14- CAUTION
Pin MS Type Receptacle in the Installation
Section of this manual for information about the cir- Note that some types of equipment, especially pumps
cuits made available at this receptacle. and large motors, have starting currents which are sig-
nificantly higher than their running current. These high-
5. TERMINAL STRIP COVER PANEL - Remove this
er starting currents may cause the circuit breaker to
panel to gain access to the circuits made available
open. If this situation occurs, the user should refrain
at the terminal strip and the 4-pin receptacle for the
from using the DC-655 auxiliary power for that equip-
optional paralleling kit. This terminal strip contains
ment.
the same circuits as the 14-pin MS-receptacle.
The cover also provides for installation of cable

strain relief clamps.
MACHINE PROTECTION
6. POSITIVE OUTPUT TERMINAL - This output ter-
minal is for connecting a welding cable. To change THERMAL FAN CONTROL
welding polarity and for proper welding cable size
refer to Electrode and Work Cables in the The machine’s cooling fan remains off when the tem-
Installation Section of this manual. perature of the rectifiers and windings inside the
machine are below that requiring air flow cooling, as
7. NEGATIVE OUTPUT TERMINALS - These output determined by electronic monitoring of several thermal
terminals are for connecting a welding cable to sensors and the welding current of the machine.
either the High Inductance or Low Inductance Depending upon the operating temperature of the
Terminal for desired arc characteristics. To change machine, the fan may remain off while welding but
welding polarity and for proper welding cable size once the fan is activated, it will remain on for at least 5
refer to Electrode and Work Cables in the minutes to assure proper cooling. This feature saves
Installation Section of this manual. energy and also minimizes the amount of dirt and
other air borne particles being drawn into the machine.
CASE BACK CONNECTIONS

FAN MOTOR FUSE
220 VAC AUXILIARY RECEPTACLE
(European Model)
(European and Export Models)
A 10 amp slow blow fuse protects the fan motor cir-
This receptacle provides up to 2 amps of 220 VAC
cuit. This fuse is located inside the DC-655 mounted
auxiliary power for a water cooler.
on the fan motor bracket.
220 VAC 2 AMP CIRCUIT BREAKER
(European and Export Models)
This breaker protects the 220 VAC auxiliary circuit MACHINE SHUTDOWN
located in the 220 VAC receptacle. The DC-655 provides shutdown modes for thermal
over-heating, excessive load currents and faults. It
also provides an idle timer shutdown feature for addi-
AUXILIARY POWER tional operating economy.
42 volt AC auxiliary power, as required for some wire

feeders, is available through the wire feeder recepta-
cle. A 10 amp circuit breaker protects the 42 volt cir-
cuit from overloads.
IDEALARC DC-655

B-7 B-7
OPERATION
THERMAL SHUTDOWN SHORTED RECTIFIER FAULT PROTECTION

This welder has thermostatic protection from exces- If a short occurs across one of the silicon controlled
sive duty cycles, overloads, loss of cooling, and high rectifiers of the DC-655, a potentially hazardous AC
ambient temperature. When the welder is subjected to voltage could appear across the welding output termi-
an overload or loss of cooling, a thermostat will open. nals, even in idle mode when no output should be pre-
This condition will be indicated by the illumination of sent. If such a fault occurs, the DC-655 will shut down
the yellow Thermostatic Protection Light on the case the input primary voltage to the transformer to prevent
front (see Figure B.1). The fan will continue to run to the fault output. Control PC board LED3, input shut-
cool the power source. No welding is possible until the down light, turns on.
machine is allowed to cool and the Thermostatic
If this input shutdown occurs the input power pilot
Protection Light goes out.
light remains lit, since the power switch is ON and
control power is still present. Welding output or auxil-
iary supply output will not be present.
OVER CURRENT PROTECTION
This input shut down is reset by turning the DC-655
SHUTDOWN input power off, then on. If the fault is not corrected
Average Current Shutdown however, the shutdown will re-occur when turning on
To protect the SCR’s , the DC-655 will shut down to the input power.
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 IDLE SHUTDOWN TIMER
for higher current). Control PC board LED4, shutdown
light, will turn on. For additional operating economy, the DC-655 can be
set up to automatically shut off the primary input
This average current shut down can only be reset by power to the main transformer after a selectable time
opening the feeder gun trigger, or switching the DC- (1/2 or 2 hr.) has expired without welding. The unex-
655 Output/Remote switch out of the “on” position. pired timer is reset with each weld.
Peak Current Shutdown The idle mode timer is activated by setting Switch #1
To protect the SCRs, the DC-655 will shut down imme- (left most) of the DIP Switch located on the lower-cen-
diately to essentially no output if the peak output cur- ter of the DC-655 Control PC board. from the down
rent exceeds 2500 amps (about 1800A average). (Off) position to the up (On) position. Setting Switch
Control PC board LED4, shutdown light, will turn on. #2 of the DIP switch to up (On) sets the shutdown time
This peak current shut down can be reset by turning to 2 hours. Setting Switch #2 of the DIP switch to
the DC-655 input power off, then on. down (Off) sets the shutdown time to 1/2 hour.
Shutdown is reset by turning the DC-655 input power
REMOTE CONTROL LEADS FAULT off, then on.
PROTECTION SHUTDOWN1
The remote control leads from the 14-pin receptacle or
terminal strip are protected against high voltage faults Switch #1 Timer On/Off
to the electrode circuit or auxiliary voltage supplies. If (UP=ON, Down=OFF)
such a fault occurs, the DC-655 will shut down the
input primary voltage to the transformer to prevent the 1 2 3 4
fault output. Control PC board LED3, input shutdown
light, turns on. DIP Switch
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 auxil- Switch #2 Time selection
iary supply output will not be present. (UP=2 hours, Down=1/2 hour)
This input shut down is reset by turning the DC-655 Note: See Weld Performance section
input power off, then on. If the fault is not corrected
for use of switch #3 and #4.
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.
IDEALARC DC-655

B-8 B-8
OPERATION
WELDING PERFORMANCE As a general guideline for CC welding, set Arc Force to

“Mid” position and increase (typically to no more than
LOW INDUCTANCE TERMINAL #7) as necessary to prevent “stubbing” or “pop-outs”
while welding. This higher arc force is recommended
The inside right Negative (-) terminal is lower choke especially for low end 6010 stick welding.
inductance and presently is only recommended for
welding with NR203Ni 1% procedures. All other VOLTS
processes are to be welded using the outside right
Negative (-) terminal with higher choke inductance. OCV
CV MODE CURRENT-LIMITING Hot Start

CV MIG and CV Sub-Arc modes employ electronic Max. Arc Force
Min. Arc Force
current limiting to limit excessive short circuit output
current which can result in undesirable arc character-
istics or nuisance over current protection shutdown
(see Machine Protection section).
Low
Hi AMPS
As shipped, the DC-655 is set for “Hi” current limiting, Setting Setting
which maintains constant voltage until the welding
current exceeds a level proportional to the voltage set- CC OUTPUT
ting, then falls off linearly at about 10 volts per 100
amps to a limited short circuit current. “Lo” current CC MODE HOT START
limiting provides the same short circuit current, but the
arc voltage begins to linearly fall off at lower current, at Hot start is built-in for CC mode stick and carbon arc
about 5 volts per 100 amps. starting. Hot Start provides an extra weld current
“boost” at the arc strike which increases with higher
“Hi” is recommended for all CV processes, especially current settings. This Hot Start level exponentially
for CV subarc and CV arc gouging, but “Lo” tends to decays to the weld current setting in a few seconds.
“soften” the arc more when welding NR203Ni 1% on
the Low Inductance (-) terminal. If “Lo” is desired, Adjustment of the Hot Start shouldn’t be necessary,
switch #4(right-most) of the DIP switch located on the but an unsealed trimmer (R81) is provided on the DC-
lower-center of the DC-655 Control PC board needs to 655 Control PC Board to adjust hot start. Full counter-
be switched from up (Hi) position to down (Lo) posi- clockwise adjustment will reduce Hot Start to zero.
tion.
Switch #3 is for test

VOLTS purposes. Keep down.
DIP Switch (as shown) CC Hot Start
Trimmer
High 1 2 3 4
Setting "HI" Current Limit
"Lo" Current Limit
Low
Setting Switch #4 "Hi"CV Current
Limit (as shown)
Note: See Machine Shutdown section

for use of switch #1 and #2.
AMPS DC-655 Control PC Board

CV OUTPUT
CC MODE ARC FORCE CC MODE ARC GOUGING

Arc Force provides extra weld current which linearly
The DC-655 is rated for air carbon arc gouging with up

increases as the welding voltage decreases below a to 3/8” (10mm) diameter carbons. CC mode gouging
level determined by the constant current setting. The is often preferred over CV mode for cutting control, but
Arc Force control knob, located behind the latched some Arc Force may be required to avoid carbon stub-
cover, adjust Arc Force from “Min” (no current bing.
increase) to “Max” (about 9A/V increase).
IDEALARC DC-655

Section C-1 Section C-1
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
IDEALARC DC-655

C-2 C-2
ACCESSORIES
FIELD INSTALLED OPTIONS REMOTE OUTPUT CONTROL

(K775 OR K857 WITH K864 ADAPTER)
K1482-1 Digital Ammeter/Voltmeter Kit - Installs
An optional “remote output control” is available. This is
easily to the front control panel and provides digital
the same remote control that is used on other Lincoln
display of actual welding voltage and amperage while
power sources (K775). The K775 consists of a control
welding. (Installation instructions are included with the
box with 28 ft (8.5m) of four conductor cable. This
kit).
connects to terminals 75, 76, and 77 on the terminal
K1483-1 Analog Ammeter/Voltmeter Kit - Installs strip and the case grounding screw so marked with the
easily to the front control panel and provides analog symbol on the machine. These terminals are locat-
display of actual welding voltage and amperage while ed behind the cover panel on the lower connection
welding. (Installation instructions are included with the panel of the DC-655. This control will give the same
kit). control as the output control on the machine.
K1484-1 Dual Feeder Kit - This kit replaces the 14- The K857 has a 6-pin MS-style connector. The K857
Pin MS-receptacle panel on the lower case front of the requires a K864 adapter cable which connects to the
DC-655. It provides two 14-Pin MS-receptacles and a 14-pin connector on the DC-655.
built in transfer circuit for connecting and operating
two like-polarity wire feeders. European DC-655 mod- REMOTE CONTROL ADAPTER CABLE (K864)
els can only use 42V feeders with this kit. (Installation
instructions are included with the kit). STRAIGHT PLUG (14 PIN) CABLE RECEPTACLE (6 SOCKET)
TO POWER SOURCE
TO: K857 REMOTE CONTROL
K1485-1 Cable Hanger Bracket - Mounts over stan-
dard lift bale of the DC-655 and provides a cable
hanger on both sides of the power source, each side
CABLE RECEPTACLE (14 SOCKET)
capable of holding up to 100 ft. of weld cable. TO: LN-7 WIRE FEEDERS
(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 A “V” cable 12” (.30m) long to connect a K857 Remote
front of the DC-655. Filter is designed to trap 80% of Control (6 pin connector) with a wire-feeder (14-pin
entering particles which are 5 microns, or larger, in connector) and the machine (14-pin connector). If a
size. (Installation instructions are included with the kit). remote control is used alone the wire-feeder connec-
Cannot be used with K1528-1 Dual process switch. tion is then not used.
NOTE: A dirty air filter may cause the thermal protec- K1528-1 Dual Process Switch - (Cannot be used with
tion of the DC-655 to prematurely activate. Remove K1486-1 Air Filter Kit) The Dual-Process Switch
and blow out, or wash and dry, the filter every two mounts easily to the front of the machine and is
months, or less if in extremely dirty conditions. designed to provide a selection between left and right
Replace if necessary. side output terminals. Each pair of output terminals
can be switched to either the DC-655, high or low
Undercarriage (K817P, K842) - The DC-655 is inductance terminals as desired. Wire feed unit cables
designed for use with the Lincoln K817P or K842 and air carbon arc cables can be connected to either
Undercarriage. Complete installation instructions are or both sides of the box and with proper connection
included with each undercarriage. When any of the can provide polarity change with just a switch change.
undercarriages are installed, the DC-655 lift bail is no Selecting one side only energizes those output studs
longer functional. Do not attempt to lift the machine and opens the other side. Installation instructions are
with the undercarriage attached. The undercarriage is included with the switch.)
designed for moving the machine by hand only.
Mechanized towing can lead to injury and /or damage K1611-1 Paralleling Kit - Provides interconnection of
to the DC-655. two DC-655 machines in parallel for doubling the cur-
rent 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 func-
tion normally. (Installation instructions are included
with the switch.)
IDEALARC DC-655

C-3 C-3
ACCESSORIES
The DC-655 can be used to power any of AUTOMATIC WIRE FEEDERS

the following Lincoln Wire feeders:
CONNECTING THE NA-3 OR LT-7 TO THE
SEMI-AUTOMATIC WIRE FEEDERS IDEALARC DC-655 (TERMINAL STRIP)
• DH-10 • LN-9* 1. Set Idealarc DC-655 POWER toggle switch to the

OFF (0) position.
• LN-10 • LN-9 GMA*
2. Disconnect main AC input power to the Idealarc
• LN-7 GMA* • LN-23P DC-655.
• LN-742 • LN-25 3. Connect the wire feeder control cable leads to the
• LN-7* • LN-8* Idealarc DC-655 terminal strip as shown in Figure
C.1.
4. Connect the wire feeder control cable ground lead
AUTOMATIC WIRE FEEDERS* to the frame terminal marked .
• NA-3 • NA-5R NOTE: The Idealarc DC-655 must be properly

• NA-5 • LT-7 Tractor grounded.
* European DC-655 models only provide 115VAC for these feeders at the ter-
minal strip (TS2)
FIGURE C.1 – NA-3 OR LT-7 WIRE FEEDER
CONNECTION TO THE IDEALARC DC-655
CONNECTION OF LINCOLN ELECTRIC 14-PIN
RECEPTACLE
CONTROL CABLE
AUTOMATIC OR SEMIAUTOMATIC WIRE POWER SOURCE
FOR CONTROL CABLE

WITH 14 PIN MS-TYPE
FEEDERS PLUG CONNECTOR
21 TO AUTOMATIC
CONTROL BOX OR
WARNING CONTROL CABLE FOR CONTROL CABLE
WITH TERMINAL STRIP
LEAD CONNECTORS

+21 - 21 41 4 2 31 32 75 76 77
• Only qualified personnel should per- 77
form this installation. 76

75
32
31
2
• Turn the input power OFF at the dis- 4
GND
connect switch or fuse box before working on this NEGATIVE POSITIVE
equipment. 21
• Do not touch electrically hot parts. ELECTRODE CABLE

TO AUTOMATIC
EQUIPMENT
Auxiliary power for wire feeder operation is available at TO WORK
both a 14-pin MS receptacle and at terminal strips

REMOTE VOLTAGE SENSING LEAD
with screw-type connections located on the front of

the machine. Refer to the Installation section for
5. Extend wire feeder control cable lead #21 so it can
pinouts and lead designations. The two circuits are
be connected directly to the work piece.
isolated, and each is protected by a circuit breaker.
a. Make a bolted connection using AWG #14 or
The following descriptions show how to connect the
larger insulated wire. Tape the bolted connec-
wire feeders using either the 14-pin MS receptacle or
tion with insulating tape.
the 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.
IDEALARC DC-655

C-4 C-4
ACCESSORIES
NOTE: The connection diagram shown in Figure C.1 FIGURE C.2 – NA-5/-5R WIRE FEEDER
shows the electrode connected for positive CONNECTION TO THE IDEALARC DC-655
polarity. To change polarity:
14-PIN
a. Set the Idealarc DC-655 POWER toggle RECEPTACLE
POWER SOURCE CONTROL CABLE
switch to the OFF (0) position. FOR CONTROL CABLE
WITH 14 PIN MS-TYPE
b. Move the electrode cable to the negative (-) 21

PLUG CONNECTOR
OR
TO NA-5/-5R
output terminal. (High inductance or low INPUT CABLE PLUG
FOR CONTROL CABLE

inductance, as needed). CONTROL CABLE
WITH TERMINAL STRIP
LEAD CONNECTORS
c. Move the work cable to the positive (+) output

terminal. +21 - 21 41 4 2 31 32 75 76 77
d. If connecting lead #21 to the terminal strip, C

B
connect it to the +21 terminal (to match work A

32
31
polarity). If work polarity changes back to 2

4
GND
negative, lead #21 must be connected to the
NEGATIVE POSITIVE
-21 terminal. 21
e. Reverse the leads on the back of the ammeter

BOLT TO CABLES FROM NA-5/-5R
and voltmeter in the automatic control box. WIRE CONTACT AS'BLY
f. If the automatic controls include a variable

voltage board, connect its jumper lead to pin TO WORK
“L”. This will permit the inch down button to REMOTE VOLTAGE SENSING LEAD
operate. However, the jumper also disables

the cold starting/autostop feature of the auto-
matic controls. Only hot starting will be avail- 4. Connect the wire feeder control cable ground lead
able. to the frame terminal marked .
6. Set the DC-655 OUTPUT CONTROL switch to the NOTE: The Idealarc DC-655 must be properly
“Remote” position and the OUTPUT TERMINALS grounded.
switch in the “Remote” position.
CONNECTING THE NA-5/-5R TO THE be connected directly to the work piece.
IDEALARC DC-655 (TERMINAL STRIP)

1. Set the Idealarc DC-655 POWER toggle switch to larger insulated wire. Tape the bolted connec-
the OFF (0) position. tion with insulating tape.
2. Disconnect main AC input power to the Idealarc b. An S-16586-X remote voltage sensing work
DC-655. lead is available for this purpose.
3. Connect the wire feeder control cable leads to the c. Keep the #21 lead electrically separate from
Idealarc DC-655 terminal strip as shown in Figure the work cable circuit and connection.
C.2. d. Tape the #21 lead to work cable for ease of
use.
IDEALARC DC-655

C-5 C-5
ACCESSORIES
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
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).
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.
IDEALARC DC-655

C-6 C-6
ACCESSORIES
FIGURE C.3
IDEALARC DC-655/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM
POWER SOURCE
LN-7 TO INPUT
CABLE PLUG
21
LN-7 CONTROL
CABLE
+21 - 21 41 4 2 31 32 75 76 77
32
31
2
4
GND
NEGATIVE POSITIVE
21
ELECTRODE CABLE
TO WIRE FEED UNIT
} TO WORK
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) posi- 4. Connect control cable between the DC-655 and
tion. the LN-7. See Figure C.3.
2. Disconnect main AC input power to the Idealarc 5. Set the MODE switch to a CV (constant voltage)
DC-655. position at the welder.
3. Connect the electrode cable from the control 6. Adjust wire feed speed at the LN-7 and set the
cable to the “+” terminal of the welder and to the welding voltage with the output CONTROL.
LN-7 wire feeder. Connect the work cable to the
NOTE: If optional remote control is used, place the
“-” terminal of the welder (High inductance or low
OUTPUT CONTROL and the OUTPUT TERMI-
inductance as needed). Reverse this hookup for
NALS switch in the “Remote” position.
negative polarity.
NOTE: Welding cable must be sized for the current
and duty cycle of the application.
IDEALARC DC-655

C-7 C-7
ACCESSORIES
CONNECTING THE LN-7 TO THE NOTE: If the work cable length is less than 25 feet
IDEALARC DC-655 (TERMINAL STRIP) and the connections to the work piece are
secure, then wire feeder control cable lead
1. Set the Idealarc DC-655 POWER toggle switch to
#21 can be connected directly to the DC-
the OFF (0) position.
655 terminal strip.
b. An S-16586-X remote voltage sensing work
DC 655.
3. Connect the wire feeder control cable leads to the
Idealarc DC-655 terminal strip as shown in Figure
C.3.
use.
to the frame terminal marked .
NOTE: The connection diagram shown in Figure
NOTE: The Idealarc DC-655 must be properly
C.3 shows the electrode connected for
grounded.
positive polarity. To change polarity:
5. PERFORM THIS STEP ONLY IF THE LN-7 IS

a. Set the IDEALARC DC-655 POWER toggle
EQUIPPED WITH A METER KIT.
Extend wire feeder control cable lead #21 so it can
b. Move the electrode cable to the negative (-)
output terminal (High inductance or low induc-
a. Make a bolted connection using AWG #14 or tance as needed).
tion with insulating tape.
terminal.
d. Connect control cable lead #21 to “+21” on
the terminal strip.
IDEALARC DC-655

C-8 C-8
ACCESSORIES
FIGURE C.4 - LN-8 OR LN-9 WIRE FEEDER CONNECTION TO THE IDEALARC DC-655
POWER SOURCE
21
TO LN-8 OR LN-9
INPUT CABLE PLUG
CONTROL CABLE
+21 - 21 41 4 2 31 32 75 76 77
} N.E.
C
B
A
32
31
2
4
GND
NEGATIVE POSITIVE
21
ELECTRODE CABLE
TO WIRE FEED UNIT
} TO WORK
CONNECTING THE LN-8 OR LN-9 TO THE 6. Connect LN-9 wire feeder control jumpers on
IDEALARC DC-655 (TERMINAL STRIP) Voltage Control board. See LN-9 Operator’s
Manual.
1. Set the Idealarc DC-655 POWER toggle switch to
the OFF (0) position. NOTE: The connection diagram shown in Figure C.4
shows the electrode connected for positive

DC-655.
a. Set the Idealarc DC-655 POWER toggle
3. Connect the wire feeder control cable leads to the
Idealarc DC-655 terminal strip as shown in Figure
C.4. b. Move the electrode cable to the negative (-)
output terminal (High inductance or low
inductance as needed).
to the frame terminal marked .
terminal.
d. Connect control cable lead #21 to “+21” on
the terminal strip.
tion with insulating tape. 7. Set the OUTPUT CONTROL switch to the
“Remote” position and the OUTPUT TERMINALS
b. An S-16586- X remote voltage sensing work
switch to the “Remote” position.

use.
IDEALARC DC-655

C-9 C-9
ACCESSORIES
CONNECTING THE LN-8 OR LN-9 TO THE CONNECTING THE DH-10 TO THE

IDEALARC DC-655 (14-PIN MS RECEPTACLE) IDEALARC DC-655 (14-PIN MS RECEPTACLE)
1. Set the POWER toggle switch to the OFF (0) posi- 1. Set the POWER toggle switch to the OFF (0) posi-
tion. tion.
2. Disconnect main AC input power to the Idealarc 2. Disconnect main AC input power to the Idealarc
DC-655. DC-655.
3. Connect the electrode cable from the LN-8 or 3. Connect the electrode cable from the DH-10 to the
LN-9 to the “+” terminal of the welder. Connect “+” terminal of the welder. Connect the work
the work cable to the “-” terminal of the welder cable to the “-” terminal of the welder (High induc-
(High inductance or low inductance as needed). tance or low inductance as needed). Reverse this
Reverse this hookup for negative polarity. See hookup for negative polarity.
Figure C.4.
NOTE: Welding cable must be sized for the current
NOTE: Welding cable must be sized for the current and duty cycle of the application.
and duty cycle of the application.
4. Connect the DH-10 input cable between the 14-
4. Connect the control cable between the 14-pin MS pin MS receptacle on the DC-655 and the input
receptacle on the DC-655 and the input cable plug cable plug on the DH-10. See Figure C.5.
on the LN-8 or LN-9. See Figure C.4.
5. Set the MODE switch to a CV (constant voltage)
5. Set the MODE switch to a CV (constant voltage) position.
position.
6. Adjust wire feed speed at the DH-10 and set the
6. Adjust wire feed speed at the LN-8 or LN-9 and welding voltage with the WIRE FEEDER VOLTAGE
set the welding voltage with the WIRE FEEDER CONTROL.
VOLTAGE CONTROL.
7. Set the DIP switches on the DH-10 for DC-655.
Place the OUTPUT CONTROL switch in the “Remote” See the DH-10 Operator’s Manual.
position and the OUTPUT TERMINALS switch in the
Place the OUTPUT CONTROL switch in the “Remote”
“Remote” position.
position and the OUTPUT TERMINALS switch in the
“Remote” position.
FIGURE C.5 – IDEALARC DC-655 DH-10 CONNECTION

DH-10
LINCOLN CV-655 WIRE
POWER SOURCE FEEDER
N.E.
- +
14 PIN 9 PIN
AMPHENOL AMPHENOL
ELECTRODE CABLE DH-10

INPUT CABLE
TO WORK
ASSEMBLY
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

NOTES
IDEALARC DC-655
Section D-1 Section D-1
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance .........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
General Maintenance..................................................................................................................D-2
General Component Locations...................................................................................................D-3
IDEALARC DC-655

D-2 D-2
MAINTENANCE
SAFETY PRECAUTIONS
WARNING

• Only qualified personnel should per-
form this maintenance.
• Turn the input power OFF at the disconnect switch
or fuse box before working on this equipment.
• Do not touch electrically hot parts.
GENERAL MAINTENANCE
1. The fan motor has sealed bearings which require

no service.
2. In extremely dusty locations, dirt may restrict the
cooling air causing the welder to run hot with pre-
mature tripping of thermal protection. Blow ou;the
welder with low pressure air at regular intervals to
eliminate excessive dirt and dust build-up on inter-
nal parts.
3. Periodically check the welding cables. Inspect for
any slits or punctures. Also make sure that all
connections are tight.
IDEALARC DC-655

D-3 D-3
MAINTENANCE
FIGURE D.1 - GENERAL COMPONENT LOCATIONS
1. CASE FRONT
2. OUTPUT TERMINALS
3. CASE SIDES
4. CASE TOP
5. RECONNECT PANEL (LOCATION)
6. INPUT CONTACTOR (LOCATION)
7. CONTROL TRANSFORMER (LOCATION)
8. CASE BACK
9. FAN ASSEMBLY
10. CONTROL PANEL
11. PC BOARDS (LOCATION)
12. CHOKE
13. MAIN TRANSFORMER
14. BASE
15. SCR RECTIFIER BRIDGE
4
3
5 6
7
D
C
-6
55 11
9
10
5
- 65
DC
2
1 3
15
12
14
13
IDEALARC DC-655


NOTES
IDEALARC DC-655
Section E-1 Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-

Theory of Operation .............................................................................................................Section E
General Description ....................................................................................................................E-2
Input Line Voltage, Contactor, Reconnect,
Fault Protection, Main and Control Transformers.......................................................................E-2
Control Board, Firing Board, Snubber/Fan
Board and Rectification ..............................................................................................................E-3
Protective Devices and Shutdown Circuits ................................................................................E-4
Thermal Protection ...............................................................................................................E-4
Over Current Protection .......................................................................................................E-4
Peak Current Protection .......................................................................................................E-4
Remote Control Fault Protection..........................................................................................E-4
Shorted Output Rectifier Fault Protection............................................................................E-4
SCR Operation ............................................................................................................................E-5
FIGURE E.1 – DC-655 BLOCK LOGIC DIAGRAM
CONTROL
TRANSFORMER
42VAC
115VAC
CONTROL
BOARD
TRANSFORMER
FAULT PROTECTION
CR2
OUTPUT ARC FORCE
32VAC OUTPUT CONTROL CONTROL
CONTROL SIGNAL
32VAC FIRING
32VAC BOARD
G S
A I
14-pin 115VAC Fan T G
Amphenol Receptacle Motor N Fan
E A Thermal
L Sensor
T SNUBBER
CONTROL
S
E
R T
115VAC
FAN BOARD MODE
M
I
R
I BOARD SWITCH
N P
A
L
GATE SIGNAL
F
42VAC E
E
D
MAIN B
R TRANSFORMER A
C
E K POSITIVE
C TERMINAL
O
N
N SHUNT F
E E
C
E
T
D
CONTACTOR 42VAC 10VAC10VAC LATCHING
RESISTOR B
CR1
A
SCR BRIDGE HIGH
C NEGATIVE
CHOKE K
TERMINAL
TO OPTIONAL
METER BOARD
LOW
IDEALARC DC-655

E-2 E-2
THEORY OF OPERATION
FIGURE E.2 – INPUT LINE VOLTAGE, CONTACTOR, RECONNECT,

FAULT PROTECTION, MAIN AND CONTROL TRANSFORMERS
CONTROL
TRANSFORMER
42VAC
115VAC
CONTROL
BOARD
TRANSFORMER
FAULT PROTECTION
CR2
OUTPUT ARC FORCE
CONTROL SIGNAL
32VAC FIRING
32VAC BOARD
G S
A I
E A Thermal
L Sensor
T SNUBBER
CONTROL
S
E
R T
115VAC
FAN BOARD MODE
M
I
R
I BOARD SWITCH
N P
A
L
GATE SIGNAL
F
42VAC E
E
D
MAIN B
R TRANSFORMER A
C
E K POSITIVE
C TERMINAL
O
N
N SHUNT F
E E
C
E
T
D
RESISTOR B
CR1 A
SCR BRIDGE HIGH
C NEGATIVE
CHOKE K
TERMINAL
TO OPTIONAL
METER BOARD
LOW
GENERAL DESCRIPTION A reconnect panel allows the user to configure the

machine for the desired input voltage. This three-

The DC-655 is a three-phase, SCR controlled DC phase AC input is applied to the primary of the main
power source. It is capable of either constant current transformer. The transformer changes the high volt-
or constant voltage output. It is rated at 650 amps, age, low current input power to a lower voltage, high-
100% duty cycle with outstanding arc characteristics er current output. The finishes or “neutrals” of the
for multiple welding processes. main secondary coils are connected together, and the
six starts of the secondary windings are connected to
the rectifier assembly.
INPUT LINE, CONTACTOR, In addition, the main transformer also has eight isolat-
ed secondary windings. There are three 32 VAC wind-
RECONNECT, FAULT PROTECTION ings, which provide power and “timing” to the firing
AND TRANSFORMERS board. The 115 VAC winding powers the fan motor
and provides the user with up to 20 amps of 115 VAC
The desired three-phase input power is connected to
auxiliary power at the receptacle or 14-pin MS type
the DC-655 through an input contactor located in the
connector. The 42 VAC winding provides up to 10
input box at the rear of the machine. Two phases of
amps at the 14-pin MS type connector. Three other
the input line are also connected to the control trans-

isolated coils are used to power the optional digital
former. The secondary of the control transformer sup-
meter PC board. One winding is rated at 42 VAC, and
plies 115 VAC power to the control board transformer
the other two are each rated at 10 VAC.
and to the input contactor through the fault protection
relay. The control board transformer supplies 42 VAC
to the control board.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
IDEALARC DC-655

E-3 E-3
THEORY OF OPERATION
FIGURE E.3 – CONTROL BOARD, FIRING BOARD, SNUBBER/FAN BOARD AND RECTIFICATION
CONTROL
TRANSFORMER
42VAC
115VAC
CONTROL
BOARD
TRANSFORMER
FAULT PROTECTION
CR2
OUTPUT ARC FORCE
CONTROL SIGNAL
32VAC FIRING
32VAC BOARD
G S
A I
E A Thermal
L Sensor
T SNUBBER
CONTROL
S
E
R T
115VAC
FAN BOARD MODE
M
I
R
I BOARD SWITCH
N P
A
L
GATE SIGNAL
F
42VAC
E
E
D
MAIN B
R TRANSFORMER A
C
E K POSITIVE
C TERMINAL
O
N
N SHUNT F
E E
C
E
T
D
RESISTOR B
CR1 A
SCR BRIDGE HIGH
C NEGATIVE
CHOKE K
TERMINAL
TO OPTIONAL
METER BOARD
LOW
CONTROL BOARD, FIRING BOARD, tion from the shunt and voltage feedback information
from the choke and welding output terminals. This

SNUBBER/FAN, BOARD AND feedback information is processed on the control
RECTIFICATION board. The control compares the commands of the
mode switch, the output control potentiometer (or
The “neutrals” of the welding secondary windings in
remote control device) and the arc force control with
the main transformer are connected together, and the
the feedback information and sends the appropriate
six starts are connected to the six Silicon Controlled
output control signal to the firing board. In the event
Rectifier (SCR) assemblies to form a six-phase output.
of a “fault condition,” the control board activates the
This six-phase AC output from the main transformer
fault relay (CR2). See Protective Devices and Shut
secondary is rectified and controlled through the SCR
Down Circuits.
bridge.
A tapped output choke is connected between the neu-
A portion of the firing board is a three-phase circuit.
tral connection of the main transformer secondaries
Each phase provides two firing pulses, one for each of
and the two negative output terminals. This large
the two SCRs controlled by that phase. When a gate
inductor stores energy, which provides current filtering
firing enable signal is received, the firing circuit sup-
for the welding output of the DC-655. Two negative
plies the proper amount of energy to the gates of the
output terminals are provided. One is connected to
power SCRs. When this gate firing signal is applied at
the tap lead in the choke, thus providing a lower induc-
the correct time, through the snubber/fan board, the
tance. The other utilizes the entire choke for higher

SCR will turn ON. The amount of ON time versus OFF
inductance arc characteristics.
time determines the output of the machine. See SCR
Operation. At this time the latching resistor is brought The snubber/fan board furnishes protection to the
into the machine’s output circuit. The latching resistor SCR bridge from the transient voltages. It also moni-
provides a pre-load for the SCR bridge. tors the thermal sensor and activates the fan motor
when cooling is necessary.
The control board receives current feedback informa-
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
IDEALARC DC-655

E-4 E-4
THEORY OF OPERATION
PROTECTIVE DEVICES AND

SHUTDOWN CIRCUITS
THERMAL PROTECTION PEAK CURRENT PROTECTION
Two thermostats protect the DC-655 from excessive If the peak current exceeds 2500 amps, the welding
operating temperatures. Excessive operating temper- output will be disabled and the control board LED 4
atures may be caused by a lack of cooling air or oper- shutdown light will turn on. The peak current shut-
ating the machine beyond the duty cycle and output down circuit can be reset by turning the DC-655 input
rating. If excessive operating temperatures should switch off.
occur, a thermostat will open. This condition will be
indicated by the illumination of the yellow REMOTE CONTROL FAULT PROTECTION
Thermostatic Protection Light located on the case The remote control leads from the 14-pin receptacles
front. The fan should continue to run, but the welding or terminal strip are protected against voltage faults to
output will be disabled until the machine cools and the the electrode circuit or auxiliary voltage supplies. If a
Thermostatic Protection Light is out. fault should occur, the welding output will be disabled
and the control board LED 4 shutdown light will turn

OVER CURRENT PROTECTION on. This fault protection shutdown circuit can be reset
If the average output current exceeds 900 amps for by opening the feeder gun trigger or switching the DC-
five to six seconds, the welding output will be dis- 655 output terminal switch to the OFF position. On
abled. The control board LED 4 shutdown light will later production machines, LED 3 input shutdown light
turn on. The higher the current, the quicker the DC- will turn on and the input contactor will open.
655 will shut down. If the average current exceeds
1200 amps, the shutdown will occur in 0.3 seconds. SHORTED OUTPUT RECTIFIER FAULT
The over current shutdown circuit can be reset by PROTECTION
opening the feeder gun trigger or switching the DC-
If a short should occur across one of the SCRs, a
655 output terminal switch to the OFF position.
potentially hazardous AC voltage could appear across
the welding output terminals. If such a fault should
occur, the input contactor will open and remove the
input power to the primary of the main transformer.
Also, the control board LED 3 input shutdown light will
turn on. Welding and auxiliary output will not be pre-
sent, but the pilot light and control board power will be
present until the power switch is turned off.
IDEALARC DC-655

E-5 E-5
THEORY OF OPERATION
FIGURE E.4 – SCR OPERATION

SCR OPERATION
A silicon controlled rectifier (SCR) is a three-terminal An SCR is fired by a short burst of current into the
device used to control rather large currents to a load. gate. This gate pulse must be more positive than the
An SCR acts very much like a switch. When a gate cathode voltage. Since there is a standard PN junc-
signal is applied to the SCR, it is turned ON and there tion between gate and cathode, the voltage between
is current flow from anode to cathode. In the ON state these terminals must be slightly greater than 0.6V .
the SCR acts like a closed switch. When the SCR is Once the SCR has fired, it is not necessary to contin-
turned OFF, there is no current flow from anode to ue the flow of gate current. As long as current contin-
cathode. Thus the device acts like an open switch. ues to flow from anode to cathode, the SCR will
As the name suggests, the SCR is a rectifier, so it remain on. When the anode to cathode current drops
passes current only during positive half cycles of the below a minimum value, called holding current, the
AC supply. The positive half cycle is the portion of the SCR will shut off. This normally occurs as the AC sup-
sine wave in which the anode of the SCR is more pos- ply voltage passes through zero into the negative por-
itive than the cathode. tion of the sine wave. If the SCR is turned on early in
the positive half cycle, the conduction time is longer,
When an AC supply voltage is applied to the SCR, the
resulting in greater SCR output. If the gate firing
device spends a certain portion of the AC cycle time
occurs later in the cycle, the conduction time is less,
in the ON state and the remainder of the time in the
resulting in lower SCR output.
OFF state. The amount of time spent in the ON state
is controlled by the Gate.
IDEALARC DC-655


NOTES
IDEALARC DC-655
Section F-1 Section F-1
TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION

Troubleshooting & Repair Section .................................................................................Section F
How to Use Troubleshooting Guide ......................................................................................F-2
PC Board Troubleshooting Procedures .................................................................................F-3
Troubleshooting Guide .................................................................................................F-4–F-12
Test Procedures
Internal Trigger Circuit Test ...........................................................................................F-13
Firing Board Test ...........................................................................................................F-17
Main Transformer (T1) Voltage Test...............................................................................F-22
Control Transformer (T2) Voltage Test...........................................................................F-27
Control Board Transformer (T3) Test .............................................................................F-30

Input Contactor Test......................................................................................................F-32
Static SCR Test .............................................................................................................F-35
Active SCR Test.............................................................................................................F-38
Thermal Fan/Snubber Board LED Chart .......................................................................F-41
Control Board LED Chart ..............................................................................................F-42
Oscilloscope Waveforms
Normal Open Circuit Voltage Waveform-Constant Current Mode................................F-43
Normal Open Circuit Voltage Waveform-Constant Voltage MIG Maximum Output .....F-44
Normal Open Circuit Voltage Waveform-Constant Voltage MIG Minimum Output ......F-45
Typical Output Voltage Waveform-Constant Voltage MIG ............................................F-46
Typical SCR Gate Voltage Waveform-Constant Voltage MIG .......................................F-47

Abnormal Open Circuit Voltage Waveform-Constant Voltage MIG ..............................F-48
Replacement Procedures
Input Contactor (CR1) Cleaning/Replacement .............................................................F-49
SCR Rectifier Bridge Removal and Replacement ........................................................F-51
Main Transformer and Choke Removal and Replacement ...........................................F-54
Retest After Repair ..............................................................................................................F-57
IDEALARC DC-655

F-2 F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
This Troubleshooting Guide is provided to help Step 3. PERFORM COMPONENT TESTS. The
you locate and repair possible machine malfunc- last column, labeled “Recommended Course of
tions. Simply follow the three-step procedure Action” lists the most likely components that may
listed below. have failed in your machine. It also specifies the

appropriate test procedure to verify that the sub-
ject component is either good or bad. If there are
Step 1. LOCATE PROBLEM (SYMPTOM). Look a number of possible components, check the
under the column labeled “PROBLEM (SYMP- components in the order listed to eliminate one
TOMS). This column describes possible symp- possibility at a time until you locate the cause of
toms that the machine may exhibit. Find the list- your problem.
ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into three main categories: Output Problems, All of the referenced test procedures referred to in
Function Problems and Welding Problems. the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
Step 2. PERFORM EXTERNAL TESTS. The locate each specific Test Procedure. All of the
second column, labeled “POSSIBLE AREAS OF referred to test points, components, terminal
MISADJUSTMENT(S)”, lists the obvious external strips, etc., can be found on the referenced elec-
possibilities that may contribute to the machine trical wiring diagrams and schematics. Refer to
symptom. Perform these tests/checks in the the Electrical Diagrams Section Table of Contents
order listed. In general, these tests can be con- to locate the appropriate diagram.
ducted without removing the case wrap-around
cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 1-800-833-9353.
IDEALARC DC-655

F-3 F-3
PC BOARD TROUBLESHOOTING PROCEDURES

- Remove the PC board from the static-shielding bag
WARNING and place it directly into the equipment. Don’t set the
ELECTRIC SHOCK PC board on or near paper, plastic or cloth which
can kill. could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield-
• Have an electrician install and ing bag.
service this equipment. Turn the
input power OFF at the fuse box - If the PC board uses protective shorting jumpers,
before working on equipment. Do don’t remove them until installation is complete.
not touch electrically hot parts.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop-
CAUTION er failure analysis.
Sometimes machine failures appear to be due to PC 4. Test the machine to determine if the failure
board failures. These problems can sometimes be symptom has been corrected by the
traced to poor electrical connections. To avoid prob- replacement PC board.
lems when troubleshooting and replacing PC boards,
please use the following procedure: NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component NOTE: Allow the machine to heat up so that all
causing the failure symptom. electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected. 5. Remove the replacement PC board and
substitute it with the original PC board to
3. If the problem persists, replace the suspect PC recreate the original problem.
board using standard practices to avoid static
a. If the original problem does not reappear by
electrical damage and electrical shock. Read
substituting the original board, then the PC
the warning inside the static resistant bag and
board was not the problem. Continue to look
perform the following procedures:
for bad connections in the control wiring
PC board can be damaged by static electricity. harness, junction blocks, and terminal strips.
- Remove your body’s static b. If the original problem is recreated by the

charge before opening the static- substitution of the original board, then the PC
shielding bag. Wear an anti-static board was the problem. Reinstall the
wrist strap. For safety, use a 1 replacement PC board and test the machine.
Meg ohm resistive cord connected 6. Always indicate that this procedure was
to a grounded part of the followed when warranty reports are to be
ATTENTION equipment frame. submitted.
Static-Sensitive - If you don’t have a wrist strap, NOTE: Following this procedure and writing on the
Devices touch an un-painted, grounded, warranty report, “INSTALLED AND SWITCHED PC
Handle only at part of the equipment frame. Keep BOARDS TO VERIFY PROBLEM,” will help avoid
Static-Safe touching the frame to prevent denial of legitimate PC board warranty claims.
Workstations static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must

be either conductive, anti-static or static-dissipative.
IDEALARC DC-655

F-4 F-4
Observe Safety Guidelines TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical dam- 1. Contact the Lincoln Electric
age is evident. Service Dept. 1-800-833-9353.
The machine is dead - the input 1. The power switch (S1) is in the 1. Check the power switch (S1)
contactor does not operate. The ON position. and associated leads and con-
pilot light is not lit. nections. See the Wiring
2. Check for blown or missing

Diagram.
fuses in the input lines.
2. Perform the Control Trans-
3. Check the three-phase input
former Test.
line voltage at the machine.
The input voltage must match
the rating plate and reconnect
panel.
The input contactor operates, but 1. Check the electrode and work 1. Perform the Internal Trigger
no welding output. The 115 VAC cables for loose or faulty con- Circuit Test.
auxiliary supply is present at the nections.
2. Perform the Firing Board Test.
receptacle.
2. If the Thermal Protection Light
3. Perform the Main Transformer
is ON, the machine is overheat-
Test.
ed. Wait for the machine to
cool and remedy the cause of 4. Perform the SCR Output
the overheating problem. See Bridge Test.

the Fan/Snubber Board LED
5. The control board may be
Chart.
faulty. See Control Board LED
3. Make certain either the output Chart.
terminals switch is in the ON
position or the external gun
trigger circuit is functioning
properly.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
IDEALARC DC-655

F-5 F-5

OUTPUT PROBLEMS
The input contactor chatters. 1. Check the three-phase input 1. Check for loose or faulty wiring
line voltage at the machine. between the input power
The input voltage must match switch (SW1), the fault protec-
the rating plate and reconnect tion relay (CR2) and the input
panel configuration. contactor. See the Wiring
Diagram.
2. The fault protection relay (CR2)
may have defective contacts.
Check or replace.
defective. See the Control
Board LED Chart.
4. The input contactor may be
faulty.
The machine is dead - the input 1. Check the three-phase input 1. Check the wiring between the
contactor does not operate. The line voltage at the machine. fault protection relay (CR2) and
pilot light is lit. The input voltage must match the input contactor (CR1).
the rating plate and reconnect
2. The fault protection relay (CR2)
panel configuration.
may have defective contacts.
2. Turn the machine off and then Check or replace.
back on to reset the fault pro-
3. The input contactor may be

tection circuit. See the Control

faulty.
Board LED Chart.
CAUTION
1-800-833-9353.
IDEALARC DC-655

F-6 F-6
TROUBLESHOOTING GUIDE Observe Safety Guidelines

OUTPUT PROBLEMS
The machine has welding output 1. Check the output control switch 1. The output control potentiome-
but no control. (SW3) for proper setting. ter, output control switch (SW3)
or associated wiring may be
2. If a remote control cable is
defective. See the Wiring
used, make certain the cable
Diagram.
and connections are good.
3. Perform the SCR Output
Bridge Test.

faulty. See the Control Board
LED Chart.
The machine does not have maxi- 1. Check the three-phase input 1. The output control potentiome-
mum output. lines at the DC-655. Make cer- ter, output control switch (SW3)
tain the input voltages match or associated wiring may be
the machine’s rating and recon- defective. See the Wiring
nect panel configuration. Diagram.
2. Put the output control switch 2. Perform the Main Transformer
(SW3) in the “Local” control Test.
position. If the problem is
resolved, the remote unit or
wire feeder may be defective. 4. Perform the SCR Bridge Test.

LED Chart.
CAUTION
1-800-833-9353.
IDEALARC DC-655

F-7 F-7


OUTPUT PROBLEMS
The 115 VAC receptacle is not 1. The circuit breaker may be 1. The circuit breaker may be
working. The machine’s welding tripped. Reset if necessary. defective. Check associated
output is normal. wiring. See the Wiring Diagram.
2. Make sure the 115 VAC plug
and “load” is in good working 2. Check for 115 VAC at terminals
condition. #31 and #32 on the terminal
strip. If 115 VAC is present at
the terminal strip, check the
wiring between the terminal

stirp, the circuit breaker and the

115 VAC receptacle. If 115 VAC
is NOT present at the terminal
strip, perform the Main
Transformer Test.
3. The 115 VAC receptacle may
be defective.
When not welding for a period of 1. This may be a normal condition.

time, the machine shuts down. See the Idle Shut Down Timer.
CAUTION
1-800-833-9353.
IDEALARC DC-655

F-8 F-8


FUNCTION PROBLEMS
The output control potentiometer 1. The output control switch (SW3) 1. The output control potentiome-
does not function when the output may be defective. ter or associated wiring may be
control switch (SW3) is in the faulty. See the Wiring Diagram.
“Local” position. The DC-655
operates normally when controlled
remotely.
The remote output control unit 1. The remote control unit or con- 1. The output control switch (SW3)
does not function properly when necting cable may be defective. may be defective. Check or
the output control switch (SW3) is Check or replace. replace. See the Wiring
in the “Remote” position. The DC- Diagram.
655 operates normally when con-
2. Check the remote control leads
trolled locally from the machine’s
#75, #76 and #77 at plug P15,
output control potentiometer.
the terminal strip and the 14-pin
MS type connector. Check for
loose or faulty connections.
See the Wiring Diagram.
CAUTION
1-800-833-9353.
IDEALARC DC-655

F-9 F-9

FUNCTION PROBLEMS
The Thermal Protection Light is on 1. Check for obstructions that 1. The fan motor could be faulty.
but the fan does not run. could prevent the fan from turn- Check or replace.
ing.
2. The Thermal Fan/Snubber PC
Board may be defective. See
the Thermal Fan/Snubber PC
Board LED Chart.
The fan runs continuously. 1. Note: The fan is thermal con- 1. The Thermal Fan Thermistor
trolled. Under normal condi- may be faulty. See the Wiring
tions, it does not continuously Diagram.
run.
2. The Thermal Fan/Snubber PC
Board may be defective. See
the Thermal Fan/Snubber PC
Board LED Chart.
One or both of the optional digital 1. Check for loose plugs P13 and 1. The digital meter board may not
meters are not lit. P12 at the digital meter PC be receiving voltages from the
board. T1 transformer windings.
Perform the Main Transformer
Test.
2. Check the wiring between Plug
J13 and the associated leads at

the main transformer. See the
Wiring Diagram.
3. The digital meter PC board may
be faulty.
CAUTION
1-800-833-9353.
IDEALARC DC-655

F-10 F-10


FUNCTION PROBLEMS
The optional digital meter is not 1. Make certain plugs P12 and 1. Check feedback leads #222,
working properly and/or the dis- P13 are securely plugged into #210, #201 and #202 for loose
play is erratic. the digital meter PC board. or faulty connections. See the
Also make sure plug P3 is Wiring Diagram.
securely plugged into the con-
2. The optional digital meter PC
trol board.
board may be faulty.
The analog meters are not reading 1. Make sure plug P3 is securely 1. Check feedback leads #222,
correctly. plugged into the control board #210, #201 and #202 for loose
and plug J14 is securely seated or faulty connections. See the
in the plug assembly from the Wiring Diagram.
control board.
2. The meter(s) may be defective.
CAUTION
1-800-833-9353.
IDEALARC DC-655

F-11 F-11


WELDING PROBLEMS
Poor arc characteristics in all 1. Check the three-phase input 1. Check the weld mode switch
processes. line voltage at the machine. (SW2) and associated leads for
The input voltage must match proper operation or loose or
the rating plate and reconnect faulty connections. See the
panel. Wiring Diagram.
2. Check the welding cables for 2. Perform the Firing Board Test.
3. Perform the SCR Bridge Test.
3. Make sure the proper welding

procedures are being used.
Test.
(Wire feed speed, arc voltage
and wire size) 5. The control board may be
4. Make sure the negative welding
LED Chart.
cable is connected to the cor-
rect negative output terminal.
(Low or High inductance)
Poor arc striking with semiauto- 1. Make sure the proper welding 1. Perform the Firing Board Test.
matic or automatic wire feeders. procedures are being used.
(Wire feed speed, arc voltage
and wire size) 3. The control board may be
2. Check the welding cables for
LED Chart.
CAUTION
1-800-833-9353.
IDEALARC DC-655

F-12 F-12
TROUBLESHOOTING GUIDE
Observe Safety Guidelines


WELDING PROBLEMS
The arc is variable or sluggish. 1. Check the three-phase input 1. Check the weld mode switch
line voltage at the machine. (SW2) and associated leads for
The input voltage must match proper operation or loose or
the rating plate and reconnect faulty connections. See the
panel configuration. Wiring Diagram.
2. Make sure the machine’s set- 2. Perform the Firing Board Test.
tings are correct for the welding
process.

3. Check the welding cables for
Test.
Also make sure cables are sized 5. The control board may be
correctly for the welding cur- faulty. See the Control Board
rent. LED Chart.
4. See CV Mode Current
Limiting.
The Arc Force Control (R4) has no 1. The Arc Force Control is active 1. Check the Arc Force Control
effect on the arc. only in the CC Stick mode. potentiometer (R4) for the cor-
rect resistance and proper
2. The effect of the Arc Force
operation. Normal resistance is
Control will be less noticeable
10,000 ohms.
at high welding currents. Weld

at low currents (less than 150 2. Check the continuity of leads

amps) and check the Arc Force #321, #322 and #328 from the
control function. Arc Force Control to the control
board. See the Wiring Diagram.
faulty. Replace.
CAUTION
1-800-833-9353.
IDEALARC DC-655

F-13 F-13
INTERNAL TRIGGER CIRCUIT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained person-
nel. Unauthorized repairs performed on this equipment may result in danger to the tech-
nician or machine operator and will invalidate your factory warranty. For your safety and
to avoid electrical shock, please observe all safety notes and precautions detailed
throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353
(WELD).
TEST DESCRIPTION
This test will help determine if the wiring and connections are good from the 14-pin
receptacle and terminal strip through the P15 and P16 connectors and thermostats to the
firing board. The technician will also be able to determine if the 42 VAC trigger supply
voltage is present.
MATERIALS NEEDED
Ohmmeter (Multimeter)
DC-655 Wiring Diagram
Simplified Trigger Diagram
IDEALARC DC-655

F-14 F-14
INTERNAL TRIGGER CIRCUIT TEST (continued)

FIGURE F.1 – FIRING BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS
LED7 LED8 LED9

J5
8 16
7 15
6 14
5 13
4 12
LED1 LED2
3 11
G2699-[ ] 2 10
1 9
J6
LED10
LED3 LED4 J7
LED6 J4
LED5
FIRING BOARD
2. If LED 10 does not light when the trigger cir-

WARNING cuit is activated, proceed with the following
voltage and continuity checks.

ELECTRIC SHOCK can kill. 3. Check the 10 Amp circuit breaker. It is the
• Do not touch electrically hot one closest to the 115V duplex receptacle.
parts. Reset if tripped.
TEST PROCEDURE
1. With the correct input power applied to the
DC-655 and the trigger circuit activated,
LED 10 on the firing board should be lit.
See Figure F.1. If LED 10 lights when the
trigger is activated, the wiring and circuitry
to the firing board is good. Perform the

Firing Board Test and see the Control
Board LED Chart. See the Simplified
Trigger Diagram.
NOTE: LED 10 should not be lit if the trigger
circuit is not activated.
IDEALARC DC-655

F-15 F-15
FIGURE F.2 – TERMINAL STRIP AND 14-PIN RECEPTACLE
K=42
A=32 J=31
B=GND I=41
L
N
C=2
H=21
G=75
D=4
E=77 F=76
POSITIVE M
LOW INDUCTANCE HIGH INDUCTANCE
OUTPUT NEGATIVE OUTPUT
TERMINAL NEGATIVE OUTPUT
TERMINAL STRIP TERMINAL TERMINAL
COVER PANEL
+21 -21 41 4 2 31 32 75 76 77
TERMINAL STRIP
4. Check for the presence of 42 VAC at the ter- 8. Check continuity (zero ohms) from pin “D”
minal strip ( #2 to #41). See the Simplified (lead #4) at the 14-pin receptacle to the out-
Trigger Diagram. put terminal switch and also to plug J5-pin
9 at the firing board. See the Simplified
5. If 42 VAC is not present at the terminal strip,
Trigger Diagram and Figures F.1 and F.2. If
check the circuit breaker and leads #42A
a resistance of any value is indicated, check
and #41 at the P15 connector. See the
the associated wires and plugs.
Simplified Trigger Diagram. Also perform
the Main Transformer Test.
6. Remove the main input supply power to the
DC-655 machine.
7. Check continuity (zero ohms) from lead
#42A ( plug P15 pin-13) to lead #2 at the 14-
pin receptacle pin “C”. Also check continu-

ity to the output terminal switch. See the
Simplified Trigger Diagram. If a resistance
of any value is indicated, check the associ-
ated wires and plugs.
IDEALARC DC-655

F-16 F-16
9. Check continuity (zero ohms) from lead #41

(plug P15 pin-10) to plug J5-pin 1 at the fir-
ing board. See the Simplified Trigger
Diagram and Figure F.1. If a resistance of
any value is indicated, check the associat-
ed wires, plugs and thermostats.
FIGURE F.3 – SIMPLIFIED TRIGGER DIAGRAM
10AMP
CIRCUIT
BREAKER TO #42 AT MAIN
TRANSFORMER
42A FIRING BOARD
TERMINAL
P16 STRIP P15
11J5 #309
14-PIN 13
RECEPTACLE TO
CONTROL
OUTPUT
C 2 5 2 5 #2 TERMINAL LED10
BOARD
SWITCH
10J5 #310
D 4 6 4 9 #4 #4 9J5 LATCHING
RESISTOR
41 11 #41 ENABLE
10
#273 #41 1J5 FIRING
N.C. N.C.
SECONDARY CHOKE LEAD CIRCUIT
THERMOSTAT THERMOSTAT ENABLE
TO #41 AT MAIN
TRANSFORMER
IDEALARC DC-655

F-17 F-17
FIRING BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained person-
nel. Unauthorized repairs performed on this equipment may result in danger to the tech-
nician or machine operator and will invalidate your factory warranty. For your safety and
to avoid electrical shock, please observe all safety notes and precautions detailed
throughout this manual.
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353
(WELD).
TEST DESCRIPTION
This test will help determine whether or not the firing board is receiving the correct volt-
ages and signals. The LEDs (Light Emitting Diodes) will help determine if the firing board
is generating gate signals for the main SCRs.
MATERIALS NEEDED
Volt/ohmmeter (Multimeter)
DC-655 wiring diagram and firing board schematic drawing
IDEALARC DC-655

F-18 F-18
FIRING BOARD TEST (continued)

FIGURE F.4 – FIRING BOARD TRIGGER CIRCUIT TEST POINTS AND LEDs
LED7 LED8 LED9

J5
(205) 8 16 (204)
(206) 7 15 (203)
(207) 6 14
(208) 5 13 (231)
4 12 (215)
LED1 LED2 3 11
G2699-[ ] 2 10
1 9
J6
LED10
LED3 LED4 J7
LED6 J4
LED5
FIRING BOARD
TEST PROCEDURE
WARNING
1. Disconnect the AC input power to the DC-
655 machine.
2. Locate the firing board on the left side of
the control box. • Do not touch electrically hot
parts.
3. Perform a visual inspection on the firing
board to see if there are any loose or faulty
connections or physical damage.
4. Connect the correct AC input power to the 5. Turn the power switch (SW1) to the ON
DC-655. position.
6. LEDs 7, 8 and 9 should be lit and equally
bright. See Figure F.4 to locate the LEDs.
Use Table F.1 to check operation of LEDs 7,
8, and 9. The three LEDs should be of
equal intensity.
IDEALARC DC-655

F-19 F-19
FIRING BOARD TEST (continued)
TABLE F.1 - LED 7, 8, 9 AND 10
IF THEN
LED 7 is ON 32 VAC power is being supplied to the

firing board from leads #203 and
#204 connected to the phase angle
winding in the Main Transformer.
Normal is 32 VAC.
LED 7 is not lit or is dimmer than The proper AC voltage may not be
the other LEDs reaching the firing board. Check for
loose or faulty connections. Perform

LED 8 is ON 32 VAC power is being supplied to the
firing board from leads #205 and #206
connected to the phase angle winding in
the Main Transformer.
LED 8 is not lit or is dimmer than The proper AC power may not be
LED 9 is ON 32 VAC power is being supplied to
the firing board from leads #207 and
#208 connected to the phase angle
winding in the Main Transformer.
LED 9 is not lit or is dimmer than The proper AC power may not be

LED 10 is ON This indicates the trigger circuit is
activated at the 14-pin receptacle or
the terminal strip or that the Output
Terminal Switch (SW5) is closed.
IDEALARC DC-655

F-20 F-20
FIGURE F.5 – 14-PIN RECEPTACLE
K=42
A=32 J=31
B=GND I=41
L N
C=2
H=21
D=4 G=75
E=77 F=76
M
7. Connect a jumper wire from pin C (lead #2) 11. Rotate the Output Control Potentiometer
to pin D (lead #4) at the 14-pin receptacle. (R1). As the pot is turned clockwise, LEDs
See Figure F.5. (Or put the Output Terminal 1 through 6 should get brighter. As the pot
Switch in the ON position.) This should ini- is turned counter-clockwise, the LEDs
tiate machine output at the welding termi- should get dimmer.
nals. LED 10 on the firing board should
If the LEDs glow and change in brightness
now be on. See Table F.1. If LED 10 does
equally as the pot is turned, and the prob-
not glow when leads #2 and #4 are con-
lem continues, the SCR bridge may be
nected together, perform the Internal
faulty. Perform the SCR Output Bridge
Trigger Test. The firing board may be
Test.
faulty.
If one or two lights stay bright or dim and
8. Locate LEDs 1 to 6 on the firing board. See
the others change, this could indicate an
Figure F.4. Each LED should glow with
open or shorted gate lead or faulty snubber
equal brightness.
board. Perform the SCR Output Bridge
NOTE: LEDs 1 through 6 indicate that the Test. If the Output Bridge and associated
SCR gate firing signals are being generated gate leads are OK, the firing board may be
by the firing board. faulty.
9. Set the Output Control Switch (SW3) in the If all of LEDs 1 through 6 do not glow or do
“Output Control at DC-655” (local) position. not change in brightness equally as the
output control is rotated, go to step 12.
10. Set the Mode Switch (SW2) in a constant
voltage (CV) position.
IDEALARC DC-655

F-21 F-21
12. Test for 9.5 VDC to 11.0 VDC between 13. Test for approximately 5.5 VDC between
leads #231 and #215 on the firing board. leads #231 and #215 on the firing board.
See Figure F.4.
Make sure the Mode Switch (SW2) is in a
constant voltage (CV) position. Put the Mode Switch (SW2) in the constant
current (CC) position.
Locate plug J5 on the firing board. Locate
leads #231 (pin-13) and #215 (pin-12). See Rotate the Output Control (R1) clockwise
Figure F.4. and counter-clockwise. The DC voltage
between leads #231 and #215 should be
Connect a jumper wire from pin C (lead #2)
constant at approximately 5.5 VDC. This
to pin D (lead #4) at the 14-pin receptacle.
voltage should not vary when the output
(Or put the Output Terminal Switch in the
control is turned.
ON position.) This should initiate machine
output at the welding terminals.
Rotate the Output Control (R1) clockwise
and counter-clockwise. The DC voltage
between leads #231 and #215 should vary

from 9.5 VDC to 11.0 VDC as the control is
turned from minimum to maximum. If the
voltage varies and LEDs 1 through 6 do
NOT vary in brightness, the firing board
may be faulty.
If the voltage does NOT vary, the control
board, control potentiometer or associated
leads may be faulty. See the Wiring
Diagram.
IDEALARC DC-655

F-22 F-22
MAIN TRANSFORMER (T1) VOLTAGE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct voltages are being applied to the primary windings of
the main transformer. The secondary windings, the auxiliary windings and the phase angle
windings will also be checked.
MATERIALS NEEDED
IDEALARC DC-655

F-23 F-23
MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)
FIGURE F.6 – INPUT CONTACTOR AND PRIMARY LEADS

TEST PROCEDURE
1. Disconnect the main input power from the 6. Make sure the input contactor (CR1) ener-
DC-655. gizes.
2. Inspect the input contactor, reconnect 7. Test with an AC voltmeter for the proper
panel and primary leads to the main trans- main AC input voltages applied to the line
former for loose or faulty connections. See side of the input contactor (CR1). See the
Figure F.6. Remove the case sides. Wiring Diagram. If the correct voltages are
not present at the line side of the input
3. Confirm that the reconnect panel is config-
contactor, check the input fuses and leads.
ured correctly for the three-phase AC input
power supplied to the DC-655. See the a. L1 to L2
connection diagram located on the inside
b. L2 to L3
of the input box assembly.

c. L1 to L3
4. Connect the correct AC three-phase input
power to the DC-655 machine. 8. Test with an AC voltmeter for the proper
AC input voltages at the output side of the
WARNING input contactor (CR1). See the Wiring
Diagram. If the correct voltages are not
present, perform the Input Contactor
ELECTRIC SHOCK can kill. Test.
• Do not touch electrically hot a. T1 to T2
parts.
b. T2 to T3
c. T1 to T3
5. Turn the power switch (SW1) to the ON

position.
IDEALARC DC-655

F-24 F-24

FIGURE F.7 - MAIN TRANSFORMER SECONDARY LEADS TO
COMMON BUS VOLTAGE CHECK
COMMON
BUS
CHOKE
SECONDARY MAIN
LEADS (6) TRANSFORMER
9. Test with an AC voltmeter for approximately NOTE: The secondary voltages will vary if the
55 VAC from each of the six main trans- input line voltages vary. If any one or more of the
former secondary leads to the common bus voltage checks are incorrect, check for loose or
connected to the output choke. See Figure faulty connections. See the Wiring Diagram. If
F.7. the leads and connections are OK, the main
transformer may be faulty.
IDEALARC DC-655

F-25 F-25

FIGURE F.8 - TERMINAL STRIP
POSITIVE LOW INDUCTANCE HIGH INDUCTANCE

OUTPUT NEGATIVE OUTPUT NEGATIVE OUTPUT
TERMINAL TERMINAL STRIP TERMINAL TERMINAL
COVER PANEL
+21 -21 41 4 2 31 32 75 76 77
TERMINAL STRIP
10. Test for 115 VAC between leads #31 and 12. Test for 42 VAC between leads #41 and #2
#32 on the terminal strip. The terminal strip on the terminal strip. The terminal strip can
can be accessed by removing the small be accessed by removing the small panel
panel at the lower portion of the case front. at the lower portion of the case front. See
See Figure F.8. 115 VAC AC should also be Figure F.8. If the correct voltage is not pre-
present at the 115 VAC receptacle. If the sent, make sure the 10 amp circuit breaker
correct voltage is not present, make sure is not tripped or faulty. Also check the
the 20 amp circuit breaker is not tripped or wiring between the main transformer, the
faulty. Also check the wiring between the terminal strip, and the circuit breaker. See
main transformer, the terminal strip, the cir- the Wiring Diagram.
cuit breaker and the receptacle. See the
13. Remove the AC input power to the DC-
Wiring Diagram.
655. Remove the screws from the control
11. If 115 VAC is NOT present and the wiring box cover and carefully lower the cover.
and circuit breaker are good, the main
14. Locate the firing board on the left side of
transformer may be defective.
the control box.
IDEALARC DC-655

F-26 F-26

FIGURE F.9 - FIRING BOARD PLUG J5 PINS
LED7 LED8 LED9

J5
(205) 8 16 (204)
(206) 7 15 (203)
(207) 6 14
(208) 5 13 (231)
4 12 (215)
LED1 LED2 3 11
G2699-[ ] 2 10
1 9
J6
LED10
LED3 LED4 J7
LED6 J4
LED5
FIRING BOARD
15. Locate plug J5 on the firing board. See 17. Locate plug J13 on the optional digital
Figure F.9. meter board. If a digital meter board is not
in place, plug J13 will not be used but will
be present in the harness. Check the fol-

WARNING lowing voltages at the appropriate leads
and pin locations.
10 VAC Plug J13 pin-1 (lead #331) to pin-2
• Do not touch electrically hot (lead #332)
parts.
(lead #334)
(lead #336)
16. Turn on the DC-655 and check for approx- 18. If the correct primary voltages are applied
imately 32 VAC at the following leads and to the main transformer and any of the sec-
pins at plug J5. These are the phase angle ondary voltages are missing or not correct,
winding voltages. See Fig. F.9. the transformer may be faulty.
NOTE: Always check the wiring between
Plug J5 pin-15 (lead #203) to pin-16 (lead

#204) the transformer windings and the test

points before replacing the transformer.
#206)
#208)
IDEALARC DC-655

F-27 F-27
CONTROL TRANSFORMER (T2) TEST
WARNING
al.
TEST DESCRIPTION
This procedure will determine if the correct voltage is being applied to the primary of the con-
trol transformer and also if the correct voltage is being induced upon the secondary winding.
MATERIALS NEEDED
IDEALARC DC-655

F-28 F-28
CONTROL TRANSFORMER (T2) TEST (continued)

FIGURE F.10 – CONTROL TRANSFORMER
211
TEST PROCEDURE
1. Disconnect the main AC input voltage to the 4. Locate the control transformer primary leads
DC-655. (H1, H2, H3, etc.). See the Wiring Diagram.
2. Remove the case top and sides. NOTE: Unused leads should be insulated and
taped. Inspect for broken or incorrect connec-
3. Locate the control transformer (T2) on the
tions.
left side of the input box (facing the back of
the machine). See Figure F.10.
IDEALARC DC-655

F-29 F-29
CONTROL TRANSFORMER (T2) TEST (continued)
5. Locate the control transformer secondary 7. If approximately 115 VAC is present at leads
leads. See Figure F.10. Lead X1 is con- X1 to X2, the control transformer is function-
nected to the coil terminal on the CR1 input ing properly.
contactor. Lead X2 is spliced into lead
8. If approximately 115 VAC is NOT present at
#211, which is then connected to the input
leads X1 to X2, make certain the correct
power switch (SW1).
input voltage is being applied to the primary
winding of the control transformer and that
WARNING the correct primary leads (H1, H2, H3, etc.)
are being used. See the connection infor-
HIGH VOLTAGE is present at mation diagram on the input access door.
the input leads. 9. If the correct voltage is being applied to the
primary of the control transformer and the
secondary voltage is incorrect or not pre-

sent, the control transformer may be defec-
6. Apply the correct three-phase input power tive.
to the DC-655 and check for 115 VAC at
leads X1 to X2.
NOTE: The DC-655 does not have to be ON
to perform this test. If the main AC input
supply voltage varies, the control trans-
former secondary voltage will vary by the
same percentage.
IDEALARC DC-655

F-30 F-30
CONTROL BOARD TRANSFORMER (T3) TEST
WARNING
al.
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary winding of the
control board transformer (T3) and also if the correct voltage is being induced upon the sec-
ondary winding.
MATERIALS NEEDED
IDEALARC DC-655

F-31 F-31
CONTROL BOARD TRANSFORMER (T3) TEST (continued)
FIGURE F.11 – CONTROL BOARD TRANSFORMER (T3) LEADS
CONTROL BOARD
TRANSFORMER
(T3)
CONTROL
BOX
PRIMARY LEADS SECONDARY

#255 AND #256 LEADS #281
AND #282
TEST PROCEDURE
1. Disconnect the main AC input power to the 5. Apply the correct three-phase input power
DC-655 machine. to the DC-655 and turn the power switch
(SW1) to the ON position.
2. Remove the case top and sides.
6. Carefully check for 42 VAC at the secondary
3. Locate the control board transformer (T3)
leads (#281 to #282). If 42 VAC is present,
mounted on the rear of the control box. See
the control board transformer (T3) is good. If
Figure F.11.
42 VAC is missing or low, proceed to the
4. Locate the transformer (T3) primary leads next step.
(#255 and $256). See Figure F.11 and the
7. Carefully check for 115 VAC at the primary
Wiring Diagram. Also locate the secondary
leads (#255 and #256). If the 115 VAC is
leads (#281 and #282).
present but the secondary voltage (42 VAC)
is missing or low, the T3 transformer may be
WARNING faulty. Replace.
8. If the 115 VAC is NOT present at the prima-
ELECTRIC SHOCK can kill. ry leads, check the associated switch (SW1)
• Do not touch electrically hot parts. and wiring. See the Wiring Diagram.
9. Perform the Control Transformer (T2) Test.
IDEALARC DC-655

F-32 F-32
INPUT CONTACTOR TEST
WARNING
al.
TEST DESCRIPTION
This test will help determine if the input contactor is receiving the correct coil voltage and if
the contacts are functioning correctly.
MATERIALS NEEDED
3/8” Nut driver
External 120 VAC supply
IDEALARC DC-655

F-33 F-33
INPUT CONTACTOR TEST (continued)
FIGURE F.12 – INPUT CONTACTOR CONNECTIONS
X1, #256
#255A
TEST PROCEDURE
1. Disconnect the main input supply power to 5. Apply the correct three-phase input power
the machine. to the DC-655 and turn the power switch
(SW1) to the ON position.
2. With the 3/8” nut driver, remove the case top
and input access cover. 6. Check for 120 VAC at the contactor coil
leads.
3. Locate the three leads connected to the
input contactor coil (X1/#256 and #255A). 7. If the 120 VAC is NOT present, with the input
See Figure F.12. power switch (SW1) on, check the switch
and associated circuitry. See the Wiring
4. Connect an AC voltmeter to the leads.
Diagram. Also see the Control Board LED
Chart. Relay CR2 may be faulty. See the
WARNING Wiring Diagram. Perform the Control
Transformer (T2) Test.
ELECTRIC SHOCK can kill. 8. If the 120 VAC IS present and the contactor
• Do not touch electrically hot parts. does NOT activate, the input contactor is
faulty. Replace the input contactor.
IDEALARC DC-655

F-34 F-34
INPUT CONTACTOR TEST (continued)
FIGURE F.13 – INPUT CONTACTOR TEST CONNECTIONS
X1, #256
#256
#255A
#255A
TEST FOR CONTACT CONTINUITY

1. Disconnect the main input supply power to 4. With the contactor activated, check the
the DC-655 machine. continuity across the contacts. (Zero ohms
or very low resistance is normal.) See
2. Locate, label and remove the three leads
Figure F.13. If the resistance is high, the
connected to the input contactor coil
input contactor is faulty. Replace the input
(X1/#256 and #255A). See Figure F.13.
contactor.
5. When the contactor is NOT activated, the
resistance should be infinite or very high

WARNING across the contacts. If the resistance is
low, the input contactor is faulty. Replace
ELECTRIC SHOCK can kill. the input contactor.
• Do not touch electrically hot

parts.
3. Using the external 120 VAC supply, apply

120 VAC to the terminals of the input con-
tactor coil. If the contactor does NOT acti-
vate, the input contactor is faulty.
IDEALARC DC-655

F-35 F-35
STATIC SCR TEST
WARNING
al.
TEST DESCRIPTION
The test is used to quickly determine if an SCR is shorted or “leaky.” See the Oscilloscope
Waveform Section in this manual for normal and abnormal SCR waveforms.
MATERIALS NEEDED
Analog ohmmeter (Multimeter)
IDEALARC DC-655

F-36 F-36
STATIC SCR TEST (continued)

FIGURE F.14 – THERMAL FAN/SNUBBER BOARD AND FIRING BOARD PLUG LOCATIONS
THERMAL FAN / SNUBBER L10124-[ ]
LED2
LED6
LED5 LED4
LED1
LED3
PLUG J9
LED7 LED8 LED9

J5
LED1 LED2
G2699-[ ]
J6
LED10
LED3 LED4 J7
LED6 J4
LED5
FIRING BOARD
TEST PROCEDURE
1. Disconnect the main AC input power to the 4. Test for high or infinite resistance from the
DC-655 machine. anode to the cathode of SCR1. See Figure
F.15. Use an analog ohmmeter (multimeter).
2. Locate and disconnect plug J9 from the
thermal fan/snubber board and plug J5 from 5. Test for high or infinite resistance from the
the firing board. See Figure F.14. cathode to the anode of SCR1 by reversing
the meter leads. See Figure F.15.
3. Remove the red insulating paint from the
heat sink test points. See Figure F.15. DO
NOT DISASSEMBLE THE HEAT SINKS.
IDEALARC DC-655

F-37 F-37
STATIC SCR TEST (continued)
FIGURE F.15 – HEAT SINK TEST POINTS
ANODE
CATHODE
REMOVE
INSULATING
PAINT
6. If a high or infinite resistance is indicated for 8. Replace plug J9 into the thermal fan/snub-
both steps #4 and #5, SCR1 is not shorted. ber board and plug J5 into the firing board.
7. If a low resistance is indicated in either steps NOTE: To further check the SCRs’ functions use
#4 or #5, there is a shorted SCR in the out- an SCR tester and proceed to the Active SCR
put rectifier bridge. Repeat steps #4 and #5 Test.
for each of the six SCRs. It may be neces-

sary to disconnect the transformer sec-
ondary leads from the rectifier assembly to
isolate the defective SCR(s). See the Wiring
Diagram.
IDEALARC DC-655

F-38 F-38
ACTIVE SCR TEST
WARNING
al.
TEST DESCRIPTION
The Active SCR Test will determine if the device is able to be gated ON and conduct current
from anode to cathode.
MATERIALS NEEDED
An SCR Tester as specified in this procedure
IDEALARC DC-655

F-39 F-39
ACTIVE SCR TEST (continued)

FIGURE F.16 – THERMAL FAN/SNUBBER BOARD AND FIRING BOARD PLUG LOCATIONS
LED2
LED6
LED5 LED4
LED1
LED3
PLUG J20 PLUG J9
LED7 LED8 LED9

J5
LED1 LED2
G2699-[ ]
J6
LED10
LED3 LED4 J7
LED6 J4
LED5
FIRING BOARD
TEST PROCEDURE
1. Disconnect the main AC input power to the 3. Remove the red insulating paint from the
machine. heat sink test points. See Figure F.17. DO
NOT DISASSEMBLE THE HEAT SINKS.
2. Locate and disconnect plug J9 from the

thermal fan/snubber board and plug J5 from
the firing board. See Figure F.16.
IDEALARC DC-655

F-40 F-40
ACTIVE SCR TEST (continued)

FIGURE F.17 – HEAT SINK TEST POINTS
ANODE
CATHODE
SW1 R2
+
V R1
SW2
A R1 = 4 ohms/10 watts
6 VOLT
LANTERN G R2 = 3 ohms/10 watts
SCR
BATTERY UNDER C
TEST
To test SCRs construct the circuit outlined above. Resistor values are plus or minus
ten precent. The voltmeter scale should be low, approximately 0-5 or 0-10 volts DC.
4. Construct the circuit shown in Figure F.17. b. If the voltage is 3-6 volts only when the
One 6-volt lantern battery can be used. Set switch is closed or there is no voltage
the voltmeter scale low, at approximately 0- when the switch is closed, the SCR is
5 volts or 0-10 volts. defective.
a. Test the voltage level of the battery. NOTE: Be sure the battery is functioning
Short leads (A) and (C). Close switch properly. A low battery can affect the
SW-1. Battery voltage should be 4.5 results of the test. Repeat the battery
volts or higher. If lower, replace the bat- test procedure in Step 4 if needed.
tery.
10. Open switch SW-1.
5. Connect the Tester to SCR 1 as shown in
11. Reconnect the Tester leads. See Figure
Figure F.17.
F.17.
a. Connect Tester lead (A) to the anode.
a. Connect Tester lead (A) to the cathode.
b. Connect Tester lead (C) to the cathode.
b. Connect Tester lead (C) to the anode.
c. Connect Tester lead (G) to the gate.
c. Disconnect Test lead (G) from the gate.
6. Close switch SW-1.
12. Close switch SW-1.
NOTE: Switch SW-2 should be open.
13. Read the meter for zero voltage.
7. Read the meter for zero voltage.
a. If the voltage is zero, the SCR is func-
a. If the voltage reading is higher than zero,
tioning.
the SCR is shorted.
b. If the voltage is higher than zero, the
8. Close or keep closed switch SW-1. SCR is shorted.
9. Close switch SW-2 for 2 seconds and 14. Perform the Active Test Procedure outlined
release and read the meter. in Steps 5-13 for SCRs 2-6.
a. If the voltage is 3-6 volts while the
15. Replace all SCR assemblies that do not
switch is closed and after the switch is
pass the above tests.
open, the SCR is functioning.
16. Plug J9 onto the thermal fan/snubber board
and plug J5 into the firing board.
IDEALARC DC-655

F-41 F-41
THERMAL FAN/SNUBBER BOARD LED CHART
LED # LED FUNCTIONS AND INDICATIONS

(Machine is ON)
1 Indicates fan should be running.
2 Indicates welding current is greater than 200 amps.
3 Indicates fan should be running due to heating of main
SCRs.
4 Indicates an open thermal fan thermistor or an open con-
nection between the thermistor and the thermal fan/snub-

ber board. See the Wiring Diagram (leads #319 and
#316).
5 Indicates a thermostat (choke or secondary) has opened.
The thermal protection light should also be illuminated.
6 Indicates the fan motor should be running. LED 6 should
be illuminated and the fan running when any
of the following LEDs are lit: LED 2, LED 3, LED 4, or
LED 5.
IDEALARC DC-655

F-42 F-42
CONTROL BOARD LED CHART
LED # LED FUNCTIONS AND INDICATIONS

(Machine is ON)
1 Indicates that the mode switch (SW2) is in the CC mode.
When LED 1 is on, LED 6 should also be
illuminated.
2 Indicates that feedback voltage is present. This informa-
tion is used when the machine is in a CV mode. This LED
should get brighter as the output voltage is increased.
3 Indicates an input shutdown. The normally closed relay

CR2 will activate causing input contactor CR1 to open.
See Remote Control Leads Fault Protection
Shutdown, Shorted Rectifier Fault Protection and Idle
Shutdown Timer in the Operation Section.
4 Indicates an over current shutdown. See Over Current
Protection Shutdown in the Operation Section.
5 Indicates output current is present.
6 Indicates that the machine is in the CC mode. LED 6
should be on whenever LED 1 is lit.
7 Indicates that the +16 VDC power supply is functioning.
This circuitry is located on the control board.
8 Indicates the control signal is being generated to control

the firing of the output SCRs. This signal is sent to the
firing board. This LED should get dimmer as the output
voltage is increased. This LED will normally be off when
the machine is in the constant current mode at open
circuit.
9 Indicates that the -10 VDC power supply is functioning.
This circuitry is located on the control board.
10 Indicates that 42 VAC is being supplied to the control
board from the control board T3 transformer.
11 Indicates that feedback voltage is present. This informa-
tion is used when the machine is in the CC mode. This

LED should get brighter as the output voltage is
increased.
IDEALARC DC-655

F-43 F-43
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

CONSTANT CURRENT MODE – NO LOAD
0 volts
50 volts 2 ms
This is the typical DC open circuit

voltage waveform generated from a
properly operating machine. Note
that each vertical division represents
50 volts and that each horizontal divi-

sion represents 2 milliseconds in
time.
Note: Scope probes connected at
machine output terminals: (+) probe
to positive terminal, (-) probe to neg-
ative high inductance terminal.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....2 ms/Div.
Coupling ............................DC
Trigger .........................Internal
IDEALARC DC-655

F-44 F-44

CONSTANT VOLTAGE MIG
MAXIMUM OUTPUT SETTING – NO LOAD
0 volts
50 volts 2 ms


time.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Coupling ............................DC
IDEALARC DC-655

F-45 F-45

MINIMUM OUTPUT SETTING – NO LOAD
0 volts
20 volts 2 ms

time.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Coupling ............................DC
IDEALARC DC-655

F-46 F-46
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

CONSTANT VOLTAGE MIG MODE
0 volts
20 volts 2 ms
This is the typical DC open circuit voltage wave-

form generated from a properly operating
machine. Note that each vertical division repre-
sents 20 volts and that each horizontal division
represents 2 milliseconds in time. The machine
was loaded with a resistance grid bank. The
grid bank meters read 650 amps at 44 VDC.

Note: Scope probes connected at machine out-
put terminals: (+) probe to positive terminal, (-)
probe to negative high inductance terminal.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Coupling ............................DC
IDEALARC DC-655

F-47 F-47
TYPICAL SCR GATE VOLTAGE WAVEFORM

MAXIMUM OUTPUT SETTING – NO LOAD
0 volts
2 volts 5 ms
This is the typical DC open circuit voltage wave-

form. The machine was in an open circuit con-
dition (no load) and operating properly. Note
that each vertical division represents 2 volts and
that each horizontal division represents 5 milli-
seconds in time.
Note: Scope probes connected at SCR gate

and cathode: (+) probe to gate, (-) probe to

cathode.
SCOPE SETTINGS
Volts/Div.......................2V/Div.
Coupling ............................DC
IDEALARC DC-655

F-48 F-48
INSTALLATION
ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

ONE OUTPUT SCR NOT FUNCTIONING
0 volts
20 volts 2 ms
This is NOT the typical DC open circuit voltage

waveform. One output SCR is not functioning.
Note the “gap” in the waveform. One SCR gate
is disconnected to simulate an open or non-
functioning output SCR. Each vertical division
represents 20 volts and each horizontal division
represents 2 milliseconds in time.
Note: Scope probes connected at machine out-

put terminals: (+) probe to positive terminal, (-)
probe to negative high inductance terminal.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Coupling ............................DC
IDEALARC DC-655

F-49 F-49
INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT
WARNING
al.
DESCRIPTION
The following procedure will aid the technician in inspecting, cleaning, and replacing the input
contactor.
MATERIALS NEEDED
Phillips head screw driver
5/16” Socket wrench
Flat head screw driver
Low pressure air source
Allen head type wrench

IDEALARC DC-655

F-50 F-50
INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued)

FIGURE F.18 - INPUT CONTACTOR CLEANING AND REMOVAL
1. INPUT SUPPLY LINE

2. INPUT CONTACTOR CR1
3. RECONNECT PANEL
CLEANING PROCEDURE CONTACTOR REPLACEMENT

1. Remove the main input supply power to the PROCEDURE
machine. 1. Disconnect main input supply power to the
2. Locate and get access to the input contac- machine.
tor (CR1) in the input box. See Figure F.18. 2. Locate and get access to the input contac-
3. Remove the input contactor cover plate tor (CR1) in the input box. See Figure F.18.
using a phillips head screwdriver. 3. Disconnect the main input supply power
leads L1, L2, and L3 to the input contactor.
WARNING Remove the control transformer primary
leads H1, H2 or H3 (dependent on input volt-

Do not apply input power to age) from the L1 and L3 terminals on the
the machine with the input input side of the contactor.
contactor cover plate re-
moved. 4. Disconnect the output leads T1, T2, and T3
from the input contactor.
5. Identify and label the leads connected to the
input contactor coil. See the Wiring
4. Blow out any dirt or dust in or around the Diagram.
contacts with a low pressure air stream. 6. Disconnect the leads from the input contac-
5. Inspect the contacts for signs of excessive tor coil (leads X1, #256 and #255A). See the
wear, pitting, or contacts fused (stuck) Wiring Diagram.
together. 7. Remove the three self-tapping mounting
a. If any of these conditions are present, screws using a 5/16” socket wrench.
replace the input contactor assembly. 8. Remove the input contactor.
6. Replace the input contactor cover plate. 9. Insert the replacement input contactor and
install it following the procedures in reverse
order.
NOTE: Be sure to reconnect all leads cor-
rectly.
IDEALARC DC-655

F-51 F-51
SCR RECTIFIER BRIDGE REMOVAL AND

REPLACEMENT PROCEDURE
WARNING
al.
DESCRIPTION
The following procedure will aid the technician in removing the SCR/Rectifier Bridge for main-
tenance or replacement.
MATERIALS NEEDED
3/8” Wrench
1/2” Wrench
9/16” Wrench
IDEALARC DC-655

F-52 F-52

REPLACEMENT PROCEDURE (continued)
FIGURE F.19 - THERMAL FAN/SNUBBER BOARD PLUG LOCATIONS
LED2
LED6
LED5 LED4
LED1
LED3
PLUG J20 PLUG J9

PROCEDURE
1. Remove the input power to the DC-655 4. Disconnect lead #222 from the negative high
machine. inductance output terminal. This lead runs
from plug J9 to the negative high inductance
2. Using the 3/8” wrench, remove the case top
output terminal. Cut any necessary cable
and sides.
ties. See the Wiring Diagram.
3. Locate and remove plugs J9 and J20 from
the Thermal Fan/Snubber Board. See Figure
F.19.
IDEALARC DC-655

F-53 F-53

REPLACEMENT PROCEDURE (continued)
FIGURE F.20 – SCR RECTIFIER BRIDGE ASSEMBLY DETAILS
MAIN TRANSFORMER
SECONDARY LEADS
SCR
RECTIFIER
BRIDGE
LEG
ASSEMBLY
MOUNTING
BRACKETS
5. Using the 1/2” socket wrench, remove the REASSEMBLY

six transformer secondary leads from the
1. Upon reassembly, apply a thin coating of
heat sink assembly. The small “A” leads do
Dow Corning 340 Heat Sink Compound to
not have to be removed. Note lead place-
all bolted connections.
ment for reassembly. See the Wiring
Diagram and Figure F.20. 2. With the left side horizontal mounting brack-
et removed, slide the heat sink assembly
6. With the 9/16” wrench, remove the shunt
into the machine.
from the left side of the heat sink assembly.
3. Support the heat sink assembly and install
7. With the 3/8” wrench, remove the four
the left side mounting bracket. Then mount
mounting bolts that hold the heat sink
the heat sink assembly to the bracket with
assembly to the horizontal mounting brack-
four bolts. Note insulator placement.
ets. Be sure to remove the insulators and
take note of placement for reassembly. 4. Attach the shunt to the left side of the heat
sink assembly.
8. While supporting the heat sink assembly,
remove the left side horizontal mounting 5. Install the six transformer secondary leads
bracket from the left side leg assembly. See to the heat sink assembly. See the Wiring
Figure F.20. Diagram.
9. Carefully slide the rectifier heat sink assem- 6. Connect lead #222 to the high inductance
bly from the machine. Clear all leads. output terminal.
7. Install plugs J9 and J20 onto the thermal

fan/snubber board.
8. Replace any cable ties cut at disassembly.
9. Install the case top and sides.
IDEALARC DC-655

F-54 F-54
MAIN TRANSFORMER AND CHOKE REMOVAL

AND REPLACEMENT PROCEDURE
WARNING
al.
DESCRIPTION
The following procedure will aid the technician in removing the main transformer and choke
for maintenance or replacement.
MATERIALS NEEDED
3/8” Wrench
7/16” Wrench
9/16” Wrench
Wire cutters
Soldering iron and solder

IDEALARC DC-655

F-55 F-55

AND REPLACEMENT PROCEDURE (continued)
FIGURE F.21 – OUTPUT CHOKE/MAIN TRANSFORMER ASSEMBLY DETAILS
CHOKE THERMOSTAT
TOP LEAD (#222A) (LEADS #273 AND 41A)
CENTER TAP CHOKE / FRAME

(LOW INDUCTANCE MOUNTING
OUTPUT LEAD) BOLTS (4)
ROPE SLING
BOTTOM CHOKE
LEAD (HIGH
INDUCTANCE
OUTPUT LEAD)
IRON/COIL
MOUNTING
BOLTS (4)
TRANSFORMER
SECONDARY
LEADS (6)
PROCEDURE 6. Using the 9/16” wrench, remove the high

inductance output lead from the bottom
1. Remove the input power to the DC-655
choke lead. See Figure F.21.
machine.
7. Support the choke with a crane or hoist.
2. Remove the case top and sides.
8. Using the 9/16” wrench, remove the four
OUTPUT CHOKE REMOVAL bolts, washers and nuts mounting the choke
3. Label and remove leads #273 and 41A from assembly to the transformer frame assem-
the choke thermostat. bly.
4. Using the 9/16” wrench, remove the flexible 9. Carefully lift the choke from the DC-655
transformer secondary lead and the #222A machine.

lead from the top lead of the output choke.
See Figure F.21.
5. Using the 9/16” wrench, remove the low
inductance output lead from the center tap
of the choke. See Figure F.21.
IDEALARC DC-655

F-56 F-56

AND REPLACEMENT PROCEDURE (continued)
MAIN TRANSFORMER REMOVAL REASSEMBLY

10. With the 1/2” wrench, remove the six trans- 1. Using the rope sling, carefully position the
former secondary leads from the SCR heat iron/coil assembly onto the DC-655. Mount
sink assembly. it to the frame assembly with four bolts,
washers and nuts.
11. Remove the transformer primary leads from
the reconnect panel. Label for reassembly. 2. Attach the transformer primary leads to the
reconnect panel.
12. Carefully label and unsolder the following
leads from the transformer windings. Cut 3. Attach the six transformer secondary leads
any necessary cable ties. See the Wiring to the SCR heat sink assembly.
Diagram.
4. Solder the following leads to the transformer
❒ 335 ❒ 203 ❒ 31 windings.

❒ 336 ❒ 204 ❒ 32A ❒ 335 ❒ 203 ❒ 31
❒ 331 ❒ 205 ❒ 41 ❒ 336 ❒ 204 ❒ 32A
❒ 332 ❒ 206 ❒ 42A ❒ 331 ❒ 205 ❒ 41
❒ 333 ❒ 207 ❒ 41 ❒ 332 ❒ 206 ❒ 42A
thermostat
❒ 334 ❒ 208 ❒ 333 ❒ 207 ❒ 41
thermostat
13. Using a rope sling and hoist, support the ❒ 334 ❒ 208
iron/coil assembly. See Figure F.21.
5. Using a crane or hoist, carefully place the
14. With the 9/16” wrench, remove the four choke onto the main transformer.
bolts, washers and nuts holding the iron/coil
6. Attach the high inductance output lead to
assembly to the frame assembly.
the bottom choke lead.
15. Cut or remove any necessary cable ties.
7. Attach the low inductance output lead to the

16. Using the hoist, carefully remove the choke center tap.
iron/coil assembly from the DC-655
8. Attach the #222A lead and flexible trans-
machine. Clear all leads.
former secondary lead to the top choke
lead.
9. Attach leads #273 and 41A to the choke
thermostat.
10. Replace any cable ties cut at disassembly.
11. Install the case top and sides.
IDEALARC DC-655

F-57 F-57
RETEST AFTER REPAIR
Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could
affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine
must be retested.
INPUT IDLE AMPS AND WATTS

Input volts/Phase/Hertz Maximum Idle Amps Maximum Idle KW
208/3/60 11.0 1.0
230/3/60 10.0 1.0
380/3/60 6.0 1.0
416/3/60 5.5 1.0
460/3/60 5.0 1.0

550/3/60 4.2. 1.0
575/3/60 4.0 1.0
200/3/50 21.0 1.3

220/3/50 19.1 1.3
230/3/50 18.3 1.3
380/3/50 11.0 1.3
400/3/50 10.5 1.3
415/3/50 10.1 1.3
440/3/50 9.6 1.3
500/3/50 8.4 1.3
550/3/50 7.7 1.3
MAXIMUM OPEN CIRCUIT VOLTAGES

Mode Input Hertz Open Circuit Volts

CC Stick 60 66/70
CV MIG 60 44/47
Auxiliary Output (#31-#32) 60 122/128 VAC
Auxiliary Output (#41-#42) 60 44/48 VAC
MINIMUM ACCEPTABLE OUTPUT VOLTAGE - AT MAXIMUM OUTPUT SETTINGS

Mode Control Settings Load
CC Stick Output Control at Maximum 815 Amps @ 44.0 Volts (Min)
Arc Force Control at
Minimum
CV MIG Output Control at Maximum 815 Amps @ 44.0 Volts (Min)
Auxiliary Output (#31-#32) N/A 5 Amps @ 120/126 VAC (Min)
Auxiliary Output (#41-#42) N/A 5 Amps #41/45 VAC (Min)
IDEALARC DC-655

SVM ERROR REPORTING FORM
We need to know if there are errors in our manuals. We also value any suggestions as to
additional tests or procedures that would make this SVM a better tool for you.
If you discover new or different “Problems or Symptoms” that are not covered in the three col-
umn troubleshooting chart, please share this information with us. Please include the
machine’s code number and how the problem was resolved.
Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 01/99

G-1 G-1
Return to Master TOC ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
ELECTRICAL DIAGRAMS SECTION
Electrical Diagrams Section...........................................................................................Section G
Wiring Diagram (60 Hz Domestic) (G3348-1)..............................................................................G-2
Control Board Schmatic (G3384) ................................................................................................G-3
Firing Board Schmatic (G2792) ...................................................................................................G-4
Thermal Fan/Snubber P.C. Board Schematic (L10123)...............................................................G-5
Control Board Layout (G3385-1) .................................................................................................G-6
Firing Board Layout (G2699-2) ....................................................................................................G-7
Thermal Fan/Snubber Board Layout (L10124-1) .........................................................................G-8
DC 655

G-2 ELECTRICAL DIAGRAMS G-2
Wiring Diagram (G3348-1)
J15 P15
DUAL (EXCEPT 380/500V & 230/400V) & SINGLE VOLTAGE
10A 42V CIRCUIT BREAKER
1 OUTPUT 8
J14 202 202
UNDER 346 VOLTS (SHOWN CONNECTED FOR LOW VOLTAGE) 42A 42 2 75 1 75 CONTROL 7
AM
32 75 75 201 6 201 -
3 2
+
TO 10K
N.D. H3 RECONNECT .0045MFD 210 210
SUPPLY 4 76 3 76 5
PANEL 3000V 236 R1 75
LINES 2 5 77 77 315 4
H2 4
+
3 R3 215
X1 L3 L1 C9 GND. 4 6 2 5 2 3 VM
L2
-
TO 237 10K 1/4W 317 2
STUD 77 7 41 6 41
RECONNECT 2 J16 OPTIONAL
11 3 9 6
C8 8 210 7 210 222 1 222
TO GROUND PER W PANEL 20A ANALOG METERS
1 32 115V 31 9 32A 8 32A
NATIONAL
C7 SW3
10 2 8 5 CIRCUIT 76 10 4 9 4 N.E.
ELECTRICAL V 31 238 76 77 OUTPUT OR
FROM T1 AUX. WINDINGS

256 BREAKER
CODE 12 1 7 115V RECEPTACLE 75 11 41 10 41 CONTROL 8
4 226
U 21 12 41 11 41 SWITCH 202 7 6 336
CR 1 32A 41 13 12 201 6 5 334
32A
CONTACTOR
FLEX 42 14 42A 13 42A 210 5 J12 4 333
32 2
TO PRIMARY LEAD 222 14 222 237 315 4 J13 3 335
255A H1 COILS
CONNECT OR INSULATE 236
AS SHOWN ON INPUT 222 215 3 2 332
CONNECTION DIAGRAM 31 317 2 331
210 1
222 1
SINGLE VOLTAGE OVER 345 VOLTS T.S.2 OPTIONAL DIGITAL
31 METER P.C. BOARD
+21 -21 41 4 2 31 32 T.S.1 75 76 77
TO
H4 H3 H2 H1
N.D. H2
SUPPLY RECONNECT
PANEL
OPTIONS
LINES
H3 255 4 2
211 255 OUTPUT
X1 L3 L2 L1 X1 X2 TERMINAL 2
SW1 282 SWITCH
T2 CONTROL POWER SWITCH
11 3 RED SW5
215
315
317
201
210
222
202
TO GROUND PER W 4
TRANSFORMER BLK
NATIONAL
10 2 281
ELECTRICAL V T3
256 CONTROL
CODE 255
12 1 BOARD
U
TRANSFORMER
CR 1 255 1 2 3 4 5 6 7 8 9 10
CONTACTOR
TO PRIMARY
PILOT 1 J3 1 201
255A H1 COILS W
256 LIGHT 2 2 202
3 3 75
256 4 4
5 J2 5 314
335 336
THERMAL 231 6 6 226
PROTECTION 7 J1
210 7
41 Y 305
LIGHT
+ - 281 8 8 317
BRASS
9 N.J. 9
41 TERMINAL
10
S 282 10 318
T1 MAIN 42V
11 S1 11 310
TRANSFORMER F N.F.
SECONDARY 238 12 1 2 3 4 12 309
41
THERMOSTAT 13 315
333 CONTROL
S 273 OFF 14 222A
10V 41 41A
P.C. BOARD
F 41 41 CHOKE LEAD 1 41A J21
334
THERMOSTAT 2 41
42A
331 3 301 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
S 2
1 2 10V 3 G1 1 4
32A
F G2 2 5 208
332
S G3 3 6 207
42A J4 J5
206
215
321
341
7
222
345
344
328
322
342
115V
346
340
PRI. S G4 4
G5 5 8 205
45V F
4 5 6 6 9 4
G6
F 31 31 10 310
N.A. 41
31 A 1 11 309
7 203 8 205 9 207 12 215
W B 2
N.G. F F F FAN 13 231
1 3
13 32V 14 32V 15 32V MOTOR
B' 4 14 214
2 PRI. S S S J7
C 5 15 203 341
3 32 204 11 206 12 208 B J22
10 204 P22
C' 6 16
4 GREEN AUX1
1 261 261 1 261
7
5 2 2 262
A' 8 J6 2 262 262
6 4 263 263 3 263
3 215
P16 7 77 FIRING CIRCUIT
300 4 342 4
P.C. BOARD 342
8 SEC.
42
9 31 32 31
GREEN 41 OUTPUT CHOKE

10 76 STANDARD
LOW
75 2 14-PIN
11
4 319 (-) 340
12 21 21 RECEPTACLE THERMAL FAN HIGH
75 (FRONT VIEW) 1 1 315 NTC 215
13 41 77 THERMISTOR (-)
14 42 76 SEC. 2 2 318 344
J11 222A
32A 3 3 317 316
222
300 4 4 41 222 222 SW2
J10 N.H.
OUTPUT
G2 14 5 222 MODE
A4 13 6 314 SWITCH
TP3 ARC FORCE (SHOWN IN CC
G1 12 7 301 222
10K
320V
G4 11 8 305 POSITION)
A1 A3 A5 30 160J R4 328
R2
A5 10
OPTIONS DUAL FEEDER P.C. BOARD 300W (ALL 3)
C6 C2 TP2
321 322
G5 9 1 319
J20 210
1 A6 8 2 316 .05MFD
210
A3 J9 600V
2 7 214 TP1 255 261 1
(ALL 3)
3 32 A2 6 6 G6 262 2
SCR SCR SCR
GREEN G1 G3 G5 A1 5 5 G5 NC COM
263 3
4 3 5
1 G3 OUTPUT SHUNT 255A
5 2 4 4 G4 342 4
J8 C1 NO
6 4 G6 3 3 G3 (50 MV @800 AMPS)
J17
7 77 222 2 2 G2 + - CR 2 J23
8 C 1 1 G1 346 FOR OPTIONAL
42 (+)
9 31 32 31 PARALLELING KIT
THERMAL FAN/ 201 202
GREEN 41 OUTPUT
10 76 SNUBBER P.C. BOARD 345
1 2 14-PIN 215
11 75
2 21
4
21 RECEPTACLE
12
32 3 75 (RIGHT)
13 41 77
GREEN 4 76 (FRONT VIEW)
14 42
2 5
4 6 G2 G4 G6
JUMPER 77 7 OUTPUT NOTES:
J19 SCR SCR SCR
PLUG 8 RECTIFIER J20 J6,J11 J4,J8,J13 J7,J10,J12,J14 J3
TO J16 2 4 6 ASSEMBLY
31 9 1 5 N.A. LEADS 4 THRU 9 ARE NOT PRESENT ON 380/500V,
1 1 2 1 3 1 4
76 10
1 AND SINGLE VOLTAGES OVER 345V MACHINES.
75 11
21 2 A6
12 A2 A4 3 4 4 6 8 N.D. TAPE UP SEPARATELY TO PROVIDE AT LEAST
3 32 2 5 6 10
41 13
4 GREEN 600V INSULATION.

42 14 J1,J9,J15,J16
5 2
J2 J17,J18,J19 J5 N.E. PLUG & LEAD ASSEMBLY GOES TO EITHER J12 (OPTIONAL DIGITAL
6 4 1 6 1 7 1 8
7 77 METERS PC BD.) OR J14 (IN LINE CONNECTOR FOR ANALOG METERS).
J18
8
42 N.F. LOCATED IN SECONDARY COIL WINDING.
9 31 32 31
GREEN 7 12 8 14 9 16
10 76 41
N.G. STANDARD 14-PIN RECEPTACLE PLUGS INTO J16 ON STANDARD
75 2 14-PIN
11 CONNECTOR CAVITY NUMBERING SEQUENCE
4 MACHINES AND IS REPLACED BY DUAL FEEDER OPTION IF USED.
12 21 21 RECEPTACLE
(LEFT) (VIEWED FROM COMPONENT SIDE OF BOARD)
13 41 77 75 N.H. LOCATED ON OUTPUT RECTIFIER FLAT HEAT SINK.
76
(FRONT VIEW)
14 42
ELECTRICAL SYMBOLS PER E1537 N.J. AS SHIPPED ONLY SWITCH #4 IS ON (UP). SEE INSTRUCTION MANUAL.
11-6-98
G3348-1
G3348-1 I-UF
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclo-
sure panels of your machine. DC 655

Control Board Schematic (G3384)
IDLE SHUTDOWN POWER SUPPLY

TIMER TIMER OUTPUT
TIMER
CHIP
315
315
DIGITAL METER PCB
TIMER INPUT
TO OPTIONAL
SHORTED SCR
TO
A.C. PROTECTION THERMAL FAN/
SNUBBER PCB
317
TO
THERMAL FAN/
TRIGGER SNUBBER PCB
318
317 OPEN
ENABLE
TO (+)
OUTPUT STUD
Vco
CC
VFB
BUFFER
CONTROL
MODE AMPLIFIER
HOT START SWITCHING GAIN=27
SLOPE
ARC FORCE BUFFER
CC CONTROL
REFERENCE INTERCEPT FIRING
CV BUFFER INTERFACE
VFB
BUFFER
CURRENT SWITCH
0.5 SEC TIMER
>15 AMP
CURRENT
SWITCH
TO OPTIONAL
DIGITAL METER PCB

201
REF CURRENT FEED BACK

COM CV SUBARC FEEDBACK
201
HOLD
LOW
CURRENT SHUT-
AMPLIFIER DOWN
202
202
TO OPTIONAL
DIGITAL METER PCB
CVI CV FEEDBACK
START
OVER
CURRENT
PROTECTION
CV CURRENT LIMITING
-10V REFERENCE
CONTROL POT
REFERENCE PEAK
CURRENT
PROTECTION
IDLE ZERO
Ico REFERENCE
REFERENCE
SIGNAL POT FAULT

BUFFER PROTECTION
TO
FIRING PCB
A
G3384
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail- G3384
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in A
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. DC 655

Firing Board Schematic (G2792)
7-17-98A
G2792
G2792
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
7-17-98A
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. DC 655

Thermal Fan/Snubber Board Schematic (L10123)
5-16-97A
L10123
L10123
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
5-16-97A
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. SQUARE WAVE TIG 275

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-6

Control Board Layout (G3385-1)
CAPACITORS = MFD/VOLTS
DC 655
ELECTRICAL DIAGRAMS
RESISTORS = OHMS/1/4 WATT UNLESS OTHERWISE SPECIFIED
C-RW
G3385-1
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board
Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may
compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
G-6
C-RW
G3385-1
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-7
G2699-2
FIRING BOARD

Firing Board Layout (G2699-2)
DC 655
ITEM
ELECTRICAL DIAGRAMS
RESISTORS = OHMS
REQ'D
CAPACITORS = MFD/VOLTS
PART NO.
DESCRIPTION
G2699-2
7-17-98A
G-7
7-17-98A
G2699-2
9.00
G-8
ITEM REQ'D PART NO. IDENTIFICATION

R8
R7
C1,C2,C3,C4,C5,C6,C8,C9 ) 8 T11577-68 0.68 MFD /400 WVDC CAPACITOR
C11,C12,C13,C14,C15,C16 6 S13490-96 .15/200
C17,C33 ) 2 S13490-25 4.7/35
8.75
C16
C6
C18,C22,C25,C27,C28,C29 10 S16668-5 .022/50
C30,C32,C34,C35
R6
C23,C26 2 T11577-57 0.1/400
C31 1 S16668-11 .1/50
C9
C15 C36 1 S13490-104 39uF/20V
C5 D1,D2,D3,D4,D5,D6,D7,D8,D9 23 T12199-1 1N4004

D10,D11,D12,D13,D14,D15
R5
D16,D17,D18,D19,D20,D21
D22,D23
J9
C14 DZ1 1 T12702-53 1N4728A
C4 J8 1 S18248-6 HEADER
J9 1 S18248-14 HEADER
R4
J10 1 S18248-8 CONNECTOR
J11 1 S18248-4 HEADER
C13 J20 1 S18248-2 HEADER

C3 LED1,LED2,LED3,LED4,LED5 6 T13657-2 RED LED
LED6
R3
OCI1 1 S15000-10 OPTO ISOLATOR
OCI2 1 S15000-12 OPTOCOUPLER TRIAC DRIVER
C12 Q1 1 T12704-68 2N4401
C8
R1,R2,R3,R4,R5,R6 6 T14648-22 50 5W
J8
C2
R7 1 T14648-2 25 5W
R2
R8 1 T14648-9 5W / 2500 OHM RESISTOR
R9,R10,R16,R19,R21,R43,R46 9 S19400-1002 10K 1/4W
4.50
C11 R48,R52
C1 R11,R37 2 S19400-4752 47.5K 1/4W

R12,R14,R33,R44,R49,R53 6 S19400-1003 100K 1/4W
R1
R13 1 S19400-1821 1.82K 1/4W
R15,R40,R41 3 S19400-1502 15K 1/4W
R17,R18 2 S19400-2802 28.0K 1/4W
R51 R24,R25,R26,R50 4 S19400-1501 1.5K 1/4W
R9
Thermal Fan/Snubber Board Layout (L10124-1)
C34
DC 655
R28 1 S19400-1500 150 1/4W
LED4
LED3
LED6
D1 R37
D21
D23
R29 1 S19400-3570 357 1/4W
J20
R57 D20
R60 R58 R35 C18
D5 R34
R30 1 S19400-4750 475 1/4W
D6 D7
L10124-1
C30 D13
R11 R31,R54,R55 3 S19400-39R2 39.2 1/4W
D8
R13
R43
D12 R17 R34,R51 2 S19400-1001 1K 1/4W
R45 C35
R18
R38 R35 1 S19400-2673 267K 1/4W
X1
C31 R41
R19
X2
R39
R44 R10 R14 D18 R38 1 S19400-8251 8.25K 1/4W
R46
C17
J10
D2
R39 1 S19400-1000 100 1/4W
D3
D4 R55
R12
C32
OCI1
R15 R54
C29
D10
R59 R42 1 S19400-3923 392K 1/4W
C25 R16 DZ1
D19 D22
D9 R50 R45 1 S19400-1623 162K/.25W
R47 1 S19400-5111 5.11K 1/4W
LED2
LED5
LED1
ELECTRICAL DIAGRAMS
D16
R56,R57,R58,R59,R60 5 S19400-2001 2.0K 1/4W
R56 C27 D15
C28 R52 TRI1 1 S18395-27 TRIAC/HEAT SINK ASSEMBLY
R26
R25
R24
R42
R53
R29
R30
R31
X1 1 S15018-13 16 PIN I.C. (SS)
OCI2
D14
D17
R48
R40 X2,X3 2 S15128-4 LM224 OP-AMP
X3
R47 X4 1 S15018-15 14 PIN I.C. (SS)
C26
C23
X4
Q1
R49
J11
R33
D11
THERMAL FAN SNUBBER

C22
TRI1
R21
R28
.25
C36 CAPACITORS = MFD/VOLTS

C33
RESISTORS = OHMS
0
5-16-97A
L10124-1
~.04
0
.25
5.75
6.00
G-8
5-16-97A
L10124-1

DC 655
NOTES

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RETURN TO MAIN INDEX

Safety Depends on You

Lincoln arc welding and cutting

Copyright © 2002 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

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CALIFORNIA PROPOSITION 65 WARNINGS

FOR ENGINE 1.h. To avoid scalding, do not remove the

current creates EMF fields around welding cables and

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ELECTRIC SHOCK can kill. ARC RAYS can burn.

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

5.e. Also see item 1.b.

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WELDING SPARKS can CYLINDER may explode

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masse. ment roxique) ou autres produits irritants.

ainsi qu’un verre blanc afin de se protéger les yeux du

prévenir ttout risque d’incendie dû étincelles.

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RETURN TO MAIN INDEX

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

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

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

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

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

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TECHNICAL SPECIFICATIONS – DC-655

230/460/60 122/61 150/75 10501

AWG(IEC-MM2) SIZES AWG(IEC-MM2) SIZES SIZE (AMPS)1

40°C (104°F) Ambient

27.5 in 22.2 in 38.0 in 720 lbs.

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RATING PLATE (LOCATED ON CASE BACK)

3 Phase transformer with Constant Voltage Output

INPUT POWER GMAW

THREE PHASE FCAW

Designates welder complies with

Designates welder can be used

(UL) standards and Canadian

Standards Association (CSA)

Designates the degree of envi- NRTL/C

Designates welder complies with

Underwriters Laboratories (UL)

SMAW Uo Open Circuit Output Voltage

U1 Input Voltage Rating(s)

X Output Duty Cycle Rating(s)

U2 Output Voltage Rating(s)

I2 Output Current Rating(s)

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Read this entire installation section INPUT

INPUT POWER SUPPLY

• Turn the Power Switch on the DC-655 “OFF” before

in excessive operating temperatures and nuisance mal/magnetic circuit breakers.

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INPUT POWER SUPPLY CONNECTIONS RECONNECT PROCEDURE

To reconnect a multiple voltage machine to a different

DUAL VOLTAGE MACHINE