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IM520-
RETURN TO MAIN MENU
SQUARE WAVE TIG 255
January, 1997
For use with machines having Code Number 10022 thru 10026 & 10134, 10451,10452,10453.
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation ...
and thoughtful operation on your
part.
DO
NOT
INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT
WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
OPERATOR'S MANUAL
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric SQUARE WAVE TIG 255 IM520-B
Summary of Contents for Lincoln Electric SQUARE WAVE TIG 255 IM520-B
- Page 1 IM520- RETURN TO MAIN MENU SQUARE WAVE TIG 255 January, 1997 For use with machines having Code Number 10022 thru 10026 & 10134, 10451,10452,10453. Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...
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Page 2: Safety
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. -
Page 3: Electric Shock Can Kill
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
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Page 6: Safety
This statement appears where the information this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! -
Page 7: Table Of Contents
TABLE OF CONTENTS Safety ...2-6 Installation...8-12 Technical Specifications ...8 Input and Output Specifications Cable and Fuse Sizes Physical Dimensions Location ...9 Machine Grounding...9 Input Connections ...10 Output Connections ...11 Operation...13-23 Safety Instructions ...13 Graphic Symbols ...14-15 General Description ...16 Design Features and Advantages...16 Welding Capability ...17 Limitations...17 Controls and Settings...18... -
Page 8: Installation
INSTALLATION TECHNICAL SPECIFICATIONS - SQUARE WAVE TIG 255 Standard Voltage 208/230/460/1/60 230/460/575/1/60 200/240/400/1/50/60 220/380/440/1/50/60 380/415/500/1/50/60 220/380/415/1/50/60 Duty Cycle 40% Duty Cycle NEMA Class II (40) 60% Duty Cycle 100% Duty Cycle Welding Current Range (Continuous) 5-315 Amps AC and DC RECOMMENDED INPUT WIRE AND FUSE SIZES For all Stick, DC TIG, and Balanced AC TIG Welding at 255A/30V/40% Duty Cycle... -
Page 9: Location
Read entire installation section before starting installation. Safety Precautions 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. •... -
Page 10: Input Connections
INSTALLATION 4. Keep the torch in good repair and all connections tight to reduce high frequency leakage. 5. The work terminal must be connected to a ground within ten feet of the welder, using one of the following methods: a) A metal underground water pipe in direct contact with the earth for ten feet or more. -
Page 11: Output Connections
Welders are shipped connected for the highest input voltage as listed on the rating Plate. To change this connection for a different input voltage, reconnect the power strap (P) to the terminal corresponding to the input voltage used. Designations on reconnect panel, LOW, MID and HIGH correspond to the nameplate input voltages of a triple voltage welder. -
Page 12: Installation
INSTALLATION The welder fittings have the following threads: Gas Inlet and Outlet: 5/8”-18 right-hand female; Water inlet and Outlet: 5/8”-18 left-hand female. The cylinder of inert shielding gas must be equipped with a pressure regulator and flow meter. Install a hose between the flow meter and gas inlet on the welder. -
Page 13: Operation
OPERATING INSTRUCTIONS General Warnings SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. -
Page 14: Graphic Symbols
OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL TIG 2-STEP & TIG 4-STEP STICK CURRENT CONTROL OUTPUT LOCAL CURRENT CONTROL REMOTE CURRENT CONTROL INCREASE OUTPUT DECREASE HIGH FREQUENCY AFTERFLOW / AFTERFLOW CONTINUOUS FREQUENCY START ONLY FREQUENCY (INCREASE &... - Page 15 GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL AC WAVE BALANCE PULSED PER SECOND OVER TEMPERATURE INPUT POWER & POLARITY & POLARITY DO NOT SWITCH WHILE WELDING WARNING WATER (COOLANT) OUTPUT WATER (COOLANT) INPUT (CONT.) GAS OUTPUT ELECTRODE CONNECTION PROTECTIVE...
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Page 16: General Description
OPERATION GENERAL DESCRIPTION The Square Wave TIG 255 is a constant current, single range square wave AC/DC TIG (GTAW) arc welding power source with built-in high frequency stabilization. It also has stick (SMAW) capability. It is available from the factory in one model only; there are no factory installed options, only variations in input voltage and frequency. -
Page 17: Welding Capability
• Strain relief holes in base for welding cables, gas and water hoses and control cables. • Easy access for input connections. Connections are simple strip and clamp of input wires (no lugs required). • Low fan noise at idle. •... -
Page 18: Controls And Settings
OPERATION CONTROLS AND SETTINGS All operator controls and adjustments are located on the case front of the Square Wave TIG 255. Refer to Figures 3 and 4 and corresponding explanations. THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO WELD MODE TIG 2-STEP... -
Page 19: Case Front Controls
7. CONTROL PANEL: The display is divided into five sections. See Figures 4A and 4B. FIGURE 4A - DISPLAY A. AC/DC INDICATOR D. MOMENTARY DISPLAY B. VOLTMETER E. BAR GRAPH C. AMMETER FIGURE 4B - DISPLAY A. AC/DC INDICATOR: This symbol represents the output polarity of the 255 . -
Page 20: Hand And Foot Amptrol Operation
OPERATION HAND AND FOOT AMPTROL ACCESSORY OPERATION Both the Hand and Foot Amptrol work in a similar manner. They are meant to be used for remote current control when Remote Current Control is selected. The TIG 2-Step mode must be selected when using an Amptrol for remote current control. -
Page 21: Tig Welding Sequence Of Operation (2 Step Mode)
TYPICAL CURRENT RANGES DCEP ( + ) DCEN ( - ) Tungsten Electrode 1%, 2% 1%, 2% Diameter Thoriated Thoriated in. (mm) Tungsten Tungsten .010 (.25) 2-15 0.020 (.50) 5-20 0.040 (1.0) 15-80 1/16 (1.6) 70-150 10-20 3/32 (2.4) 150-250 15-30 (3.2) 250-400... -
Page 22: Tig Welding Sequence Of Operation (4 Step Mode)
OPERATION 10. Press and release the Arc Start Switch, and set the gas flow meter. The welder is now ready for welding. 11. Position the tungsten electrode at the start of the weld at a 65 to 75 angle with the horizontal so that the electrode is approximately 1/8”... -
Page 23: Stick Welding
BALANCED (0): The amounts of positive and negative are the same. CLEANING (+1 to +5): Provides more positive current than negative. Since the positive current produces the “cleaning” or oxide removal on aluminum, this setting is used for welding on heavily oxidized aluminum. PENETRATION (-1 to -10): Provides more negative current than positive. -
Page 24: Accessories
ACCESSORIES OPTIONS / ACCESSORIES • Hand Amptrol (K963) • Foot Amptrol (K870) • Arc Start Switch (K814) • Magnum Cooler Horizontal TIG Mounting Bracket (K559-2) • Undercarriage (K932-1) UNDERCARRIAGE FUNCTION The Square Wave TIG 255 is designed to be used with a Lincoln K932-1 Undercarriage. -
Page 25: Maintenance
MAINTENANCE Safety Precautions WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform 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. -
Page 26: Maintenance
MAINTENANCE FIGURE 6 - GENERAL ASSEMBLY EXPLODED VIEW 1. MAIN TRANSFORMER 2. OUTPUT STUDS 3. POLARITY SWITCH 4. RECTIFIER ASSEMBLY 5. CONTROL BOX ASSEMBLY 6. SPARK GAP ASSEMBLY 7. PROTECTION PC BOARD - (Mounted to rear of control box assembly) –... -
Page 27: Troubleshooting
How To Use Troubleshooting Guide This Troubleshooting Guide is designed to be used by the machine Owner/Operator. 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, please observe all safety notes and precautions detailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshooting this equipment. -
Page 28: Troubleshooting Guide
Authorized Field Service Facility for technical troubleshooting assistance before you proceed. POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS 1. Contact The Lincoln Electric Service Dept. (216) 383-2531 1. Make certain that the input power switch is in the “ON”... - Page 29 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Machine regularly over heats - thermostat opens, PL1 (yellow light on front panel) glows. The fan runs but machine has no output and no display. Machine makes a very loud buzzing noise in DC Stick Mode, or in DC TIG Mode when the arc start or amptrol is pressed.
- Page 30 TROUBLESHOOTING Troubleshooting Guide PROBLEMS (SYMPTOMS) The yellow light (PL1) on the front panel is not lit. One or more keypad lights (LEDS) are dark and cannot be lit when their respective keys are pressed - machine is operable. The Beeper (Piezoelectric Buzzer) cannot be heard - machine operating normally.
- Page 31 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Machine output is intermittently lost. Gas flow and high frequency are also interrupted. Arc “Flutters” when TIG welding. Lack of penetration in AC TIG welding. Black areas along weld bead. Black areas along weld bead at or near end of weld.
- Page 32 TROUBLESHOOTING Troubleshooting Guide PROBLEMS (SYMPTOMS) Machine has low output when in TIG 4-Step Mode. Weak high frequency - machine has normal welding output. The display shows zero amps, but indicates open circuit voltage (approximately 53V). The arc start switch or amptrol is not actuated. High frequency “Spark”...
- Page 33 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) No high frequency. Machine is in the TIG Mode and has normal output. No gas or water flow when arc start switch or amptrol is activated in the TIG Mode.
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Page 34: Troubleshooting Guide
TROUBLESHOOTING Troubleshooting Guide PROBLEMS (SYMPTOMS) Stick electrode “Blasts Off” when arc is struck. Cannot adjust AC Wave Balance when welding in the Stick Mode. Machine welds at a very low output regardless of the preset current setting - arc is stable. Variable or sluggish welding arc when welding in the Stick Mode. -
Page 35: Wiring Diagrams
WIRING DIAGRAM – –... -
Page 36: Wiring Diagrams
WIRING DIAGRAM 235A 239A – –... -
Page 37: Basic Course
_______________________________________________ _______________________________________________ Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month Year BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Price Code $5.00 $15.00 $4.50 $5.00... - Page 38 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
- Page 39 Keep your head out of fumes. Turn power off before servicing. Use ventilation or exhaust to remove fumes from breathing zone. Los humos fuera de la zona de Desconectar el cable de respiración. alimentación de poder de la Mantenga la cabeza fuera de los máquina antes de iniciar cualquier humos.
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Page 40: Limited Warranty
INCLUDING: PARTS & LABOR S22127-2 LIMITED WARRANTY TO OBTAIN WARRANTY COVERAGE: You are required to notify Lincoln Electric, your Lincoln Distributor, Lincoln Service Center or Field Service Shop of any defect within the warranty period. Written notification is recommended. WARRANTY REPAIR:...
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