SQUARE WAVE TIG 355 For use with machines having Code Numbers: 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.
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can kill. 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.
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.
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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
TIG Welding Sequence of Operation (4-Step Mode) ...B-19 Overload Protection...B-20 Auxiliary Power ...B-20 Accessories...Section C Options/Accessories...C-1 Maintenance ...Section D Safety Precautions...D-1 Input Filter Capacitor Discharge Procedure ...D-1 Routine and Periodic Maintenance ...D-2 General Component Locations...D-3 Troubleshooting ...Section E Wiring Diagram, Dimension Prin tand Equipment Manufacturer’s Certification Form..Section F Parts Manual ...P196 Series TABLE OF CONTENTS SQUARE WAVE TIG 355...
TECHNICAL SPECIFICATIONS - SQUARE WAVE TIG 355 INPUT - SINGLE PHASE ONLY Input Voltages: Input Currents @ 350A/34 VDC Duty Cycle 40% Duty Cycle 60% Duty Cycle 100% Duty Cycle Maximum Open Circuit Voltage 80 Volts Max. RECOMMENDED INPUT WIRE AND FUSE SIZES For all Stick, DC TIG, and Balanced AC TIG Welding at 350A/34V/40% Duty Cycle Based on the 1990 U.S.
LIFTING WARNING CYLINDER MAY EXPLODE if damaged. • Do not lift the welder with a cylinder attached. The Square Wave TIG 355 weighs 510 lbs. (232 kg) without a gas cylinder. Lift the machine by the lift bail only. Never lift the machine with a cylinder attached.
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 fol- lowing methods. a) A metal underground water pipe in direct con- tact with the earth for ten feet or more.
Unbalanced AC TIG welding draws higher input cur- rents than those for stick, DC TIG, or Balanced AC TIG welding. The welder is designed for these higher input currents. However, where unbalanced AC TIG welding above 230 amps is planned, the higher input currents require larger input wire sizes and fuses.
440/50 Article 630 of the 1990 U.S. National Electrical Code allows the rated ampacity of the supply conductors to be determined by multiplying the nameplate rating by the appropriate multiplier, depending on the duty cycle of the welder. INSTALLATION TABLE A.1 Type 75°C...
With power source off, connect the torch cable to the “Electrode” terminal on the welder. Connect a sepa- rate work cable to the “Work” terminal of the welder. See Table A.3 for recommended work cable sizes. Both work and electrode cables should be routed through the cable strain relief holes provided in the base directly below the welding ouput terminals.
Failure to do so could result in water valve mal- function and overheating of the water-cooled torch. Connect the torch water line to the welder “Water Out” fitting. Use a nonmetallic drain line from the electrode connection to the drain or water recirculating pump.
OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS • Insulate yourself from the work and ground. • Always wear dry insulating gloves. • Do not weld on containers that have held com- bustibles.
GENERAL DESCRIPTION The Square Wave TIG 355 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. The Square Wave TIG 355 gives the operator full control of the welding current plus the ability to preset weld and start cur- rents.
• 115 Volt receptacle with 15 amp circuit breaker. • Excellent arc starting and stability up through 400 amps. • High resistance to AC arc rectification. • No tungsten spitting within current range of elec- trode. • Compact size, requires only a 22.25 in x 26 in (565 mm 660 mm) footprint.
CONTROLS AND SETTINGS UPPER CASE FRONT CONTROLS Controls on the upper case front control panel are used for manual TIG and stick welding. Their func- tions are described below. Some controls are active in both TIG and stick welding, while others are active in TIG only.
Start period and come on again during the Crater Fill period.) OFF: No high frequency. 5. DIGITAL VOLTMETER/AMMETER Displays the output voltage of the welder when the VOLTS/AMPS switch (Item 7) is held in the “VOLTS” position. When the VOLTS/AMPS SWITCH IS IN THE “AMPS”...
9. AUTO BALANCE Illuminates only when the Auto Balance function is active. The welder must be in the AC TIG mode, with the AC Wave Balance control fully clockwise. 10. AFTERFLOW This control adjusts the amount of time the gas and water valves stay open after the end of a weld.
At Maximum, the arc will be more forceful and less prone to sticking but will produce more spatter. 12. PREFLOW This control adjusts the amount of time the gas and water valves are open before the arc starts. It is adjustable from 0 to 10 seconds. The Preflow time occurs only if the valves were closed (no gas flow) when the Arc Start switch or Amptrol was pressed.
Example: The Peak Current control is preset at 50 amps and the Amptrol is partially down, giving a peak current of 30 amps. Current control is set at 50%, the Background (low pulse) current will be 15 amps. The Amptrol raises and lowers the Peak current. Since Background current is always a percentage of Peak current, the Amptrol also raises and low- ers the Background current.
• ARC ESTABLISHED LED goes on when the arc is fully established and goes out if the arc goes out. • START LED is on from the time the arc is estab- lished until current begins to go up (soft start) or down (hot start).
B-12 HAND AND FOOT AMPTROL OPERATION Both the Hand and Foot Amptrol (optional kits K870 or K963) 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.
Function controls on TIG welding. STICK WELDING 1. Remove the Amptrol or Arc Start switch from the Remote Receptacle. 2. Turn the welder on. The pilot light on the front panel indicates when the power is on. 3. Select LOCAL current control; OPERATION Select STICK mode.
B-15 (illustrated in the 2-Step Mode for clarity) REMOTE AMPTROL CONTROLS FROM 2 AMPS UP TO PRESET CURRENT START TIME START CURRENT REMOTE AMPTROL CONTROLS FROM 2 AMPS UP TO PRESET CURRENT OPERATION TABLE B.1 SPECIFIC EFFECTS OF CONTROLS EFFECT OF CONTROLS ON TIG WELDING PRESET CURRENT LOCAL CURRENT CONTROL...
B-16 MAX START TIME REMOTE AMPTROL CONTROLS FROM 2 AMPS UP TO PRESET CURRENT FAST FADE-OUT -3 SEC. CRATER FILL TIME START CRATER FILL CURRENT % CURRENT REMOTE AMPTROL CONTROLS FROM 2 AMPS UP TO PRESET CURRENT OPERATION EFFECT OF CONTROLS ON TIG WELDING LOCAL OR REMOTE CURRENT CONTROL PRESET CURRENT...
B-17 START TIME START CURRENT BACKGROUND % CURRENT SPOT TIME SPOT TIME REMOTE AMPTROL CONTROLS CURRENT FROM 2 AMPS UP TO PRESET CURRENT THE SPOT TIMER CAN BE USED TO TIME A PROGRAMMED SEQUENCE OF START AND/OR PULSE UP TO 5 SECONDS LONG, OPTIONALLY FOLLOWED BY CRATER FILL. IF CRATER FILL IS USED, FADE-OUT BEGINS AT THE END OF THE SPOT TIME.
It will be electrically “hot” when TIG welding. 1. Connect an Arc Start switch to the Remote Receptacle. 2. Turn the welder, water supply (if so equipped) and gas supply on. The pilot light on the front panel indicates when the power is on.
The Square Wave TIG 355 has thermostatic protection from overloads, loss of cooling, and high ambient tem- peratures. When the welder is subjected to an over- load or loss of cooling, a thermostat will open. If the secondary thermostat opens, the effect will be...
A separate switch on the Amptrol starts the welding sequence. switch on the welder is set in the LOCAL position, the Amptrol works as an arc start switch only; it does not control current. (Current is controlled by the rheostat on the front panel.) When the Current Control switch...
SAFETY PRECAUTIONS INPUT POWER FACTOR CAPACITOR DISCHARGE PROCEDURE This procedure ensures that the power factor capaci- tors are discharged, for greater safety when you are working on the Square Wave TIG 355 with INPUT POWER REMOVED. 1. Remove input power to the machine. 2.
• Control box assembly • Spark gap assembly • Protection PC board 3. Inspect the welder output terminals and control cables for fraying, cuts, and bare spots. 4. Inspect the spark gap spacing at regular intervals. To access the spark gap, remove the nameplate located on the lower right section of the output panel.
FIGURE D.2 – GENERAL COMPONENT LOCATIONS MAINTENANCE 1. OUTPUT RECTIFIER/SCR BRIDGE ASSEMBLY 2. INPUT CONTACTOR 3. RECONNECT PANEL 4. PILOT TRANSFORMER 5. FAN AND FAN MOTOR 6. INPUT POWER FACTOR CAPACITOR 7. MAIN TRANSFORMER 8. CHOKE 9. HIGH VOLTAGE TRANSFORMER 10.
SYMPTOM Machine will not turn on. Control circuit fuse (F1) keeps blowing. Digital meter does not light, but welder turns on as indicated by the Pilot Light and fan operation. Accessories plugged into 115 volt recep- tacle do not work.
STICK WELDING CAUSE AND REMEDY Welder has overheated and secondary thermostat has opened. Allow welder to cool before attempting to turn on. Be sure to provide adequate ventilation around welder to prevent recurrence. Weld current is set too high for electrode size. Reduce weld current.
TROUBLESHOOTING GUIDE SYMPTOM Machine does not respond (no gas flow, no high frequency, no open circuit voltage) when Arc Start Switch or Amptrol is pressed. No gas or water flow when Arc Start Switch is closed in TIG mode. No High Frequency. Weak high frequency.
TROUBLESHOOTING GUIDE SYMPTOM Machine has gas flow and high frequency but no open circuit voltage when the Arc Start Switch or Amptrol is pressed. Difficulty in getting tungsten to “light off”. Machine welds only at minimum output when the Current Control switch is in the REMOTE position.
The Start Current dial is labeled MIN to MAX of the welder output or, 2 to 400 amps. Always be sure to use the Start Read pushbutton to check the Start Current preset reading on the digital ammeter before welding.
Ground the shield to terminal 1 or 2 on TS701. Be sure that the white ground lead is on the Interface PC board tab terminal and is connected to the welder chassis screw. SQUARE WAVE TIG 355 Observe Safety Guidelines detailed throughout this manual.
The above identified equipment has been installed and will be operated and maintained in compliance with manufacturer’s recommendations made in the accompanying oper- ating manual. Certifying Signature & Title Date THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO U.S.A. The Lincoln Electric Company S14929 (9-2-83E)
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