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Lincoln Electric SQUARE WAVE IM467-B Operator's Manual

Lincoln electric welder user manual
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SQUARE WAVE TIG 355

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.
• 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
RETURN TO MAIN MENU
For use with machines having Code Numbers:
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
IM467-B
9951, 10056, 10389
9952, 10057, 10390
9953, 10058
9954, 10059
9955, 10060
Copyright © 2003 Lincoln Global Inc.
May, 2003

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Summary of Contents for Lincoln Electric SQUARE WAVE IM467-B

  • Page 1: Square Wave Tig

    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.

  • Page 2: Safety

    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.
  • 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 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.

  • Page 7: Table Of Contents

    Safety...i-iv Installation ...Section A Technical Specifications Square Wave TIG 355 ...A-1 Input and Output Specifications ...A-1 Cable and Fuse Sizes...A-1 Physical Dimensions ...A-1 Safety Precautions...A-2 Select Suitable Location ...A-2 Stacking...A-2 Lifting ...A-2 Tilting ...A-2 High Frequency Precautions...A-2 Input Connections...A-3 Ground Connection ...A-3 Input Supply Connections...A-3 Reconnect Procedure ...A-4 Output Connections...A-6...
  • Page 8 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...

  • Page 9: Installation

    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.

  • Page 10: Safety Precautions

    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.

  • Page 11: Input Connections

    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.

  • Page 12: Reconnect Procedure

    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.
  • Page 13 440/50 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...

  • Page 14: Output Connections

    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.

  • Page 15: Stick Electrode Cable Connection

    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.

  • Page 16: Operation

    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.

  • Page 17: General Description

    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.

  • Page 18: Welding Capability

    • 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.

  • Page 19: Controls And Settings

    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.
  • Page 20 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”...
  • Page 21 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.
  • Page 22 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.
  • Page 23 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.
  • Page 24 • 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).

  • Page 25: Lower Case Front Controls

    B-10 LOWER CASE FRONT CONTROLS Refer to Figure B.3 for the location of the following controls. FIGURE B.3 – LOWER CASE FRONTCONTROLS OPERATION SQUARE WAVE TIG 355 B-10...
  • Page 26 (more than 40% over rated voltage). If this fuse blows, the digital meters will not light and the input contactor will not latch when the Power On/Off Start pushbutton is pressed and released.

  • Page 27: Hand And Foot Amptrol Operation

    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.
  • Page 28 B-13 B-13 OPERATION FIGURE B.4 – AMPTROLS USED WITH CURRENT CONTROL IN THE LOCAL POSITION FIGURE B.5 – AMPTROLS USED WITH CURRENT CONTROL IN REMOTE POSITION SQUARE WAVE TIG 355...

  • Page 29: Welding Operation

    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.
  • Page 30 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...
  • Page 31 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...
  • Page 32 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.

  • Page 33: Square Wave Tig

    B-18 TYPICAL CURRENT RANGES DCEN (-) DCEP (+) 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 25-40 5/32 (4.0)

  • Page 34: Square Wave Tig

    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.

  • Page 35: Overload Protection

    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...

  • Page 36: Accessories

    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...

  • Page 37: Maintenance

    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.

  • Page 38: Routine And Periodic Maintenance

    • 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.

  • Page 39: General Component Locations

    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.

  • Page 40: Troubleshooting

    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.

  • Page 41: Troubleshooting Guide

    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.

  • Page 42: Tig Welding

    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.
  • Page 43 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.
  • Page 44 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.
  • Page 45 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.
  • Page 46 DIAGRAMS SQUARE WAVE TIG 355...
  • Page 47 DIAGRAMS SQUARE WAVE TIG 355...
  • Page 48 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)
  • Page 49 Notes...
  • Page 50 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 51 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 52 • 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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