Lincoln Electric SQUARE WAVE SVM118-A Service Manual
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Lincoln Electric SQUARE WAVE SVM118-A Service 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.
World's Leader in Welding and Cutting Products
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
RETURN TO MAIN INDEX
For use with machines having Code Numbers:

SERVICE MANUAL

Sales and Service through subsidiaries and Distributors Worldwide
SVM118-A
9951
9952
9953
9954
9955
Premier Manufacturer of Industrial Motors
August, 1998

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Summary of Contents for Lincoln Electric SQUARE WAVE SVM118-A

  • 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

    “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.
  • Page 3 WELDING SPARKS can cause fire or explosion. 4.a. Remove fire hazards from the weld- ing area. If this is not possible, cover them to prevent the welding sparks from Remember that sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 4 FOR ENGINE powered equipment. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. 7.c. Do not add the fuel near an open flame welding arc or when the engine is run- ning.
  • 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 Protegez-vous contre la secousse électrique: Les circuits à...

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety...i-iv Installation ...Section A Installation Section Table of Contents ...A-1 Technical Specifications ...A-2 Safety Precautions...A-3 Select Suitable Location (Stacking, Tilting, Lifting) ...A-3 High Frequency Interference Protection...A-3 Input Connections...A-4 Reconnect Procedure ...A-5 Output Connections...A-7 Operation...Section B Safety Instructions ...B-2 General Description ...B-3...
  • Page 7 Section A-1 - INSTALLATION SECTION - Installation Technical Specifications Square Wave TIG 355 ...A-2 Input and Output Specifications ...A-2 Cable and Fuse Sizes...A-2 Physical Dimensions ...A-2 Safety Precautions...A-3 Select Suitable Location ...A-3 Stacking...A-3 Lifting ...A-3 Tilting ...A-3 High Frequency Precautions...A-3 Input Connections...A-4 Ground Connection ...A-4 Input Supply Connections...A-4...

  • Page 8: 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 9: 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 10: 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 11: 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 12 440/50 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 13: 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 14: 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 15 Section B-1 - OPERATION SECTION - Operation...Section B Safety Instructions ...B-2 General Description ...B-3 Recommended Processes ...B-3 Operational Features and Controls ...B-3 Design Features and Advantages ...B-3 Welding Capability...B-4 Limitations ...B-4 Controls and Settings ...B-5 Upper Case Front Controls ...B-5 Lower Case Front Controls ...B-11 Hand and Foot Amptrol™...

  • 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. • 220 Volt European (Schuko) type receptacle with 2 amp circuit breaker for water coolers (50/60Hz machines only). • Excellent arc starting and stability up through 400 amps. • High resistance to AC arc rectification. •...

  • Page 19: Controls And Settings (Upper And Lower Case Front Controls

    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. If the Background Current control is set at 50%, the Background (low pulse) current will be 15 amps. The Amptrol raises and lowers the Peak current.
  • Page 24 B-10 • 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-11 B-11 OPERATION LOWER CASE FRONT CONTROLS Refer to Figure B.3 for the location of the following controls. FIGURE B.3 – LOWER CASE FRONTCONTROLS SQUARE WAVE TIG 355...
  • 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-13 HAND AND FOOT AMPTROL OPERATION Both the Hand and Foot Amptrol (optional kits K870 or K812) 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-14 B-14 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-16 (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-17 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-18 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 B-19 TYPICAL CURRENT RANGES DCEN (-) DCEP (+) Tungsten Electrode 1%, 2% 1%, 2% Diameter Thoriated Thoriated in. (mm) Tungsten 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...

  • Page 34: Tig Welding Sequence Of Operation (2-Step Mode

    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 Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES - Accessories...Section C Options/Accessories...C-2 SQUARE WAVE TIG 355...
  • Page 37 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 38 Section D-1 Section D-1 TABLE OF CONTENTS -MAINTENANCE- Maintenance ...Section D Safety Precautions...D-2 Input Filter Capacitor Discharge Procedure ...D-2 Routine and Periodic Maintenance ...D-3 General Component Locations...D-4 SQUARE WAVE TIG 355...

  • Page 39: Safety Precautions

    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 40: 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 41: 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 42 Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E General Description ...E-2 Input Power Circuit: Input Voltage, Contactor, Reconnect Panel, Pilot Transformer, Control Transformer, Power Factor Capacitors, and Main Transformer...E-2 Output Rectification and Feedback Control ...E-3 High Voltage/High Frequency Circuit...E-4 DC Welding Output ...E-5 AC Welding Output ...E-6 SCR Operation ...E-7...

  • Page 43: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 – INPUT VOLTAGE, CONTACTOR, RECONNECT PANEL, PILOT TRANSFORMER, CONTROL TRANSFORMER, POWER FACTOR CAPACITORS AND MAIN TRANSFORMER HIGH FREQUENCY SPARK ELECTRODE SENSE UPPER PANEL CONTROL SWITCHES PANEL ELECTRODE SENSE HIGH VOLTAGE 115VAC TRANSFORMER REMOTE CIRCUIT FEED - THRU RECEPTACLE TRIGGER BOARD...

  • Page 44: Output Rectification And Feedback Control

    THEORY OF OPERATION FIGURE E.3 – OUTPUT RECTIFICATION AND FEEDBACK CONTROL HIGH FREQUENCY SPARK ELECTRODE SENSE UPPER PANEL CONTROL SWITCHES PANEL ELECTRODE SENSE HIGH VOLTAGE 115VAC TRANSFORMER REMOTE CIRCUIT FEED - THRU RECEPTACLE TRIGGER BOARD REMOTE GAS/WATER COMMANDS SOLENOIDS 115VAC INTERLOCK INTERLOCK 115VAC -...

  • Page 45: High Voltage/High Frequency Circuit

    THEORY OF OPERATION FIGURE E.4 – HIGH VOLTAGE/HIGH FREQUENCY CIRCUIT HIGH FREQUENCY SPARK ELECTRODE SENSE UPPER PANEL CONTROL SWITCHES PANEL ELECTRODE SENSE HIGH VOLTAGE 115VAC TRANSFORMER REMOTE CIRCUIT FEED - THRU RECEPTACLE TRIGGER BOARD REMOTE GAS/WATER COMMANDS SOLENOIDS 115VAC INTERLOCK INTERLOCK HI-FREQ AND GAS/WATER 115VAC -...

  • Page 46: Dc Welding Output

    THEORY OF OPERATION FIGURE E.5 – DC WELDING OUTPUT CIRCUIT HIGH FREQUENCY SPARK ELECTRODE SENSE UPPER PANEL CONTROL SWITCHES PANEL ELECTRODE SENSE HIGH VOLTAGE 115VAC TRANSFORMER REMOTE CIRCUIT FEED - THRU RECEPTACLE TRIGGER BOARD GAS/WATER REMOTE COMMANDS SOLENOIDS 115VAC INTERLOCK INTERLOCK 115VAC - HI-FREQ AND GAS/WATER...

  • Page 47: Ac Welding Output

    THEORY OF OPERATION FIGURE E.6 – AC WELDING OUTPUT CIRCUIT HIGH FREQUENCY SPARK ELECTRODE SENSE UPPER PANEL CONTROL SWITCHES PANEL ELECTRODE SENSE HIGH VOLTAGE 115VAC TRANSFORMER REMOTE CIRCUIT FEED - THRU RECEPTACLE TRIGGER BOARD REMOTE GAS/WATER COMMANDS SOLENOIDS 115VAC INTERLOCK INTERLOCK HI-FREQ AND GAS/WATER 115VAC -...

  • Page 48: Scr Operation

    THEORY OF OPERATION SCR OPERATION A silicon controlled rectifier (SCR) is a three-terminal device used to control rather large currents to a load. An SCR acts very much like a switch. When a gate signal is applied to the SCR, it is turned ON and there is current flow from anode to cathode.

  • Page 49: Protective Circuits

    THEORY OF OPERATION PROTECTIVE CIRCUITS Protective circuits are designed into the Square Wave TIG 355 to sense trouble and shut down the machine before the trouble damages the internal machine com- ponents. Both thermal protection and current over- load are included. THERMAL PROTECTION Thermostats protect the machine from excessive operating temperatures.

  • Page 50: How To Use Troubleshooting Guide

    Section F-1 -TROUBLESHOOTING & REPAIR SECTION- Troubleshooting & Repair Section...Section F How to Use Troubleshooting Guide...F-2 PC Board Troubleshooting Procedures and Replacement...F-3 Troubleshooting Guide ...F-4 Test Procedures ...F-20 Input Power Factor Capacitor Voltage Check and Discharge Procedure...F-20 ARC Start Trigger Circuit Test...F-22 Power Board Test ...F-25 Input Contactor Test ...F-28 Pilot Transformer Test ...F-32...

  • Page 51: Troubleshooting And Repair

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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.

  • Page 52: Pc Board Troubleshooting Procedures And Replacement

    • If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete. • If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shield- ing bag. This will prevent further damage and allow proper failure analysis.

  • Page 53: Troubleshooting Guide

    – no displays. 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 216-383-2531 or 1-800-833-9353.

  • Page 54: Troubleshooting Guide

    (F1) repeatedly fails. 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 216-383-2531 or 1-800-833-9353.
  • Page 55 Stick or TIG modes. 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 216-383-2531 or 1-800-833-9353.
  • Page 56 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 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.
  • Page 57 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 216-383-2531 or 1-800-833-9353.
  • Page 58 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 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.
  • Page 59 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 216-383-2531 or 1-800-833-9353.
  • Page 60 LEDs are lit. 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 216-383-2531 or 1-800-833-9353.
  • Page 61 TIG Mode and has normal output. 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 216-383-2531 or 1-800-833-9353.
  • Page 62 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 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.
  • Page 63 TIG 4-Step mode. 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 216-383-2531 or 1-800-833-9353.
  • Page 64 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 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.
  • Page 65 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 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.
  • Page 66 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 216-383-2531 or 1-800-833-9353.
  • Page 67 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 216-383-2531 or 1-800-833-9353.
  • Page 68 TIG mode. 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 216-383-2531 or 1-800-833-9353.

  • Page 69: Input Power Factor Capacitor Voltage Check And Discharge Procedure

    INPUT POWER FACTOR CAPACITOR VOLTAGE CHECK AND DISCHARGE PROCEDURE 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 manual.
  • Page 70 F-21 TROUBLESHOOTING & REPAIR INPUT POWER FACTOR CAPACITOR VOLTAGE CHECK AND DISCHARGE PROCEDURE (continued) FIGURE F.1 – POWER FACTOR CAPACITOR DISCHARGE DETAILS TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the sheet metal screws that hold the right case side in place.

  • Page 71: Arc Start Trigger Circuit Test

    TROUBLESHOOTING & REPAIR ARC START TRIGGER CIRCUIT TEST 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 manual.
  • Page 72 F-23 TROUBLESHOOTING & REPAIR ARC START TRIGGER CIRCUIT TEST (continued) FIGURE F.2 – 6-PIN AMPHENOL RECEPTACLE TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the screws and carefully lower the front control panel.
  • Page 73 F-24 TROUBLESHOOTING & REPAIR ARC START TRIGGER CIRCUIT TEST (continued) FIGURE F.3 – ARC START TRIGGER CIRCUIT CONTROL TRANSFORMER CONTROL BOARD 24VAC FEED - THRU PROTECTION BOARD BOARD #204 1J16 1J18 8J23 4.2 ohms 4.2 ohms max. max. #207 3J16 5J18 5J23 4.2 ohms...

  • Page 74: Power Board Test

    F-25 TROUBLESHOOTING & REPAIR 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 manual.
  • Page 75 F-26 TROUBLESHOOTING & REPAIR POWER BOARD TEST (continued) FIGURE F.4 - POWER BOARD TEST POINTS G2081-[ TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the screws and carefully lower the front control panel.
  • Page 76 F-27 TROUBLESHOOTING & REPAIR POWER BOARD VOLTAGE TEST CHART Check Points Signals Being IJ4 to 2J4 AC supply voltage from T5 transformer 4J4 to 6J4 AC supply voltage from T5 transformer 4J4 to 5J4 AC supply voltage from T5 transformer 10J4 to 12J4 AC supply voltage from T5 transformer...

  • Page 77: Input Contactor Test

    F-28 TROUBLESHOOTING & REPAIR 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 electri- cal shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 78 F-29 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (continued) FIGURE F.5 - INPUT CONTACTOR TEST POINTS TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the machine top and sides. 3. Locate the two leads, #243 and #244, con- nected to the input contactor coil.
  • Page 79 F-30 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (continued) • If 120 VAC is present when the Start button is held in but the contactor does not stay activated when the button is released, check the CR1 interlock, the power Start/Stop pushbutton, and associated circuitry.
  • Page 80 F-31 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (continued) FIGURE F.6 - INPUT CONTACTOR (CR1) SIMPLIFIED CONTROL CIRCUIT STOP START T2 PILOT INTERLOCK TRANSFORMER #243 CR 1 #244 N. C. SECONDARY THERMOSTAT .33 OHMS MAX. 9J15 3J17 #241 #272 CR 1 .33 OHMS MAX.

  • Page 81: Pilot Transformer Test

    TROUBLESHOOTING & REPAIR PILOT TRANSFORMER TEST 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 manual.
  • Page 82 F-33 TROUBLESHOOTING & REPAIR PILOT TRANSFORMER TEST (continued) FIGURE F.7 - PILOT TRANSFORMER CONNECTIONS TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the machine top and sides. 3. Locate terminals X1 and X2 connected to the pilot transformer secondary.

  • Page 83: Feed-Thru Pc Board Test

    TROUBLESHOOTING & REPAIR FEED-THRU PC BOARD TEST 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 manual.
  • Page 84 F-35 TROUBLESHOOTING & REPAIR FEED-THRU PC BOARD TEST (continued FIGURE F.8 - FEED-THRU PC BOARD LOCATION TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the machine top and sides. 3. Perform the power factor capacitor dis- charge procedure.
  • Page 85 F-36 F-36 TROUBLESHOOTING & REPAIR FEED-THRU PC BOARD TEST (continued) FIGURE F.9 - FEED-THRU PC BOARD PLUG DETAILS – PLUGS J15 AND J16 FIGURE F.10 - FEED-THRU PC BOARD PLUG DETAILS – PLUGS J17 AND J18 7 6 5 8 7 6 3 2 1 VIEW FROM EDGE OF BOARD SQUARE WAVE TIG 355...
  • Page 86 F-37 TROUBLESHOOTING & REPAIR FEED-THRU PC BOARD TEST (continued) FEED THRU PC BOARD RESISTANCE TEST POINTS Check Points 5J15 to 7J17 4J15 to 6J17 6J15 to 10J17 7J15 to 9J17 10J15 to 4J17 2J15 to 1J17 8J15 to 2J17 9J15 to 3J17 1J15 to 5J17 1J16 to 1J18 2J16 to 8J17...

  • Page 87: Protection Pc Board Test

    TROUBLESHOOTING & REPAIR PROTECTION PC BOARD TEST 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 manual.
  • Page 88 F-39 TROUBLESHOOTING & REPAIR PROTECTION PC BOARD TEST (continued) FIGURE F.11- PROTECTION PC BOARD LOCATION AND MOUNTING DETAILS TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the screws and carefully lower the front control panel.
  • Page 89 F-40 TROUBLESHOOTING & REPAIR PROTECTION PC BOARD TEST (continued) PROTECTION PC BOARD RESISTANCE TEST POINTS CHART Test Points 1J22 to 3J23 2J22 to 4J23 3J22 to 7J23 5J22 to 1J23 4J22 to 2J23 6J22 t 5J23 3J22 to 8J23 7J23 to 8J23 Component(s) Being Tested L1 and Board Trace...

  • Page 90: Main Transformer Test

    F-41 TROUBLESHOOTING & REPAIR 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 manual.
  • Page 91 F-42 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST (continued) FIGURE F.12 - MAIN TRANSFORMER LOCATION AND WIRING DETAILS TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the machine top and sides. 3. Perform the power factor capacitor dis- charge procedure.
  • Page 92 F-43 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST (continued) 7. Check the voltages at the test points listed on the Main Transformer Voltage Test Points Chart. NOTE: Readings will fluctuate if line voltages fluctuate. • If any of the secondary or auxiliary voltages is missing or out of specification and the correct input voltage is applied to the prima- ry winding, the main transformer may be...

  • Page 93: Control Transformer (T5) Voltage Test

    TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T5) VOLTAGE TEST 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 manual.
  • Page 94 F-45 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T5) VOLTAGE TEST (continued) FIGURE F.13 - LOCATION OF CONTROL BOARD AND CONTROL TRANSFORMER TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16” nut driver, remove the machine case top and sides. 3.
  • Page 95 F-46 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T5) VOLTAGE TEST (continued) 6. Check fuse F1 (0.5 amp). Test the resis- tance from 6J15, on the feed-thru PC board, to the #265 lead at the control trans- former. Also check the resistance from 7J15, on the feed-thru PC board, to the #266 lead at the control transformer.

  • Page 96: Control Board Test

    F-47 TROUBLESHOOTING & REPAIR 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 manual.
  • Page 97 F-48 TROUBLESHOOTING & REPAIR CONTROL PC BOARD TEST (continued) FIGURE F.15 – CONTROL PC BOARD LOCATION TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16” nut driver, remove the screws and carefully lower the case front control panel.
  • Page 98 F-49 TROUBLESHOOTING & REPAIR CONTROL PC BOARD TEST (continued) FIGURE F.16 – CONTROL PC BOARD PLUG DETAILS G2512-[ CONTROL PLUG J13 LOCATION 6. Check the test points for the appropriate voltages. See Figure F.16. • If the correct voltages are applied to the control PC board and the correct voltage signals are NOT being generated by the control PC board, the control PC board may...
  • Page 99 F-50 TROUBLESHOOTING & REPAIR CONTROL PC BOARD TEST (continued) CONTROL PC BOARD VOLTAGE TEST POINTS CHART Test Points 3J13 to 5J13 4J13 to 5J13 1J13 to 2J13 R11 to 5J13 R32 to 5J13 R13 to 5J13 R66 to 5J13 R8 to 5J13 Signals Being Expected Checked...

  • Page 100: Static Scr Test

    F-51 TROUBLESHOOTING & REPAIR 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 manual.
  • Page 101 F-52 TROUBLESHOOTING & REPAIR FIGURE F.17 – POWER PC BOARD PLUG LOCATIONS G2081-[ TEST PROCEDURE 1. Remove the input power to the machine. 2. With the 5/16” nut driver, remove the machine case top and sides. 3. Perform the Input Power Factor Capacitor Voltage Check and Discharge procedure.
  • Page 102 F-53 TROUBLESHOOTING & REPAIR SCR 3 & 4 Anode and Negative Plate Cathode SCR1 & 2 Cathode and Positive Plate STATIC SCR TEST (continued) FIGURE F.18 – SCR TEST POINTS SCR4 SCR1 Anode SQUARE WAVE TIG 355 F-53 SCR3 Cathode Anode Choke SCR2...

  • Page 103: Active Scr Test

    F-54 TROUBLESHOOTING & REPAIR 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 manual.
  • Page 104 F-55 TROUBLESHOOTING & REPAIR FIGURE F.19 - POWER BOARD PLUG LOCATIONS G2081-[ TEST PROCEDURE 1. Remove the input power to the machine. 2. With the 5/16” nut driver, remove the machine case top and sides. 3. Perform the Input Power Factor Capacitor Voltage Check and Discharge procedure.
  • Page 105 F-56 TROUBLESHOOTING & REPAIR SCR 3 & 4 Anode and Negative Plate Cathode SCR1 & 2 Cathode and Positive Plate ACTIVE SCR TEST (continued) FIGURE F.20 – SCR TEST POINTS SCR4 SCR1 Anode SQUARE WAVE TIG 355 F-56 SCR3 Cathode Anode Choke SCR2...
  • Page 106 F-57 TROUBLESHOOTING & REPAIR FIGURE F.21 - SILICON CONTROLLED RECTIFIER TEST SETUP. To test SCRs construct the circuit outlined above. Resistor values are plus or minus ten percent. The voltmeter scale should be low, approximately 0-5 or 0-10 volts DC. SILICON CONTROLLED RECTIFIER TEST (Heat Sink Mounted Units)

  • Page 107: Normal Open Circuit Voltage Waveform (Dc Stick Mode

    F-58 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. DC STICK MODE CAUTION 2 ms 50 volts This is the typical DC (+) output volt- age waveform generated from a properly operating machine.

  • Page 108: Normal Open Circuit Voltage Waveform (Ac Stick Mode

    F-59 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. AC STICK MODE CAUTION 2 ms 50 volts This is the typical AC output voltage waveform generated from a properly operating machine.

  • Page 109: Normal Open Circuit Voltage Waveform (Dc Tig Mode

    F-60 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. DC TIG MODE CAUTION 2 ms 50 volts This is the typical DC (+) output volt- age waveform generated from a properly operating machine.

  • Page 110: Normal Open Circuit Voltage Waveform (Ac Tig Mode

    F-61 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. AC TIG MODE CAUTION 2 ms 50 volts This is the typical AC output voltage waveform generated from a properly operating machine.

  • Page 111: Typical Output Voltage Waveform - Machine Loaded (Dc Tig Mode

    F-62 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. DC TIG MODE CAUTION 2 ms 20 volts MACHINE LOADED TO 350 AMPS AT 34VDC This is a typical DC (+) output voltage...

  • Page 112: Ac Tig Mode (Balanced Waveform

    F-63 TROUBLESHOOTING & REPAIR AC TIG MODE (BALANCED WAVEFORM) HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. CAUTION 2 ms 20 volts MACHINE LOADED TO 350 AMPS AT 34VAC This is a typical AC output voltage waveform generated from a properly...

  • Page 113: Abnormal Open Circuit Voltage - (Dc Tig Mode, One Output Scr Not Functioning

    F-64 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE – DC TIG MODE ONE OUTPUT SCR NOT FUNCTIONING HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. CAUTION 2 ms 50 volts This is NOT the typical DC (+) output voltage waveform.

  • Page 114: Abnormal Open Circuit Voltage - (Ac Tig Mode, One Output Scr Not Functioning

    F-65 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE – AC TIG MODE ONE OUTPUT SCR NOT FUNCTIONING HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. CAUTION 2 ms 50 volts This is NOT the typical AC output voltage waveform.

  • Page 115: Control Pc Board Removal And Replacement

    TROUBLESHOOTING & REPAIR CONTROL PC BOARD REMOVAL AND REPLACEMENT 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 manual.
  • Page 116 F-67 TROUBLESHOOTING & REPAIR CONTROL PC BOARD REMOVAL AND REPLACEMENT (continued) TEST PROCEDURE Before starting the following procedure, refer to the topic "PC Board Troubleshooting Procedures" at the beginning of this section. 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the sheet metal screws that hold the front control panel in place.

  • Page 117: Power Pc Board Removal And Replacement

    TROUBLESHOOTING & REPAIR POWER PC BOARD REMOVAL AND REPLACEMENT 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 manual.
  • Page 118 F-69 TROUBLESHOOTING & REPAIR POWER PC BOARD REMOVAL AND REPLACEMENT (continued) G2081-[ PROCEDURE Before starting the following procedure, refer to the topic "PC Board Troubleshooting Procedures" at the beginning of this section. 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the sheet metal screws that hold the front control panel in place.

  • Page 119: Input Contactor (C1) Removal And Replacement

    TROUBLESHOOTING & REPAIR INPUT CONTACTOR REMOVAL AND REPLACEMENT 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 manual.
  • Page 120 F-71 TROUBLESHOOTING & REPAIR INPUT CONTACTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.24 – INPUT CONTACTOR CONNECTIONS PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the case top and sides. 3. Perform the Input Power Factor Capacitor Voltage Check.
  • Page 121 F-72 TROUBLESHOOTING & REPAIR INPUT CONTACTOR REMOVAL AND REPLACEMENT (continued) 13. Replacement: Mount the contactor brack- et assembly to the case back and attach it with the 4 mounting screws. 5/16" nut driver. 14. Attach leads #243 and #242 to the con- tactor interlock located on the bottom of the contactor.

  • Page 122: Fan Motor And Blade Removal And Replacement

    TROUBLESHOOTING & REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT 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 manual.
  • Page 123 F-74 TROUBLESHOOTING & REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (continued) FIGURE F.25- FAN MOTOR AND BLADE MOUNTING DETAILS PROCEDURE The following procedure allows you to remove and replace either of the two fans on the Square Wave TIG 355. 1.

  • Page 124: Output Rectifier Removal And Replacement

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT 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 manual.
  • Page 125 F-76 F-76 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) FIGURE F.26 – OUTPUT RECTIFIER CONNECTION DETAILS Step 13 Step 12 Step 11 Step 10 Step 7 Step 5 Step 9 Step 6 Step 15 Step 8 SQUARE WAVE TIG 355...
  • Page 126 F-77 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the case top and sides. 3. Perform the Input Power Factor Capacitor Voltage Check. For Steps 4-27, refer to Figure F.26. 4.

  • Page 127: Scr Removal And Replacement

    TROUBLESHOOTING & REPAIR SCR REMOVAL AND AND REPLACEMENT 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 manual.
  • Page 128 SCR mounting surfaces. 7. Apply a thin (0.001” to 0.003”) layer of PEN- ETROX A-13 (Lincoln Electric #E2529) or PENETROX A, heat sink compound, to each heat sink’s SCR mounting surface.
  • Page 129 F-80 TROUBLESHOOTING & REPAIR SCR REMOVAL AND AND REPLACEMENT 8. Place the new SCR betwen the heat sinks. Be sure that the outer metal ring of the SCR is facing toward the same heat sink as the old SCR’s metal ring. Be sure that the roll pin of the heat sink engages the “hole”...
  • Page 130 F-81 TROUBLESHOOTING & REPAIR SCR REMOVAL AND AND REPLACEMENT FIGURE F.29 – SCR CLAMP ASSEMBLY DETAILS – 1/2” WIDE SPRING Cap Screw Leaf Spring Heat Sink Plain Washer Clamp Nut 5) Re-inspect the SCR for proper seating. 6) Clamp the cap screws. Use the procedure for 1/4-28 cap screws or 1/4-20 bolts, depending on which you have.
  • Page 131 F-82 TROUBLESHOOTING & REPAIR SCR REMOVAL AND AND REPLACEMENT FIGURE F.30 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING B. PROCEDURE FOR THE 5/8 INCH WIDE SPRING: 1) Place a piece of sleeving around each cap screw. 2) Insert the cap screws through the leaf spring.
  • Page 132 F-83 TROUBLESHOOTING & REPAIR SCR REMOVAL AND AND REPLACEMENT FIGURE F.31 – SCR CLAMP ASSEMBLY DETAILS – 5/8” WIDE SPRING Cap Screw Leaf Spring Heat Sink Plain Washer Clamp Nut Clamping procedure for 1/4-20 cap screws. Note: This procedure can only be used with 1/4-20 cap screws.

  • Page 133: Retest After Repair

    F-84 TROUBLESHOOTING & REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components. NOTE: 50 Hz machines may be tested using 60 Hz power.
  • Page 134 F-85 TROUBLESHOOTING & REPAIR RECOMMENDED METERS FOR MACHINE OUTPUT TESTS VOLTMETER: AC and DC True RMS Meter – Fluke 8922A or equivalent AMMETER: Columbia Type AX AC or DC Tong Ammeter IMPORTANT: IF OTHER TYPE METERS ARE USED RESULTS MAY NOT BE ACCURATE FIGURE F32.
  • Page 135 TABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagram Section ....... . . Section G Wiring Diagram .
  • Page 136 NOTES SQUARE WAVE TIG 355...

  • Page 137: Wiring Diagram

    MODE 2 STEP/4 STEP FREQUENCY UNLESS OTHERWISE SPECIFIED TOLERANCE THIS SHEET CONTAINS PROPRIETARY INFORMATION THE LINCOLN ELECTRIC CO. ON HOLE SIZES PER E2056 OWNED BY AND IS ON 2 PLACE DECIMALS IS .02 NOT TO BE REPRODUCED, DISCLOSED OR USED 5-14-93F ON 3 PLACE DECIMALS IS .002...

  • Page 138: Machine Schematic

    WORK LEAD COLOR CODING 0.5 A B=BLACK N=BROWN 1.5 A R=RED CONNECTOR PIN NUMBERS: 115V/15A VIEW OF CONNECTOR ON PC BOARD .22/400V EQUIP. THE LINCOLN ELECTRIC CO. TYPE CLEVELAND, OHIO U.S.A. SUBJECT SCALE NONE G2113 DATE 4-2-92 REF. 8/98 .0047/...

  • Page 139: Meter Pc Board (M15893) Schematic

    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.

  • Page 140: Feed Through Pc Board (L8096) Schematic

    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.

  • Page 141: Electrical Diagrams

    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.

  • Page 142: Power Pc Board (G2081) Schematic

    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.

  • Page 143: Control Pc Board (G2512) Schematic

    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.

  • Page 144: Protection Pc Board (M16062) Layout

    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.

  • Page 145: Power Pc Board (G2081) Layout

    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.

  • Page 146: Bypass Pc Board (M15299) Layout

    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.

  • Page 147: Feed Through Pc Board (L8096) Layout

    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.

  • Page 148: Control Pc Board (G2512) Layout

    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.

  • Page 149: Meter Pc Board (M15893) Layout

    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.

This manual is also suitable for:

Square wave tig 355

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