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Lincoln Electric SQUARE WAVE TIG 255 SVM100-A manual

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Table of contents for the manual

  • Page 1

    SQU ARE W A VE TIG 255 SER VICE MANUAL Sales and Service through Subsidiaries and Distributors Worldwide 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100 World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors SVM100-A December 1995 Safety Depends on You Lincoln arc welding and cutting[...]

  • Page 2

    i SAFETY SQUARE WAVE TIG 255 PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur- chase a copy of “Safety in Welding[...]

  • Page 3

    ii SQUARE WAVE TIG 255 SAFETY FOR ELECTRICALL Y powered equipment. 6.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 6.c. Ground the equipment in accordance with [...]

  • Page 4

    iii SAFETY SQUARE WAVE TIG 255 Mar. ‘93 ELECTRIC AND MAGNETIC FIELDS may be dangerous 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines 8.b. EMF fields may interfere with some pacemakers, and welders having a pacema[...]

  • Page 5

    iv SAFETY SQUARE WAVE TIG 255 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions 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: [...]

  • Page 6

    MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety .........................................................................................................................i-iv Installation ......................................................................................................Section A Technical Specifications ...................[...]

  • Page 7

    Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Input and Output Specifications Cable and Fuse Sizes Physical Dimensions Location .........................[...]

  • Page 8

    A-1 INST ALLA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TECHNICAL SPECIFICA TIONS – SQUARE W A VE TIG 255 For all Stick, DC TIG, and Balanced AC TIG Welding at 255A/30V/40% Duty Cycle Based on [...]

  • Page 9

    A-2 INST ALLA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Read entire installation section before starting installation. SAFETY PRECAUTIONS SELECT SUIT ABLE LOCA TION Place the welder where clean c[...]

  • Page 10

    A-3 INST ALLA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 gr[...]

  • Page 11

    A-4 INST ALLA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RECONNECT PROCEDURE On multiple input voltage welders, be sure the recon- nect panel is connected per the following instructions for the vo[...]

  • Page 12

    A-5 INST ALLA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DO NOT operate a water-cooled torch unless water is flowing. Water doesn’t flow until solenoid is actuated. If using a water-cooled torch[...]

  • Page 13

    Operation ..........................................................................................................Section B Safety Precautions .................................................................................................B-1 Graphic Symbols ........................................................................................[...]

  • Page 14

    B-1 OPERA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and g[...]

  • Page 15

    B-2 OPERA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ON 2 A TIG 2-STEP TIG 4-STEP STICK CURRENT CONTROL OUTPUT LOCAL CUR- RENT CON- TROL REMOTE CUR- RENT CON- TROL INCREASE OUTPUT DECREASE HIGH FR[...]

  • Page 16

    B-3 OPERA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OVER TEMPER- A TURE INPUT POWER DC+ POLARITY DC- POLARITY DO NOT SWITCH WHILE WELD- ING W ARNING W A TER (COOLANT) OUTPUT W A TER (COOLANT) INP[...]

  • Page 17

    B-4 OPERA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC • Welding current limit can be preset from 5 to 315 amps and is displayed on the Ammeter when not welding. • Auto Balance circuitry automat[...]

  • Page 18

    B-5 OPERA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC • Strain relief holes in base for welding cables, gas and water hoses and control cables. • Easy access for input connections. Connections [...]

  • Page 19

    B-6 OPERA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 4. AC WAVE BALANCE: These keys are active in the AC TIG mode only. They are used to set the amount of cleaning and/or penetration produced duri[...]

  • Page 20

    B-7 OPERA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A. AC/DC INDICATOR: This symbol represents the output polarity of the 255 . . . either AC or DC. AC is shown in Figure B.2.a; DC is shown in Fi[...]

  • Page 21

    B-8 OPERA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TABLE B.1 RECOMMENDED POLARITY SETTINGS FOR TIG WELDING Type of Welding Electrode Polarity High Frequency Setting Stainless Steel Aluminum &[...]

  • Page 22

    B-9 OPERA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 5. Select Continuous High Frequency if welding with AC polarity, or Start Only High Frequency if welding with DC- polarity. High Frequency Off [...]

  • Page 23

    B-10 OPERA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 5. Select Continuous High Frequency if welding with AC polarity, or Start Only High Frequency if welding with DC- polarity. High Frequency Off[...]

  • Page 24

    B-1 1 OPERA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Up/Down. Adjustment of the pulses per second (pulse frequency), allows for control of the heat input into the work piece. This adjustment can[...]

  • Page 25

    B-12 OPERA TION SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Note that some types of equipment, especially pumps and motors, have starting currents which are signifi- cantly higher than their running cur[...]

  • Page 26

    B-13 NOTES SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 27

    SQUARE WAVE TIG 255 Accessories ......................................................................................................Section C Available Option and Accessories .........................................................................C-1 Undercarriage Function .........................................................................[...]

  • Page 28

    C-1 ACCESSORIES SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPTIONS / ACCESSORIES • Hand Amptrol (K812) • Foot Amptrol (K870) • Arc Start Switch (K814) • Magnum Cooler Horizontal TIG Mounting Br[...]

  • Page 29

    Maintenance .....................................................................................................Section D Safety Precautions .................................................................................................D-1 Routine and Periodic Maintenance ........................................................................D-[...]

  • Page 30

    D-1 MAINTENANCE SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRIC SHOCK can kill. • Only qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch o[...]

  • Page 31

    D-2 MAINTENANCE SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE D.1 - GENERAL ASSEMBLY EXPLODED VIEW 1, MAIN TRANSFORMER 5. CONTROL BOX ASSEMBLY 2. OUTPUT TERMINALS 6. SPARK GAP ASSEMBLY 3. POLARITY [...]

  • Page 32

    D-3 NOTES SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 33

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SQUARE WAVE TIG 255 Theory of Operation Section ...........................................................................Section E Power Supply Operation ...............................................................................E-1 - E-5 Input Line Voltage an[...]

  • Page 34

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-1 THEOR Y OF OPERA TION INPUT LINE VOL T AGE AND MAIN TRANSFORMER LINE SWITCH R E C O N N E C T MAIN TRANSFORMER X2 X1 POWER FACTOR CAPACITORS F[...]

  • Page 35

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-2 THEOR Y OF OPERA TION OUTPUT RECTIFICA TION AND FEEDBACK CONTROL LINE SWITCH R E C O N N E C T MAIN TRANSFORMER X2 X1 POWER FACTOR CAPACITORS [...]

  • Page 36

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-3 THEOR Y OF OPERA TION HIGH VOL T AGE / HIGH FREQUENCY CIRCUIT LINE SWITCH R E C O N N E C T MAIN TRANSFORMER X2 X1 POWER FACTOR CAPACITORS FAN[...]

  • Page 37

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-4 THEOR Y OF OPERA TION LINE SWITCH R E C O N N E C T MAIN TRANSFORMER X2 X1 POWER FACTOR CAPACITORS FAN 115VAC PROTECTION SNUBBER BOARD A[...]

  • Page 38

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-5 THEOR Y OF OPERA TION LINE SWITCH R E C O N N E C T MAIN TRANSFORMER X2 X1 POWER FACTOR CAPACITORS FAN 115VAC PROTECTION SNUBBER BOARD A[...]

  • Page 39

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-6 THEOR Y OF OPERA TION A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load. An SCR acts very mu[...]

  • Page 40

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-7 THEOR Y OF OPERA TION A thermostat protects the machine from excessive operating temperatures. Excessive operating temper- atures may be caused by a lack [...]

  • Page 41

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SQUARE WAVE TIG 255 Troubleshooting & Repair Section ................................................................Section F Safety Precautions .................................................................................................F-1 How to Use Trou[...]

  • Page 42

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-1 TROUBLESHOOTING & REP AIR This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-[...]

  • Page 43

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-2 TROUBLESHOOTING & REP AIR CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor el[...]

  • Page 44

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-3 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Major Physical[...]

  • Page 45

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-4 TROUBLESHOOTING & REP AIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) The voltmeter [...]

  • Page 46

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-5 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) 115VAC Recepta[...]

  • Page 47

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-6 TROUBLESHOOTING & REP AIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) The ammeter di[...]

  • Page 48

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-7 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) The yellow lig[...]

  • Page 49

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-8 TROUBLESHOOTING & REP AIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) The control pa[...]

  • Page 50

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-9 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) AC/DC Indicato[...]

  • Page 51

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-10 TROUBLESHOOTING & REP AIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Machine outpu[...]

  • Page 52

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-1 1 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Lack of pene[...]

  • Page 53

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-12 TROUBLESHOOTING & REP AIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Machine has l[...]

  • Page 54

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-13 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) High frequenc[...]

  • Page 55

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SQUARE WAVE TIG 255 F-14 TROUBLESHOOTING & REP AIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) No gas or wat[...]

  • Page 56

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-15 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Stick electro[...]

  • Page 57

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-16 TROUBLESHOOTING & REP AIR SQUARE WAVE 255 CONTROL G2150  J1 J2 J3 J4 J5 J6 J7 J8 1J3 2J3 12J6 13J6 5J6 6J6 PROTECTION/SNUBBER L9255  J10 J11 J1[...]

  • Page 58

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-17 TROUBLESHOOTING & REP AIR CONTROL TRANSFORMER (T2) VOL T AGE TEST W ARNING CAUTION Service and repair should only be performed by Lincoln Electric fa[...]

  • Page 59

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-18 TROUBLESHOOTING & REP AIR CONTROL TRANSFORMER (T2) VOL T AGE TEST (continued) CONTROL BOX CONTROL BOARD LOCATED INSIDE CONTROL TRANSFORMER LOCATED IN[...]

  • Page 60

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-19 TROUBLESHOOTING & REP AIR CONTROL TRANSFORMER (T2) VOL T AGE TEST (continued) SQUARE WAVE 255 CONTROL G2150 BLACK BLACK RED WHITE RED (1) YELLOW (10)[...]

  • Page 61

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-20 TROUBLESHOOTING & REP AIR PROTECTION/SNUBBER BOARD CONTINUITY TEST TEST DESCRIPTION Many circuits pass through the protection/snubber board. The purp[...]

  • Page 62

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-21 TROUBLESHOOTING & REP AIR PROTECTION/SNUBBER BOARD CONTINUITY TEST (continued) CONTROL BOX PROTECTION/SNUBBER BOARD LOCATED ON BACK OF CONTROL BOX[...]

  • Page 63

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-22 TROUBLESHOOTING & REP AIR PROTECTION/SNUBBER BOARD CONTINUITY TEST (continued) Check Points Component(s) Being Checked Maximum Allowable Resistance 5[...]

  • Page 64

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-23 TROUBLESHOOTING & REP AIR ARC ST ART TRIGGER CIRCUIT TEST TEST DESCRIPTION The Arc Start Trigger Test determines if the wiring and connections are go[...]

  • Page 65

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-24 TROUBLESHOOTING & REP AIR ARC ST ART TRIGGER CIRCUIT TEST (continued) CONTROL BOX CONTROL BOARD LOCATED INSIDE PROTECTION/SNUBBER BOARD LOCATED ON[...]

  • Page 66

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-25 TROUBLESHOOTING & REP AIR ARC ST ART TRIGGER CIRCUIT TEST (continued) PROTECTION/SNUBBER L9255 J10 J11 J12 J13 J14 J15 10J12 3J12 3J13 11J13 6. Test [...]

  • Page 67

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-26 TROUBLESHOOTING & REP AIR ST A TIC SCR TEST TEST DESCRIPTION The Static SCR Test is a quick check to determine if an SCR is shorted or “leaky”. S[...]

  • Page 68

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-27 TROUBLESHOOTING & REP AIR ST A TIC SCR TEST (continued) PROTECTION/SNUBBER L9255  J10 J11 J12 J13 J14 J15 REMOVE PLUGS J10 & J13 TEST PROCEDUR[...]

  • Page 69

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-28 TROUBLESHOOTING & REP AIR ACTIVE SCR TEST TEST DESCRIPTION The Active SCR Test will determine if the device is able to be gated “ON” and conduct [...]

  • Page 70

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-29 TROUBLESHOOTING & REP AIR ACTIVE SCR TEST (continued) PROTECTION/SNUBBER L9255  J10 J11 J12 J13 J14 J15 REMOVE PLUGS J10 & J13 TEST PROCEDURE [...]

  • Page 71

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-30 TROUBLESHOOTING & REP AIR ACTIVE SCR TEST (continued) SW1 R2 SW2 R1 A G C V SCR under test R1= 4 ohms /10 watts R2= 3 ohms/ 10 watts 6volt?[...]

  • Page 72

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-31 TROUBLESHOOTING & REP AIR NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM DC STICK MODE CAUTION HIGH VOL T AGE / HIGH FREQUENCY can damage test equipment. ?[...]

  • Page 73

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-32 TROUBLESHOOTING & REP AIR NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM AC STICK MODE CAUTION HIGH VOL T AGE / HIGH FREQUENCY can damage test equipment. ?[...]

  • Page 74

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-33 TROUBLESHOOTING & REP AIR NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM DC TIG MODE CAUTION HIGH VOL T AGE / HIGH FREQUENCY can damage test equipment. •[...]

  • Page 75

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-34 TROUBLESHOOTING & REP AIR NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM AC TIG MODE CAUTION HIGH VOL T AGE / HIGH FREQUENCY can damage test equipment. •[...]

  • Page 76

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-35 TROUBLESHOOTING & REP AIR TYPICAL OUTPUT VOL T AGE W A VEFORM - MACHINE LOADED DC TIG MODE CAUTION HIGH VOL T AGE / HIGH FREQUENCY can damage test eq[...]

  • Page 77

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-36 TROUBLESHOOTING & REP AIR 0 volts 20 volts 2ms CH1 AC TIG MODE (AUT O - BALANCE ON) CAUTION HIGH VOL T AGE / HIGH FREQUENCY can damage test equipment[...]

  • Page 78

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-37 TROUBLESHOOTING & REP AIR TYPICAL SCR GA TE VOL T AGE W A VEFORM CAUTION HIGH VOL T AGE / HIGH FREQUENCY can damage test equipment. • Perform all v[...]

  • Page 79

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-38 TROUBLESHOOTING & REP AIR ABNORMAL OPEN CIRCUIT VOL T AGE - DC STICK MODE ONE OUTPUT SCR NOT FUNCTIONING CAUTION HIGH VOL T AGE / HIGH FREQUENCY can [...]

  • Page 80

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-39 TROUBLESHOOTING & REP AIR ABNORMAL OPEN CIRCUIT VOL T AGE - AC STICK MODE ONE OUTPUT SCR NOT FUNCTIONING CAUTION HIGH VOL T AGE / HIGH FREQUENCY can [...]

  • Page 81

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-40 TROUBLESHOOTING & REP AIR F AN MOTOR AND BLADE REMOV AL TEST DESCRIPTION The following procedure will aid the technician in gaining access to the fan[...]

  • Page 82

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-41 TROUBLESHOOTING & REP AIR F AN MOTOR AND BLADE REMOV AL (continued) TEST PROCEDURE 1. Remove main supply power to machine. 2. Remove case sides and t[...]

  • Page 83

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-42 TROUBLESHOOTING & REP AIR SCR HEA T SINK ASSEMBL Y REMOV AL TEST DESCRIPTION The following procedure will aid the technician in the removal and repla[...]

  • Page 84

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-43 TROUBLESHOOTING & REP AIR SCR HEA T SINK ASSEMBL Y REMOV AL (continued) TEST PROCEDURE 1. Remove main power supply to machine. 2. Remove case sides a[...]

  • Page 85

    11 / 94 SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-44 TROUBLESHOOTING & REP AIR RETEST AFTER REP AIR Should a machine under test be rejected for any reason requiring the removal of any mechanical[...]

  • Page 86

    SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-45 TROUBLESHOOTING & REP AIR Test Points Voltages X1 – X2 73 – 78 VAC X3 – X4 (230 – 232) 116 – 122 VAC X3 – X5 (230 – 52A) 217 – 228 VA[...]

  • Page 87

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SQUARE WAVE TIG 255 Electrical Diagrams .........................................................................................Section G Control PC Board (G2150) Components ...............................................................G-2 Protection Snubber PC Bo[...]

  • Page 88

    G-2 ELECTRICAL DIAGRAMS SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will inv[...]

  • Page 89

    G-3 ELECTRICAL DIAGRAMS SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will inv[...]

  • Page 90

    G-4 ELECTRICAL DIAGRAMS SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC X19 IC-UNDERVOLTAGE-SENSING,RESET, MCU X10 IC-CMOS,INVERTER,SCHMITT, HEX,HC14A C65,C66 CAPACITOR-TAEL,4.7,35V,10% X11,X14 IC-OP-AMP,QU[...]

  • Page 91

    G-5 NOTES SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 92

    G-6 SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory[...]

  • Page 93

    G-7 SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory[...]

  • Page 94

    G-8 NOTES SQUARE WAVE TIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 95

    G-9 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 255 231 TO GROUND PER NATIONAL ELECTRIC CODE 229 PIEZO BUZZER (+) (-) C1 (1,3) (1,2) (1,1) (2,2) (2,1) (3,1) (4,1) (4,2) (5,1) (5,2) TO KEYPAD MATRIX X1 240 230 230D 230B 50/60 HZ 237 238 236A C2 232 230C MACHINES ONLY 230E 236 235 232B 229A 239A 239 235A 238A R3 R4 52A CLEVELAND, OHIO U.S.A. C-RW G2719 R WI[...]

  • Page 96

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC G-10 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 255 MACHINE SCHEMA TIC — SQUARE W A VE TIG 255 SCR2 GATE SCR3 GATE SCR1 GATE SCR4 SCR1 SCR3 SCR2 MAIN RECTIFIER D1 150 /400 OUTPUT [...]

  • Page 97

    G-11 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 255 CONTROL BOARD SCHEMA TIC — SQUARE W A VE TIG 255 (G2150) D46 100 R14 1.00K R113 +15V IOGND J5 1 SCR GATE 100V 1A Q6 J5 3 J8 11 16VAC AUX SCR3 AUX SCR3 windings ) ( 1 of 5 XFMR secondary J8 5 SCR CATHODE 1.00K R118 3 3 475K R116 CNY17-3 OCI6 4 2 1 6 5 267 R64 +15V SCR GATE 1W 18V DZ5 1W 30V DZ6 1.00K R[...]

  • Page 98

    G-12 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 255 CONTROL BOARD SCHEMA TIC — SQUARE W A VE TIG 255 (cont’d) (G2150) N+5V LGND ROW 5 130 8.0MHz Y1 1.00M R71 1K R87 100V 22p C22 4.75K R81 4.75K R210 1.0 35V C23 C20 GND RES IN X19 50V 0.1 C33 C5 J6 10 +15V 475 R83 D39 D34 IOGND 18 15V C16 D7 L+5V J6 11 J6 3 D0-D7 D4 D6 C25 D5 D0 1K R84 D3 X32 4 1.00K [...]

  • Page 99

    G-13 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 255 PROTECTION/SNUBBER BOARD SCHEMA TIC — SQUARE W A VE TIG 255 (L9255) A NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . This Printed Circuit Board schematic is provided for reference onl[...]

  • Page 100

    G-14 ELECTRICAL DIAGRAMS SQUARE W AVE TIG 255 KEYP AD LED BOARD — SQUARE W A VE TIG 255 (L9212) NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . This Printed Circuit Board schematic is provided for reference only . It may not be to[...]