Lincoln Electric IM467-B manual

IM467-B May , 2003 For use with machines having Code Numbers: 9951, 10056, 10389 9952, 10057, 10390 9953, 10058 9954, 10059 9955, 10060 SQU ARE W A VE TIG 355 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and th[...]

FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _______________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical[...]

iv SAFETY iv 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. Les circuits [...]

v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

T ABLE OF CONTENTS vi vi SQUARE W A VE TIG 355 Page Safety .................................................................................................................................................i-iv Installation ............................................................................................................................. Se[...]

T ABLE OF CONTENTS vii vii SQUARE W A VE TIG 355 TIG W elding Sequence of Operation (4-Step Mode) .........................................................B-19 Overload Protection ............................................................................................................ ......B-20 Auxiliary Power ..................................[...]

INST ALLA TION A-1 A-1 SQUARE W A VE TIG 355 TECHNICAL SPECIFICA TIONS - SQUARE WA VE TIG 355 INPUT - SINGLE PHASE ONL Y Input V oltages: 208 230 460 575 Input Currents @ 350A/34 VDC 110 100 50 40 RA TED OUTPUT Duty Cycle Amps V olts at Rated Amperes 40% Duty Cycle 350 34 v 60% Duty Cycle 300 32 v 100% Duty Cycle 220 29 v OUTPUT Maximum Open Contin[...]

Read this entire installation section before you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. Only qualified personnel should install, use, or service this e[...]

3. Be sure the tor ch and work cable rubber coverings are fr ee of cuts and cracks that allow high fre- quency leakage. Cables with high natural rubber content, such as Lincoln Stable-Arc ® better r esist high frequency leakage than neopr ene and other synthetic rubber insulated cables. 4. Keep the torch in good r epair and all connections tight t[...]

INST ALLA TION A-4 A-4 SQUARE W A VE TIG 355 FIGURE A.2 – INPUT SUPPL Y CONNECTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and gr ound. • Always wear dry insulating gloves. RECONNECT PROCEDURE On multiple input voltage welders, be sure t[...]

The Square W ave TIG 355 should be permanently wired into the power system. Plugs or connectors ar e not recommended. INST ALLA TION A-5 A-5 SQUARE W A VE TIG 355 T ABLE A.1 RECOMMENDED INPUT WIRE AND FUSE SIZES For all Stick, DC TIG, and Balanced AC TIG W elding Based on the 1990 U.S. National Electrical Code (2) 40% Duty Cycle Input Ampere T ype [...]

OUTPUT CONNECTIONS ELECTRIC SHOCK can kill. • Keep the electrode holder , TIG torch and cables insulation in good condition and in place. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself fr om work and ground. • T urn the power off pushbutton on the Square W ave TIG 355 “off” befor e con[...]

DO NOT operate a water -cooled torch unless water is flowing. W ater doesn’t flow until the solenoid is actu- ated. If using a water -cooled torch with a Magnum water cooler , connect the cooler water outlet to the “Water V alve In” fitting. Connect the TIG torch inlet to the “W ater V alve Out” fitting. If using a water -cooled torch wit[...]

OPERA TION B-1 B-1 SQUARE W A VE TIG 355 OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. • Insulate yourself from the work and gr ound. • Al[...]

GENERAL DESCRIPTION The Square W ave TIG 355 is a constant current, single range square wave AC/DC TIG (GT AW) ar c welding power source with built-in high fr equency stabilization. It also has stick (SMAW) capability . The Square W ave TIG 355 gives the operator full control of the welding current plus the ability to pr eset weld and start cur- re[...]

• 115 V olt receptacle with 15 amp cir cuit breaker . • Excellent arc starting and stability up through 400 amps. • High resistance to AC arc r ectification. • 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. • Strain relief holes in base for welding ca[...]

CONTROLS AND SETTINGS UPPER CASE FRONT CONTROLS Controls on the upper case fr ont 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 . Refer to Figure B.1 for contr ol locations. OPERA TION B-4 B-4 SQUARE W A VE [...]

UPPER CASE FRONT CONTROL P ANEL The upper case front panel contr ols are used for man- ual TIG and stick welding. 1. CURRENT CONTROL SWITCH A two-position toggle switch: LOCAL (P ANEL): Current is contr olled by the machine settings; remote Amptr ol has no affect on current. REMOTE: Current is contr olled by a remote Amptrol up to the curr ent set [...]

6. PEAK CURRENT CONTROL Presets the maximum welding curr ent the machine will produce, fr om 2 through 400 amps. The preset curr ent is displayed on the digital ammeter when you are not welding. NOTE: The ammeter display is an indicator of the preset curr ent. Actual welding current will be slightly differ ent. If you use an Amptrol, it will contr [...]

At Maximum, the arc will be mor e forceful and less prone to sticking but will pr oduce more spatter . 12. PREFLOW This control adjusts the amount of time the gas and water valves are open befor e the arc starts. It is adjustable from 0 to 10 seconds. The Preflow time occurs only if the valves wer e closed (no gas flow) when the Arc Start switch or[...]

Example: The Peak Current contr ol is preset at 50 amps and the Amptrol is partially down, giving a peak current of 30 amps. If the Backgr ound Current contr ol is set at 50%, the Background (low pulse) current will be 15 amps. The Amptrol raises and lowers the Peak curr ent. Since Background curr ent is always a percentage of Peak current, the Amp[...]

• ARC EST ABLISHED LED goes on when the arc is fully established and goes out if the arc goes out. • ST ART LED is on from the time the ar c is estab- lished until current begins to go up (soft start) or down (hot start). Note that the Start LED is off during upslope if a soft start is used. • PEAK LED goes on after the Start period. If the P[...]

OPERA TION B-10 B-10 SQUARE W A VE TIG 355 LOWER CASE FRONT CONTROLS Refer to Figure B.3 for the location of the following contr ols. FIGURE B.3 – LOWER CASE FRONTCONTROLS 4 5 3 2 1 9 8 7 6[...]

1. POWER ON/OFF — A momentary start/stop pushbutton, which controls the input contactor . If the input power supply goes off or if the thermo- stat in the welder trips, the start pushbutton must be pressed to r estart the welder . 2. PILOT LIGHT — Indicates when the input contac- tor is ener gized (power is on). Do not switch polarity under loa[...]

HAND AND FOOT AMPTROL OPERA TION Both the Hand and Foot Amptrol (optional kits K870 or K963) work in a similar manner . They are meant to be used for remote curr ent control when Remote Current control is selected. The TIG 2-Step mode must be selected when using an Amptrol for r emote current control. As explained below , Amptrols can also be used [...]

OPERA TION B-13 B-13 SQUARE W A VE TIG 355 FIGURE B.4 – AMPTROLS USED WITH CURRENT CONTROL IN THE LOCAL POSITION FIGURE B.5 – AMPTROLS USED WITH CURRENT CONTROL IN REMOTE POSITION[...]

WELDING OPERA TION INITIAL ST ART -UP Be sure the Squar e Wave TIG 355 has been installed correctly with r espect to location, high frequency pro- tection, input power , and output connections. If you are TIG welding, connect a K870 or K963 Amptrol or a K814 Ar c Start switch to the Remote Receptacle. Check that the gas supply is on. Check for the [...]

OPERA TION B-15 B-15 SQUARE W A VE TIG 355 T ABLE B.1 SPECIFIC EFFECTS OF CONTROLS (illustrated in the 2-Step Mode for clarity) PRESET CURRENT LOCAL CURRENT CONTROL ALL LOWER P ANEL SWITCHES OFF REMOTE CURRENT CONTROL ALL LOWER P ANEL SWITCHES OFF LOCAL OR REMOTE CURRENT CONTROL ST ART SWITCH ON ST ART CURRENT SET HIGHER THAN PRESET CURRENT (HOT ST[...]

OPERA TION B-16 B-16 SQUARE W A VE TIG 355 PRESET CURRENT PRESET CURRENT CRA TER FILL % CURRENT MAX ST ART TIME LOCAL OR REMOTE CURRENT CONTROL ST ART SWITCH ON ST ART CURRENT SET LOWER THAN PRESET CURRENT (SOFT ST ART) ST ART TIME: V ARIABLE ALL OTHER P ANEL SWITCHES OFF LOCAL CURRENT CONTROL CRA TER FILL SWITCH ON CRA TER FILL % CURRENT V ARIABLE[...]

OPERA TION B-17 B-17 SQUARE W A VE TIG 355 PRESET CURRENT PRESET CURRENT CRA TER FILL % CURRENT BACKGROUND % CURRENT CLOSE ARC ST ART SWITCH OPEN ARC ST ART SWITCH AFTER SPOT TIME PREFLOW ST ART TIME ST ART CURRENT LOCAL CURRENT CONTROL ST ART SWITCH ON (SHORT HOT ST ART SHOWN) PULSE SWITCH ON CRA TER FILL SWITCH ON (SLOW F ADE-OUT SHOWN) SPOT SWIT[...]

OPERA TION B-18 B-18 SQUARE W A VE TIG 355 T ABLE B.2 TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES (2) DCEN (-) DCEP (+) T ungsten 1%, 2% 1%, 2% Electrode 1%, 2% 1%, 2% Thoriated Thoriated TIG T orch Diameter Thoriated Thoriated Pure T ungsten Pure T ungsten Stainless Nozzle in. (mm) T ungsten T ungsten T ungsten Zir conated T ungsten Zirconi[...]

TIG WELDING SEQUENCE OF OPERA TION (2-STEP MODE) Do not leave stick electrode welding cable connected. It will be electrically “hot” when TIG welding. 1. Connect an Amptrol or Arc Start switch to the Remote Receptacle. 2. T ur n the welder , water supply (if equipped) and gas supply on. The pilot light on the front panel indicates when the powe[...]

11. Hold the Arc Start switch down until an ar c is established. At this point, the Arc Start Switch can be released, and the weld will continue. Press and r elease the Arc Start switch a second time to stop the arc. When the Afterflow timer completes the cycle, the gas and water valves close. T o make another weld, repeat steps 10 and 11. Note: St[...]

OPTIONS/ACCESSORIES The following options/accessories are available for your Square W ave TIG 355 from your local Lincoln Electric Distributor . Undercarriage (K841) – Includes a platform, wheels, and brackets for supporting the welder and two gas cylinders. Pump Mounting Platform (K827) – Mounts on top of the welder to provide a mounting surfa[...]

MAINTENANCE D-1 D-1 SQUARE W A VE TIG 355 W ARNING SAFETY PRECAUTIONS • Only Qualified personnel should perform this maintenance. • T ur n the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. INPUT POWER F ACTOR CAP ACITOR DISCHARGE PROCEDURE This procedur e ensures [...]

5. If any voltage is present, DISCHARGE EACH INDI- VIDUAL CAP ACITOR as follows: a. Obtain a 500 Ohm r esistor . Grip the 500 ohm resistor with insulated gloves and insulated gripping pliers and hold the resistor acr oss the terminals on each capacitor for 20 seconds. See Figure D.1. b. With the volt/ohmmeter , recheck each capac- itor for voltage.[...]

MAINTENANCE D-3 D-3 SQUARE W A VE TIG 355 FIGURE D.2 – GENERAL COMPONENT LOCA TIONS 1. OUTPUT RECTIFIER/SCR BRIDGE ASSEMBL Y 2. INPUT CONT ACTOR 3. RECONNECT P ANEL 4. PILOT TRANSFORMER 5. F AN AND F AN MOTOR 6. INPUT POWER F ACTOR CAP ACITOR 7. MAIN TRANSFORMER 8. CHOKE 9. HIGH VOL T AGE TRANSFORMER 10. PC BOARDS (POWER, CONTROL) 11. CASE FRONT [...]

E-1 E-1 SQUARE W A VE TIG 355 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed throughout this manual. GENERAL MACHINE TROUBLE SYMPTOM CAUSE AND REMEDY Machine will not turn on. 1. Input supply lines not “hot”. Check input supply line fuses. 2. Blown control circuit fuse (F1). Replace. 3. Thermostat (secondary) has opene[...]

TROUBLESHOOTING E-2 E-2 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed throughout this manual. STICK WELDING SYMPTOM CAUSE AND REMEDY Machine shuts off in Stick mode. 1. Welder has overheated and secondary thermostat has opened. Allow welder to cool before attempting to turn on. Be sure to provide adequate ventilatio[...]

TROUBLESHOOTING E-3 E-3 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed throughout this manual. TIG WELDING SYMPTOM CAUSE AND REMEDY Machine does not respond (no gas flow , no 1. Defective Arc Start Switch or Amptrol. Check for con- high frequency , no open circuit voltage) when tinuity between pins D and E on cable c[...]

E-4 E-4 SQUARE W A VE TIG 355 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed throughout this manual. SYMPTOM CAUSE AND REMEDY Machine has gas flow and high frequency but no 1. T urn High Frequency Switch OFF . Look at the two LED’s in open circuit voltage when the Arc Start Switch the upper left corner of the Power PC bo[...]

TROUBLESHOOTING E-5 E-5 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed throughout this manual. SYMPTOM CAUSE AND REMEDY T ungsten is eroding quickly . 1. Current potentiometer is set too high for tungsten size. Reduce welding current or increase tungsten size. 2. In AC, Wave Balance control may be set too far towards[...]

TROUBLESHOOTING E-6 E-6 SQUARE W A VE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed throughout this manual. ACCESSORIES SYMPTOM CAUSE AND REMEDY K870 Foot Amptrol or K963 Hand Amptrol. Amptrol does not control welder output with 1. Check continuity between pins D and E in the cable connec- Current Control switch in REMOTE and tor[...]

DIAGRAMS SQUARE W A VE TIG 355 F-1 F-1 WIRING DIAGRAM - Square W ave TIG355 DUAL VOLTAGE MACHINE SINGLE VOLTAGE MACHINE MODE S10 LOCAL STICK CONTINUOUS REMOTE TIG OFF S11 S12 START TO GROUND PER NATIONAL ELECTRIC CODE 303 301 302 304 7-25-97C SQUARE WAVE TIG 355 WIRING DIAGRAM 2519 G 4 STEP 2 STEP S19 HIGH FREQUENCY CURRENT CONTROL 2 STEP/4 STEP[...]

DIAGRAMS SQUARE W A VE TIG 355 F-2 F-2 DIMENSION PRINT - Square W ave TIG355 6-18-93C 17275 M S.W. TIG 355 K841 50.41 26.00 6.67 15.22 .74 24.12 .94 23.28 22.25 11.12 7.11 20.00 27.65 LOCATION OF .406 MOUNTING HOLES. * ** * 43.93 34.84 45.20 3.25 Ø[...]

EQUIPMENT MANUF ACTURER’S CERTIFICA TION T ype of Equipment Model Number Code Number Serial Number Operating Instruction Manual Number The High Frequency Generator of the above identified equipment has been tested under field test condition standards recommended by the Joint Industry Committee on High Frequency Stabilized Arc Welding Machines. It[...]

Notes[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA EL US[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes fro[...]

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