Instruction/ maintenance manual of the product SQUARE WAVE TIG 255 IM520-B Lincoln Electric
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SQU ARE W A VE TIG 255 OPERA TOR’S MANUAL Sales and Service through Subsidiaries and Distributors Worldwide 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.
– 2 – FOR ENGINE powered equipment. 1.a. Turn 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.
– 3 – SAFETY 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 – FOR ELECTRICALL Y powered equipment. 8.a. Turn 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.
– 5 – SAFETY PRÉCA UTIONS 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 suivantes: Sûreté Pour Soudage A L’Arc 1.
– 6 – 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.
– 7 – T ABLE OF CONTENTS Page Safety .....................................................................................................................2-6 Installation ............................................................................
– 8 – INST ALLA TION TECHNICAL SPECIFICA TIONS - SQU ARE W A VE TIG 255 For all Stick, DC TIG, and Balanced AC TIG Welding at 255A/30V/40% Duty Cycle Based on the 1993 US. National Electrical Code For Unbalanced AC TIG Welding Above 180 Amps, 255A/16V/40% Duty Cycle, Auto Balance Based on the 1993 U.
– 9 – INST ALLA TION Read entire installation section before starting installation. Safety Precautions SELECT SUIT ABLE LOCA TION Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the side louvers.
– 10 – INST ALLA TION 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 following methods: a ) A metal underground water pipe in direct contact with the earth for ten feet or more.
– 11 – INST ALLA TION TABLE 1 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable Machine Size Lengths up to 100 ft 100 to 200 ft 200 to 250 ft 255 Amp 40% Duty Cycle #2 (35mm 2 ) #1 (45mm 2 ) 1/0 (55mm 2 ) Welders are shipped connected for the highest input voltage as listed on the rating Plate.
– 12 – INST ALLA TION 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 with a Magnum water cooler, connect the cooler water outlet to the ‘Water Valve In” fitting.
– 13 – ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes.
– 14 – ON 2 A TIG 2-STEP TIG 4-STEP STICK CURRENT CONTR OL OUTPUT LOCAL CURRENT CONTR OL REMO TE CURRENT CONTR OL INCREASE OUTPUT DECREASE HIGH FREQUENCY CONTINUOUS HIGH FREQUENCY ST AR T ONL Y HI.
– 15 – O VER TEMPERA TURE INPUT PO WER DC+ POLARITY DC- POLARITY DO NO T SWITCH WHILE WELDING W ARNING W A TER (COOLANT) OUTPUT W A TER (COOLANT) INPUT W ORK CONNECTION GAS OUTPUT GAS INPUT ELECTR.
– 16 – • Welding current limit can be preset from 5 to 315 amps and is displayed on the Ammeter when not welding. • Auto Balance circuitry automatically provides the proper amount of cleaning and penetration when AC TIG welding. Manual AC wave balance adjust- ment is also possible.
– 17 – • Strain relief holes in base for welding cables, gas and water hoses and control cables. • Easy access for input connections. Connections are simple strip and clamp of input wires (no lugs required). • Low fan noise at idle. • Modular construction for easy servicing.
– 18 – OPERA TION 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 during an AC TIG weld. Auto Balance™ automatically sets the AC Wave Balance according to the welding current.
– 19 – OPERA TION A. AC/DC INDICATOR: This symbol represents the output polarity of the 255 . . . either AC or DC. AC is shown in Figure 4A; DC is shown in Figure 4B. B . VOLTMETER: This meter displays open circuit voltage as well as welding voltage, as measured on the output studs of the Square Wave TIG 255.
– 20 – TABLE 2 RECOMMENDED POLARITY SETTINGS FOR TIG WELDING Type of Welding Electrode Polarity High Frequency Setting Stainless Steel Aluminum & Magnesium Other Metals DC- AC DC- START CONTIN.
– 21 – OPERA TION 7. If welding with AC polarity, select Auto Balance™. This gives the optimum ratio between cleaning and penetration, automatically adjusted for the output current. If manual adjustment of the AC Wave Balance is desired, select Manual Balance, and adjust the wave balance with the Cleaning and Penetration keys.
– 22 – OPERA TION 9. Set the Afterflow time with the Seconds Up/Down keys. Afterflow time provides shielding gas flow (and cooling water, if used) after the weld. Use short Afterflow times with low currents and small tungstens, long afterflow times at high output currents with large tungstens.
– 23 – OPERA TION 50/60Hz MACHINES - (Codes 10024 thru 10026 & 10134) Square Wave TIG 255 machines rated for 50/60Hz operation provide 2 amps of 220 volt AC power at a continental European (Schuko) type receptacle, located on the lower case back of the machine.
– 24 – A CCESSORIES OPTIONS / A CCESSORIES • Hand Amptrol (K963) • Foot Amptrol (K870) • Arc Start Switch (K814) • Magnum Cooler Horizontal TIG Mounting Bracket (K559-2) • Undercarriage (K932-1) UNDERCARRIAGE FUNCTION The Square Wave TIG 255 is designed to be used with a Lincoln K932-1 Undercarriage.
– 25 – MAINTENANCE ELECTRIC SHOCK can kill. • Only qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. To avoid receiving a high frequency shock, keep the TIG torch and cables in good condition.
– 26 – MAINTENANCE 38 1 5 22 11 2 6 4 28 3 2 FIGURE 6 - GENERAL ASSEMBLY EXPLODED VIEW 1. MAIN TRANSFORMER 5. CONTROL BOX ASSEMBLY 2. OUTPUT STUDS 6.
– 27 – TR OUBLESHOO TING How T o Use T roub leshooting Guide This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
– 28 – TR OUBLESHOO TING T roubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPT OMS) Major Physical or Electrical Damage is Evident. Machine is Dead - No Output - No Fan No Displays. Fan runs - Display and control panel dark.
– 29 – TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide PROBLEMS (SYMPT OMS) Machine regularly over heats - thermostat opens, PL1 (yellow light on front panel) glows. The fan runs but machine has no output and no display.
– 30 – TR OUBLESHOO TING T roubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPT OMS) The yellow light (PL1) on the front panel is not lit. One or more keypad lights (LEDS) are dark and cannot be lit when their respective keys are pressed - machine is operable.
– 31 – TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide PROBLEMS (SYMPT OMS) Machine output is intermittently lost. Gas flow and high frequency are also interrupted. Arc “Flutters” when TIG welding.
– 32 – TR OUBLESHOO TING T roubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPT OMS) Machine has low output when in TIG 4-Step Mode. Weak high frequency - machine has normal welding output. The display shows zero amps, but indicates open circuit voltage (approximately 53V).
– 33 – TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide PROBLEMS (SYMPT OMS) No high frequency. Machine is in the TIG Mode and has normal output. No gas or water flow when arc start switch or amptrol is activated in the TIG Mode.
– 34 – TR OUBLESHOO TING T roubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPT OMS) Stick electrode “Blasts Off” when arc is struck. Cannot adjust AC Wave Balance when welding in the Stick Mode.
– 35 – WIRING DIA GRAM 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 .
– 36 – WIRING DIA GRAM 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 240 231 231D 231B 50/60 .
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W ARNING A VISO DE PRECA UCION 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.
W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ WARRANTY P E R F O R M A N C E P L U S P R O T E C T I O N L I N C O L N E L E C T R I C 3 YEAR INCLUDING: PARTS & LABOR S22127-2 • Sales and Service through Subsidiaries and Distributors Worldwide • 22801 St.
An important point after buying a device Lincoln Electric SQUARE WAVE TIG 255 IM520-B (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
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If you already are a holder of Lincoln Electric SQUARE WAVE TIG 255 IM520-B, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric SQUARE WAVE TIG 255 IM520-B.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric SQUARE WAVE TIG 255 IM520-B. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric SQUARE WAVE TIG 255 IM520-B along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
