Lincoln-electric IM520 SQUARE WAVE TIG 255 User Manual

SQUARE WAVE TIG 255OPERATOR’S MANUALSales and Service through Subsidiaries and Distributors Worldwide22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U

– 10 –INSTALLATION4. Keep the torch in good repair and all connectionstight to reduce high frequency leakage.5. The work terminal must be connected to

– 11 –INSTALLATIONTABLE 1Cable Sizes for Combined Lengths of CopperElectrode and Work CableMachine SizeLengths up to100 ft 100 to 200 ft 200 to 250 ft

– 12 –INSTALLATIONDO NOT operate a water-cooled torch unless water isflowing. Water doesn’t flow until solenoid is actuated.If using a water-cooled to

– 13 –ELECTRIC SHOCKcan kill.• Do not touch electrically live partsor electrode with skin or wetclothing.• Insulate yourself from work andground.• Alw

– 14 –ON2ATIG 2-STEPTIG 4-STEPSTICKCURRENTCONTROLOUTPUTLOCALCURRENTCONTROLREMOTECURRENTCONTROLINCREASEOUTPUTDECREASEHIGHFREQUENCYCONTINUOUSHIGHFREQUEN

– 15 –OVERTEMPERATUREINPUTPOWERDC+POLARITYDC-POLARITYDO NOTSWITCHWHILEWELDINGWARNINGWATER(COOLANT)OUTPUTWATER(COOLANT)INPUTWORKCONNECTIONGAS OUTPUTGAS

– 16 –• Welding current limit can be preset from 5 to 315amps and is displayed on the Ammeter when notwelding.• Auto Balance circuitry automatically p

– 17 –• Strain relief holes in base for welding cables, gasand water hoses and control cables.• Easy access for input connections. Connectionsare simp

– 18 –OPERATION4. AC WAVE BALANCE: These keys are active inthe AC TIG mode only. They are used to set theamount of cleaning and/or penetration produce

– 19 –OPERATIONA. AC/DC INDICATOR: This symbol represents theoutput polarity of the 255 . . . either AC or DC. ACis shown in Figure 4A; DC is shown in

– 2 –FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be run

– 20 –TABLE 2RECOMMENDED POLARITYSETTINGS FOR TIG WELDINGType of WeldingElectrodePolarityHigh FrequencySettingStainless SteelAluminum & MagnesiumO

– 21 –OPERATION7. If welding with AC polarity, select Auto Balance™.This gives the optimum ratio between cleaning andpenetration, automatically adjust

– 22 –OPERATION9. Set the Afterflow time with the Seconds Up/Downkeys. Afterflow time provides shielding gas flow(and cooling water, if used) after th

– 23 –OPERATION50/60Hz MACHINES - (Codes 10024 thru 10026 & 10134)Square Wave TIG 255 machines rated for 50/60Hzoperation provide 2 amps of 220 vo

– 24 –ACCESSORIESOPTIONS / ACCESSORIES• Hand Amptrol (K963)• Foot Amptrol (K870)• Arc Start Switch (K814)• Magnum Cooler Horizontal TIG Mounting Brack

– 25 –MAINTENANCEELECTRIC SHOCK can kill.• Only qualified personnel shouldperform this maintenance.• Turn the input power OFF at thedisconnect switch

– 26 –MAINTENANCE381522112642832FIGURE 6 - GENERAL ASSEMBLY EXPLODED VIEW1. MAIN TRANSFORMER 5. CONTROL BOX ASSEMBLY2. OUTPUT STUDS 6. SPARK GAP ASSEM

– 27 –TROUBLESHOOTING How To Use Troubleshooting GuideThis Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized r

– 28 –TROUBLESHOOTINGTroubleshooting GuideObserve Safety Guidelinesdetailed in the beginning of this manual.PROBLEMS(SYMPTOMS)Major Physical or Electr

– 29 –TROUBLESHOOTINGObserve Safety Guidelinesdetailed in the beginning of this manual.Troubleshooting GuidePROBLEMS(SYMPTOMS)Machine regularly over h

– 3 –SAFETYARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when wel

– 30 –TROUBLESHOOTINGTroubleshooting GuideObserve Safety Guidelinesdetailed in the beginning of this manual.PROBLEMS(SYMPTOMS)The yellow light (PL1) o

– 31 –TROUBLESHOOTINGObserve Safety Guidelinesdetailed in the beginning of this manual.Troubleshooting GuidePROBLEMS(SYMPTOMS)Machine output is interm

– 32 –TROUBLESHOOTINGTroubleshooting GuideObserve Safety Guidelinesdetailed in the beginning of this manual.PROBLEMS(SYMPTOMS)Machine has low output w

– 33 –TROUBLESHOOTINGObserve Safety Guidelinesdetailed in the beginning of this manual.Troubleshooting GuidePROBLEMS(SYMPTOMS)No high frequency. Mach

– 34 –TROUBLESHOOTINGTroubleshooting GuideObserve Safety Guidelinesdetailed in the beginning of this manual.PROBLEMS(SYMPTOMS)Stick electrode “Blasts

– 35 –WIRING DIAGRAM231TO GROUND PER NATIONAL ELECTRIC CODE229PIEZOBUZZER(-)(+)C1(1,3)(1,2)(1,1)(2,2) (2,1)(3,1)(4,1)(4,2)(5,1)(5,2)TO KEYPAD MATRIXX1

– 36 –WIRING DIAGRAM231TO GROUND PER NATIONAL ELECTRIC CODE229PIEZOBUZZER(-)(+)C1(1,3)(1,2)(1,1)(2,2) (2,1)(3,1)(4,1)(4,2)(5,1)(5,2)TO KEYPAD MATRIXX1

Now Available...12th EditionThe Procedure Handbook of Arc WeldingWith over 500,000 copies of previous editions publishedsince 1933, the Procedure Hand

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

– 4 –FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Instal

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲WARRANTYPERFORMANCEPLUSPROTECTIONLINCOLNELECTRIC3YEARINCLUDING: PARTS & LABOR S22127-2• Sales and Service through Subsid

– 5 –SAFETYPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parr

– 6 –Thank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as m

– 7 –TABLE OF CONTENTSPageSafety ...

– 8 –INSTALLATIONTECHNICAL SPECIFICATIONS - SQUARE WAVE TIG 255For all Stick, DC TIG, and Balanced AC TIGWelding at 255A/30V/40% Duty CycleBased on t

– 9 –INSTALLATIONRead entire installation section before startinginstallation.Safety PrecautionsSELECT SUITABLE LOCATIONPlace the welder where clean c