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IM520-B
January, 1997
SQUARE WAVE TIG 255
For use with machines having Code Number 10022 thru 10026 & 10134, 10451,10452,10453.
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, thin
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SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause chemicals known to the State of California to cause cancer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DE
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SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Use suit
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SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hoses, fitt
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SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales 7. Quand on ne soude pas, poser la pince à une endroit isolé de suivantes: la masse. Un court-circuit accidental peut provoquer un
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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is
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TABLE OF CONTENTS Page Safety .....................................................................................................................2-6 Installation................................................................................................................8-12 Technical Specifications ............................................................................................8 Input and Output Specifications Cable and Fuse Sizes Physical Dimensions Location ...................
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INSTALLATION TECHNICAL SPECIFICATIONS - SQUARE WAVE TIG 255 INPUT - SINGLE PHASE ONLY Standard Input Current at Code (1) Voltage Number Rated Output 208/230/460/1/60 10022 81/74/37 230/460/575/1/60 10023 74/37/30 200/240/400/1/50/60 10024 85/77/44 220/380/440/1/50/60 10452 77/45/39 380/415/500/1/50/60 10453 45/41/33 220/380/415/1/50/60 10451 77/45/41 RATED OUTPUT Duty Cycle Volts at Rated Amperes Amps 40% Duty Cycle 30 255 NEMA Class II (40) 60% Duty Cycle 28 200 100% Duty Cycle 26 150 OUT
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INSTALLATION Read entire installation section before starting MACHINE GROUNDING AND HIGH installation. FREQUENCY INTERFERENCE PROTECTION Safety Precautions The frame of the welder must be grounded. A ground terminal marked with the symbol is located at the bottom of the input box for this purpose. See your WARNING local and national electrical codes for proper ELECTRIC SHOCK can kill. grounding methods. • Only qualified personnel should perform this installation. The spark gap osci
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INSTALLATION 4. Keep the torch in good repair and all connections See Figure 1 for the location of the rating plate, the entry hole, and the reconnect panel. tight to reduce high frequency leakage. FIGURE 1 - REAR PANEL 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. 1 b) A 3/4” (19mm) galvanized pipe or a 5/8” 2 (16mm) solid galvanized ir
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INSTALLATION Welders are shipped connected for the highest input FIGURE 2 - FRONT PANEL voltage as listed on the rating Plate. To change this connection for a different input voltage, reconnect the power strap (P) to the terminal corresponding to the input voltage used. Designations on reconnect panel, LOW, MID and HIGH correspond to the nameplate input voltages of a triple voltage welder. Dual voltage 1 4 2 3 welders use only LOW and HIGH. Single voltage L9119-1 welders use only HIGH. DC POWER
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INSTALLATION The welder fittings have the following threads: Gas Inlet and Outlet: 5/8”-18 right-hand female; Water inlet and Outlet: 5/8”-18 left-hand female. The cylinder of inert shielding gas must be equipped with a pressure regulator and flow meter. Install a hose between the flow meter and gas inlet on the welder. WARNING Observe the safety precautions necessary for handling and using compressed gas containers. Contact your supplier for specific information. _______________________________
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OPERATION OPERATING INSTRUCTIONS General Warnings SAFETY INSTRUCTIONS WARNING 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. • Use ventilation or exhaust to remove fumes from breathing zone. WELDING SPARKS can cause fire or explosion • Keep flammable material away. • Do not weld on containers that
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OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL AFTERFLOW / TIG 2-STEP & AFTERFLOW 2 TIME TIG 4-STEP CONTINUOUS HIGH STICK FREQUENCY START ONLY CURRENT HIGH CONTROL FREQUENCY OUTPUT OFF LOCAL CURRENT CONTROL ON REMOTE CURRENT CLEAN CONTROL (INCREASE & POSITIVE INCREASE POLARITY) PENETRATE A OUTPUT (INCREASE & NEGATIVE POLARITY) DECREASE TIG PULSER HIGH HF FREQUENCY – 14 –
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OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL (CONT.) AC WAVE GAS OUTPUT BALANCE PULSED PER f GAS INPUT SECOND OVER ELECTRODE TEMPERATURE CONNECTION INPUT PROTECTIVE POWER GROUND DC+ & POLARITY SINGLE PHASE TRANSFORMER DC- AC & DC & POLARITY RECTIFIER POWER SOURCE DO NOT SWITCH WHILE TIG (GTAW) WELDING WARNING SINGLE PHASE WATER WORK (COOLANT) CONNECTION OUTPUT WATER AC POLARITY (COOLANT) INPUT – 15 –
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OPERATION • Welding current limit can be preset from 5 to 315 GENERAL DESCRIPTION amps and is displayed on the Ammeter when not welding. The Square Wave TIG 255 is a constant current, single range square wave AC/DC TIG (GTAW) arc • Auto Balance circuitry automatically provides the welding power source with built-in high frequency proper amount of cleaning and penetration when stabilization. It also has stick (SMAW) capability. It is AC TIG welding. Manual AC wave balance adjust- available from
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OPERATION • 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. • Simple keypad layout allows even novice users to operate with minimal instruction. • Unused controls are automatically locked out to simplify setup. Examples: the AC wave balance control has no effect in DC; the High Fr
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OPERATION CONTROLS AND SETTINGS All operator controls and adjustments are located on the case front of the Square Wave TIG 255. Refer to Figures 3 and 4 and corresponding explanations. FIGURE 3 - CONTROL PANEL KEYS 7 G2612 THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA AC/DC OUTPUT CAPACITY: 255 AMPS 30 VOLTS 40% DUTY CYCLE CURRENT CONTROL AC WAVE BALANCE TIG PULSER WELD MODE HF HIGH FREQUENCY 2 AFTERFLOW TIG 2-STEP LOCAL REMOTE CONTINUOUS OFF ON SECONDS HF AUTO- MANUAL BALANCE BALANCE A
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OPERATION 7. CONTROL PANEL: The display is divided into five E. BAR GRAPH DISPLAY: This area provides a sections. See Figures 4A and 4B. graphical display of values shown on the Ammeter and on the Momentary Display. When the Momentary Display is blank (as in Figure 4A), the FIGURE 4A - DISPLAY Bar Graph Display represents values shown on the ammeter. When a low value is shown on the C ammeter, only a few “bars” will appear on the left D A B hand side of the Bar Graph Display. As the ammeter va
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OPERATION WELDING OPERATION HAND AND FOOT AMPTROL ACCESSORY OPERATION TIG Welding Both the Hand and Foot Amptrol work in a similar Familiarize yourself with the Controls and Display manner. They are meant to be used for remote current Section before attempting operation of the Square control when Remote Current Control is selected. Wave TIG 255. The TIG 2-Step mode must be selected when using an Amptrol for remote current control. As explained TIG Welding Guidelines below, Amptrols can also be u
