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Lincoln Electric IM520-B - page 1
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.S.A. Tel. (216) 481-8100 World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors IM520-B January, 1997 Safety Depends on You Lincoln arc welding and cut ...
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Lincoln Electric IM520-B - page 2
– 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. ______________________________________ ...
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Lincoln Electric IM520-B - page 3
– 3 – SAFETY ARC RA YS can b urn. 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 ...
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Lincoln Electric IM520-B - page 4
– 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. 8.c. Ground the equipment in accordance with the U.S. National El ...
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Lincoln Electric IM520-B - page 5
– 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. Protegez-vous contre la secousse électrique: a. Les circuit ...
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Lincoln Electric IM520-B - page 6
– 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. Save this manual and keep it handy for quick referenc ...
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Lincoln Electric IM520-B - page 7
– 7 – T ABLE OF CONTENTS Page Safety .....................................................................................................................2-6 Installation ................................................................................................................8-1 2 Technical Specifications ................................ ...
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Lincoln Electric IM520-B - page 8
– 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.S. National Electrical Code Code Number 10022 ...
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Lincoln Electric IM520-B - page 9
– 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. Dirt, dust or any foreign material that can be drawn into the welder should be kept at a min ...
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Lincoln Electric IM520-B - page 10
– 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. b ) A 3/4” (19mm) gal ...
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Lincoln Electric IM520-B - page 11
– 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. To change this connection for a ...
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Lincoln Electric IM520-B - page 12
– 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. Connect the TIG torch inlet to the “Water Valve Out” fitting. If using a water-cool ...
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Lincoln Electric IM520-B - page 13
– 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. • Use ventilation or exhaust to remove fumes from breathing zone. WELDING SPARKS ...
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Lincoln Electric IM520-B - page 14
– 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 ART ONL Y HIGH FREQUENCY OFF CLEAN (INCREASE POSITIVE POLARITY) PENETRA TE (INCREASE NEGA TIVE POLARITY) TIG PULSER AFTERFLO W / AFTERFLO W TIME GRAPHIC SYMBOLS TH ...
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Lincoln Electric IM520-B - page 15
– 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 ODE CONNECTION PR O TECTIVE GR OUND SINGLE PHASE TRANSFORMER A C & DC RECTIFIER PO WER SOURCE TIG (GT A W) SINGLE PHASE PULSED PER SECOND GRAPHIC ...
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Lincoln Electric IM520-B - page 16
– 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. • 2-Step/4-Step Arc Start Switch Capability. • TIG Puls ...
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Lincoln Electric IM520-B - page 17
– 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. • Simple keypad layout allows even novice users to operate w ...
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Lincoln Electric IM520-B - page 18
– 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. If manual adjustment is desired, the Manual Balance key can be pressed, and t ...
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Lincoln Electric IM520-B - page 19
– 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. C . AMMETER: The ammeter can display ...
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Lincoln Electric IM520-B - page 20
– 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 CONTINUOUS START OPERA TION WELDING OPERA TION TIG Welding Familiarize yourself with the Controls and Display Section before attempting operation of the Squ ...
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Lincoln Electric IM520-B - page 21
– 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. See the Advance ...
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Lincoln Electric IM520-B - page 22
– 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. 10. Press and release the Arc Start Switch, and set ...
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Lincoln Electric IM520-B - page 23
– 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. This circuit is protected from shorts and overloading by a 2 amp circuit breaker ...
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Lincoln Electric IM520-B - page 24
– 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. Complete installation instructions ...
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Lincoln Electric IM520-B - page 25
– 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. 1. Disc ...
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Lincoln Electric IM520-B - page 26
– 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. SPARK GAP ASSEMBLY 3. POLARITY SWITCH 7. PROTECTION PC BOARD - 4. RECTIFIER ASSEMBLY (Mounted to rear of control box assembly) ...
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Lincoln Electric IM520-B - page 27
– 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. For your safety, please observe all safety notes and ...
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Lincoln Electric IM520-B - page 28
– 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. No output from machine in either Stick or TIG modes. The voltmeter r ...
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Lincoln Electric IM520-B - page 29
– 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. Machine makes a very loud buzzing noise in DC Stick Mode, or in ...
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Lincoln Electric IM520-B - page 30
– 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. The Beeper (Piezoelectric Buzzer) ...
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Lincoln Electric IM520-B - page 31
– 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. Lack of penetration in AC TIG welding. Black areas along weld bead. Black areas alo ...
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Lincoln Electric IM520-B - page 32
– 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). The arc start switc ...
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Lincoln Electric IM520-B - page 33
– 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. Machine has output - fan runs. When toggling between the ...
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Lincoln Electric IM520-B - page 34
– 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. Machine welds at a very low output regardless of the preset current setting - arc is stable. V ...
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Lincoln Electric IM520-B - page 35
– 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 HZ 237 238 236A C2 232 230C MACHINES ONLY 230E 236 235 232B 229A 239A 239 235A 238A R3 R4 52A 4-19-96D G2719 WIRING DIAGRAM - SQUARE WAVE TIG 255 CODE ...
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Lincoln Electric IM520-B - page 36
– 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 HZ 237 238 236A C2 232B 231C MACHINES ONLY 236 235 232C 229A 239A 239 235A 238A R3 R4 1-24-97H G3302 WIRING DIAGRAM - SQUARE WAVE TIG 255 CODE 10451, ...
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Lincoln Electric IM520-B - page 37
Now A vailable...12th Edition The Procedure Handbook of Ar c W elding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. This printing will go fast so don’t delay. Place your order now using the coupon below. The hardbound book contain ...
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Lincoln Electric IM520-B - page 38
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. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL ...
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Lincoln Electric IM520-B - page 39
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. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes fr ...
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Lincoln Electric IM520-B - page 40
▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ 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. Clair Ave. Cleveland, Ohio 4 ...
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