Lincoln Electric SQUARE WAVE IM565-B Page 26 Operator'S Manual Download

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WIRING DIAGRAM

SQUARE WAVE TIG 175

L10060

(-)

(+)

SCR4

SCR2

SCR1

(-)

SCR3

115VAC

OPEN

CLOSED

216

218

217

220

FRONT GANG

PC BOARD

THERMAL LIGHT

INPUT PLUG

PL1

MODE SWITCH

TL1

SV1

S2A

BYPASS/

STABILIZER

FAN

R 222

W 221

( STICK - CLOSED

TIG - OPEN )

ARC STARTER AS’BLY

236A

237

W 221 (+)

R 222 (-)

313

314

277

276

275

277

276

275

241

244

242

243

231

233

311

312

243

244

231

233

TIG

STICK

234

235

234
235

210

232

204

236

209

230

238

201

236B

217

218

216

220

POWER "ON" LIGHT

236A

REMOTE

RECEPTACLE

REMOTE

AMPTROL

SPARK

GAP

DC+

DC-

A-C, D-E, B-F

B-D, C-E, A-F, G-H

B-D, A-E, C-F, G-H

POLARITY SWITCH MICRO SWITCH

(REAR VIEW,

SHOWN IN AC POSITION)

115VAC

B 232

B 230

W 204

W 201

U 210

R 209

115VAC

18VAC

78VAC

TO GROUND PER

POLARITY

SWITCH

ELECTRICAL SYMBOLS PER E1537.

CURRENT CONTROL

H3 (230V)

H2 (208V)

NATIONAL ELECTRICAL CODE

VOLTAGE RECONNECTION

230 VOLT CONNECTION (AS SHOWN)

H1 and H3 TO POWER SWITCH.

208 VOLT CONNECTION

H1 and H2 TO POWER SWITCH.

H3 NOT CONNECTED: INSULATE.

H2 NOT CONNECTED; INSULATE.

R 241

B 242

238

236

TOROID

POS

WIRING DIAGRAM - SQUARE WAVE TIG 175 (208/ 230/ 1/ 60)

B X4

W X5

W X3

W X6

B X7

B X8

10K A-B

AT MINIMUM

C1 AND C2 MUST ALWAYS BE

CONNECTED ACROSS POWER SWITCH.

7-12-96

Summary of Contents for SQUARE WAVE IM565-B

Page 1: ...OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 10265 10387 10456 Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in...

Page 2: ...AY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E2...

Page 3: ...rical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders ...

Page 4: ...event the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Weldin...

Page 5: ...iés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloi...

Page 6: ...he information must be followed to avoid minor personal injury or damage to this equipment CAUTION 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 receive...

Page 7: ...L CONNECTION 5 CONNECTIONS FOR STICK SMAW WELDING 5 STICK ELECTRODE CABLE AND WORK CABLE CONNECTION 5 OPERATION SECTION 6 SAFETY PRECAUTIONS 6 GENERAL DESCRIPTION 6 INCLUDED EQUIPMENT 6 FOR GTAW TIG WELDING 6 FOR SMAW STICK WELDING 6 FOR INSTALLATION AND STARTUP 6 WELDING CAPABILITY 6 CONTROLS AND SETTINGS 7 OPERATING STEPS 8 WELDING IN TIG MODE 8 AMPTROLTM ACCESSORY OPERATION 8 BENEFITS OF THE SQ...

Page 8: ...nt Range 10 175 Amps AC and DC INPUT SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES 1 Input Voltage phase Frequency 208 1 60 230 1 60 460 1 60 575 1 60 Input Ampere Rating on Nameplate 59 53 27 22 Type 75 C Copper Ground Wire in Conduit AWG IEC Sizes 10 5 2 mm2 10 5 2 mm2 14 2 1 mm2 14 2 1 mm2 Fuse Super Lag or Breaker Size 100 100 50 40 Type 75 C Copper Wire in Condui...

Page 9: ...rformed under electrically hazardous conditions such as welding in wet areas or on or in the workpiece MACHINE GROUNDING AND HIGH FRE QUENCY INTERFERENCE PROTECTION The welder must be grounded See your local and national electrical codes for proper grounding methods The high frequency generator being similar to a radio transmitter can be blamed for radio TV and electronic equipment interference pr...

Page 10: ...hree phase line Choose an input and grounding wire size according to local or national codes Refer to the Technical Specifications page at the beginning of this section Fuse the input circuit with the recommended super lag fuses or delay type1 circuit breakers Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if not weld INPU...

Page 11: ...plifies loading and unloading of gas cylinders A cylinder is loaded by leaning it slightly sideways and rolling it toward the platform The cylinder s weight will push the platform downward against the floor forming a ramp At this point the cylinder may be rolled up the platform into its final position Secure the cylinder in place with the provided chain Unload by following these steps in reverse F...

Page 12: ... for other available remote controls CONNECTIONS FOR STICK SMAW WELDING STICK ELECTRODE CABLE AND WORK CABLE CONNECTION Refer to Included Equipment in the Operation Section of this manual for STICK welding equipment which is included with the Square Wave TIG 175 An electrode holder with cable is supplied with the Square Wave TIG 175 Turn the Power Switch OFF Connect the cable quick connect plug in...

Page 13: ...APABILITY The Square Wave TIG 175 is rated at 150 amps 15 volts at 25 duty cycle on a ten minute basis It is capable of higher duty cycles at lower output currents It is capable of 175 amps 27 volts at a lower duty cycle If the duty cycle is exceeded a thermal protec tor will shut off the output until the machine cools SQUARE WAVE TIG 175 ELECTRIC SHOCK can kill Do not touch electrically live part...

Page 14: ...CONTROL This control is active in both TIG and Stick modes In Stick mode the current control sets the welding current In TIG mode this control sets the maximum current The Amptroltm will adjust the welding current from the machine mini mum to this maximum setting 5 OVER TEMPERATURE LIGHT If the welder overheats due to blocked air flow high ambient air temperature or exceeded duty cycle an internal...

Page 15: ...start and stop the welding if no remote control of the current is desired Refer to the Accessories section of this manual Both the Hand and Foot Amptrol work in a similar man ner For simplicity the following explanation will refer only to Amptrols meaning both Foot and Hand mod els The term minimum refers to a foot pedal in the up position as it would be with no foot pressure or a Hand Amptrol in ...

Page 16: ...110 105 135 Fleetweld 37 DC 70 95 100 135 145 Max Fleetweld 47 DC 75 95 100 145 135 Max Jet LH MR DC 85 110 110 160 130 Max Blue Max Stainless DC 40 80 75 110 95 110 Red Baron Stainless DC 40 70 60 100 90 140 Mild steel procedures are based on recommended procedures listed in C2 10 8 94 and the maximum rating of the Square Wave TIG 175 Jet LH MR procedures are based on Jet LH 78 MR Blue Max proced...

Page 17: ...p K860 1 LA 17 12 5 ft long back cap K860 5 LA 17 25 ft long back cap NOTE Each torch requires a quick connector plug S22529 1 and strain relief boot M17255 be installed onto the cable Collets collet bodies and nozzles are not included and must be ordered separately Quick Connect Plug S22529 1 and Strain Relief Boot M17255 One of each is shipped with the welder to connect the Magnum LA 9 torch If ...

Page 18: ...ndition 5 Clean air louvers to ensure proper air flow and cooling 6 The fan motor has sealed ball bearings which require no maintenance 7 The arc starter spark gap spacing is factory set at 0 015 inch It typically will not require periodic maintenance Refinishing the contacts is not rec SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE WARNING WARNING ommended If the contacts are replaced reset ...

Page 19: ...S The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION If you have exhausted all of the items in step 2 Contact your Local Lincoln Authorize...

Page 20: ...voltage when arc start switch or Amptrol is activated fan is work ing 1 Make certain that the input power switch is in the ON position and machine is plugged in 2 Check the input voltage at the machine Input voltage must match the rating plate and voltage connection Refer to Reconnect Procedure in the Installation sec tion of this manual 3 Blown or missing fuses in input line 1 Check for proper in...

Page 21: ...MS POSSIBLE AREAS OF MISADJUSTMENTS S RECOMMENDED COURSE OF ACTION Machine regularly over heats ther mostat opens Yellow light on front panel glows The fan runs but machine has no output 1 Welding application may exceed recommended duty cycle Reduce the duty cycle 2 Dirt and dust may have clogged the cooling channels inside the machine Blow out unit with clean dry low pressure air 3 Air intake and...

Page 22: ...re that the machine is ground ed properly according to the installation instructions If there are other high frequency sources in the area make cer tain that they are grounded properly 2 Check Amptrol for proper opera tion and loose connections 3 Check for proper input voltage and proper voltage reconnec tion 1 Tungsten electrode may be too large in diameter for the current setting 2 Tungsten not ...

Page 23: ...ly or organic conta mination from the work piece 2 Tungsten electrode may be cont aminated Replace or sharpen 3 Check for contaminated gas or leaks in the gas line torch or connections 4 Gas shielding may be insuffi cient Increase gas flow reduce tungsten stickout beyond gas cup 1 Check for poor connections in the welding circuit 2 Gas shielding may be insuffi cient Increase gas flow reduce tungst...

Page 24: ...ng of the work piece The end of the tungsten electrode melts away 1 If the machine location is in a highly dirty environment with conductive contaminants check and clean the spark gap with a low pressure air stream per the maintenance instructions 1 Gas supply is empty or not turned on 2 Flow regulator may be set too low 3 Gas hose may be pinched 4 Gas flow may be blocked with dirt Check filter sc...

Page 25: ... CAUTION STICK WELDING PROBLEMS PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTS S RECOMMENDED COURSE OF ACTION Stick electrode Blasts Off when arc is struck Stick electrode sticks in the weld puddle 1 Weld current may be set too high for electrode size Reduce current control setting or use a larger diameter electrode 1 The weld current may be set too low Increase the current control setting or ...

Page 26: ... C L E R E M O T E A M P T R O L J4 J 4 S P A R K G A P B B A C D C D C A C D E B F B D C E A F G H B D A E C F G H P O L A R I T Y S W I T C H M I C R O S W I T C H R E A R V I E W S H O W N I N A C P O S I T I O N 1 1 5 V A C B B 2 3 2 B 2 3 0 W 2 0 4 W 2 0 1 U 2 1 0 R 2 0 9 1 1 5 V A C 1 8 V A C 1 8 V A C 7 8 V A C T1 L 1 L 2 T O G R O U N D P E R P O L A R I T Y S W I T C H E L E C T R I C A L...

Page 27: ...TICK CLOSED TIG OPEN THERMAL LIGHT TL1 J5 236A 115VAC L1 SCR4 Y SCR3 SCR2 SCR1 H3 R2 233 277 276 231 312 244 311 242 241 ARC STARTER AS BLY 233 275 231 276 243 237 C4 277 R3 236A F S F S POWER ON LIGHT 314 313 W 221 R 222 217 G1 218 G2 G3 220 275 STICK 243 J2 TIG 244 J1 A B C D E E D C A B J6 236B T1 78VAC 18VAC 18VAC 115VAC POLARITY SWITCH 10K A B AT MINIMUM AMPTROL REMOTE RECEPTACLE REMOTE J4 G4...

Page 28: ...NOTES SQUARE WAVE TIG 175 ...

Page 29: ...16 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location Orders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only Prices include shipment by 4 th Class Book Rat...

Page 30: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 31: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 32: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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