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TROUBLESHOOTING

E-3

E-3

SQUARE WAVE TIG 355

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

detailed throughout this manual.

TIG WELDING

SYMPTOM

CAUSE AND REMEDY

Machine does not respond (no gas flow, no

1.

Defective Arc Start Switch or Amptrol. Check for con-

high frequency, no open circuit voltage) when

tinuity between pins D and E on cable connector when Arc

Arc Start Switch or Amptrol is pressed.

Start Switch or Amptrol is pressed.

2.

Defective Protection PC board. Replace.

3.

Defective Control PC board. Replace.

No gas or water flow when Arc Start Switch

1.

Gas supply is empty or not turned on.

is closed in TIG mode.

2.

Pinched gas or water hose.

3.

Gas and High Frequency fuse (F2) blown. Replace fuse.

4.

Gas and High Frequency fuse (F2) is too small. Use 1.5 amp
fuse.

5.

Gas and water lines or solenoids are blocked with dirt. Clean
out and use filters to prevent recurrence.

6.

Power PC board is defective. Replace.

No High Frequency.

1.

High Frequency switch S12 must be in either START or
CONTINUOUS position for high frequency to function.

2.

Preflow control is set too long. Reduce Preflow setting. (High
Frequency does not come on until end of preflow period.)

3.

Gas and High Frequency fuse (F2) blown. Replace fuse F2.

4.

Gas and High Frequency fuse (F2) is too small. Use 1.5 amp
fuse.

5.

Spark Gap is too large. Set to gap specified on cover plate.

6.

Power PC board is defective. Replace.

Weak high frequency.

1.

Spark gap is set too close. Set to 0.015 inches (0.381 mm)
gap for most applications.

2.

High Frequency Intensity control set too low. Increase to suit.

3.

Work and electrode cables in poor condition, allowing high
frequency to “leak” to ground. Use good quality cables,
preferably those with a high natural rubber content, as short
as possible.

4.

No shielding gas. Adjust gas flow for 10 to 30 CFH (4.7 to
14.1 l/min.) for most applications. (High frequency will not
jump from the tungsten to the work without shielding gas.)

Machine shuts down (pilot light goes out

1.

If open circuit voltage is greater than 80 volts before shut-

and fans stop) when Arc Start Switch or

down occurs, Control PC board is defective. Replace.

Amptrol is pressed.

Cannot preset a current on Ammeter when the

1.

Defective Arc Start Switch. There should be

no

continuity

Arc Start Switch or Amptrol is

not

pressed.

between pins D and E of cable connector when Arc Start
Switch or Amptrol is

not

pressed.

2.

Defective Current Control potentiometer. Replace.

3.

Defective Control PC board. Replace.

4.

Defective Feedthrough PC board. Replace.

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Содержание SQUARE WAVE IM467-B

Страница 1: ...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 think before you act and be careful OPERATOR S MANUAL 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 ww...

Страница 2: ...ER 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 purchase 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 E205 is avail...

Страница 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 ...

Страница 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...

Страница 5: ...és 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 Eloig...

Страница 6: ...tion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number______________________________...

Страница 7: ...Connections A 3 Reconnect Procedure A 4 Output Connections A 6 TIG Torch Connection A 6 Stick Electrode Cable Connection A 7 Operation Section B Safety Instructions B 1 General Description B 2 Recommended Processes B 2 Operational Features and Controls B 2 Design Features and Advantages B 2 Welding Capability B 3 Limitations B 3 Controls and Settings B 4 Upper Case Front Controls B 4 Lower Case Fr...

Страница 8: ...ccessories Section C Options Accessories C 1 Maintenance Section D Safety Precautions D 1 Input Filter Capacitor Discharge Procedure D 1 Routine and Periodic Maintenance D 2 General Component Locations D 3 Troubleshooting Section E Wiring Diagram Dimension Prin tand Equipment Manufacturer s Certification Form Section F Parts Manual P196 Series ...

Страница 9: ...e in Wire in Conduit Super LAG Voltage or Breaker Rating on Conduit AWG AWG IEC Input Conduit AWG AWG IEC or Breaker Frequency Size Nameplate IEC Sizes Sizes Amperes IEC Sizes Sizes Size 208 60 150 110 4 25mm2 6 16mm2 148 2 35mm2 6 16mm2 200 230 60 125 100 6 16mm2 6 16mm2 134 2 35mm2 6 16mm2 175 460 60 60 50 8 10mm2 10 6mm2 67 6 16mm2 8 10mm2 80 575 60 50 40 8 10mm2 10 6mm2 54 6 16mm2 8 10mm2 70 P...

Страница 10: ...enera tor being similar to a radio transmitter can be blamed for many radio TV and electronic equipment interfer ence problems These problems may be the result of radiated interference Proper grounding methods can reduce or eliminate radiated interference The Square Wave TIG 355 has been field tested under recommended installation conditions It complies with FCC allowable limits for radiation For ...

Страница 11: ...Failure to observe these recommended installation procedures can cause radio or TV interference problems and result in unsatisfactory welding per formance resulting from lost high frequency power INPUT CONNECTIONS Be sure the voltage phase and frequency of the input power is as specified on the rating plate located on the front of the machine Welder supply line entry provision is in the case rear ...

Страница 12: ...and HIGH correspond to the nameplate input voltages of a triple voltage welder Dual voltage welders use only LOW and HIGH Single voltage welders use only HIGH EXAMPLE On a 208 230 460 volt welder LOW is 208V MID is 230V and HIGH is 460V Fuse the input circuit with the recommended super lag fuses or delay type1 circuit breakers Choose an input and grounding wire size according to local or national ...

Страница 13: ... 60 200 50 137 4 6 150 220 50 124 4 6 125 440 50 65 8 10 60 TABLE A 2 RECOMMENDED INPUT WIRE AND FUSE SIZES For Unbalanced AC TIG Welding Above 230 AMPS Based on the 1990 U S National Electrical Code 2 60 Duty Cycle Input Amperes at 300 Amp Type 75 C Input Unbalanced Wire in Conduit Grounding Wire Fuse Size Volt Freq AC Output AWG Copper Cond AWG Copper Cond Super Lag 208 60 148 2 6 200 230 60 134...

Страница 14: ...de cables should be routed through the cable strain relief holes provided in the base directly below the welding ouput terminals Connect the TIG torch gas and water fittings to the welder fittings any torch with fittings that conform to Compressed Gas Association CGA standards can be used The welder fittings have the following threads Gas Inlet and Outlet 5 8 18 right hand female Water inlet and O...

Страница 15: ...ater cooled torch Connect the torch water line to the welder Water Out fitting Use a nonmetallic drain line from the electrode connection to the drain or water recirculating pump For other water coolers or torches consult the manu facturer s instructions for the water cooler or TIG torch being used STICK ELECTRODE CABLE CONNECTION Turn the Power switch Off Run the electrode and work cables through...

Страница 16: ...cloth ing Insulate yourself from the 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 have held com bustibles ARC RAYS can burn Wear eye ear and body protection Observe add...

Страница 17: ...rrent pulse on and Crater Fill controls fade out peak current The following additional features are also standard Digital ammeter selectable for either volts or amps Status Indicator LEDs for gas and water high frequen cy arc established start peak background crater fill DESIGN FEATURES AND ADVANTAGES Designed to NEMA EW 1 and International IEC 974 Standards Single output range of 2 400 amps cover...

Страница 18: ...ater fittings Large safety margins and protective circuits protect rectifiers from transient voltages and high currents Line voltage compensated Thermostatically protected Electronic over current protection WELDING CAPABILITY The Square Wave TIG 355 is NEMA Class II 40 Power Source rated 350 amps at 34 volts 40 duty cycle The duty cycle is based upon a 10 minute time period For 40 duty cycle it is...

Страница 19: ...ocations OPERATION B 4 B 4 SQUARE WAVE TIG 355 1 REMOTE LOCAL CURRENT CONTROL SWITCH 7 VOLTS AMPS METER SWITCH 12 PREFLOW TIMER 2 MODE SWITCH STICK TIG 8 AC WAVE BALANCE 13 SPOT CONTROLS 3 2 STEP 4 STEP SWITCH 9 AUTO BALANCE LED 14 START CONTROLS 4 HIGH FREQUENCY SWITCH 10 AFTERFLOW 15 PULSE CONTROLS 5 DIGITAL VOLTMETER AMMETER 11 STICK ARC FORCE 16 CRATER FILL CONTROLS 6 PEAK CURRENT CONTROL 17 S...

Страница 20: ...own during the Preflow time The Arc switch can be released once an arc is established NOTE If the Crater Fill switch Item 16 is ON welding will continue after the Arc Start switch is pressed and released the second time See Crater Fill Controls NOTE If the arc goes out while welding in the 4 Step mode the machine will try to re establish an arc for a period of two seconds The output con tactor wil...

Страница 21: ...e current produces the cleaning or oxide removal on aluminum this setting is used for heavily oxidized aluminum Use only the amount of cleaning required Greater amounts of positive current will heat the tungsten more and possibly cause it to melt or spit Also the arc is usually more flared and less stable with more positive cleaning current PENETRATION Above 3 on the dial Provides more negative cu...

Страница 22: ...ent preset by the Start Current control The Volts Amps switch Item 7 must be in the AMPS position to read preset current Start Current Control Locked out if the Start switch is off Presets the current that will be provided at the start of the weld The current can be preset from 2 to 400 amps The position of the amptrol has no effect on the initial current The present Start Current is displayed on ...

Страница 23: ... the Spot Time The current control item 1 switch must be in LOCAL when using Crater Fill OFF Locks out Crater Fill controls Fade out Control Controls how slowly the cur rent fades out The FAST setting will cause current to ramp down from the welding current toward 2 amps in approximately 1 2 second the SLOW set ting in approximately 20 seconds The time for downslope to the Crater Fill Current leve...

Страница 24: ...ill light in response to the control cir cuit command even if other components do not work For example if the gas supply is turned off or the gas solenoid valve malfunctions or the fuse is blown the gas will not flow even though the Gas and Water LED lights up Another example is the High Frequency LED which can light yet there will not be high frequency due to a blown fuse or defective high freque...

Страница 25: ...OPERATION B 10 B 10 SQUARE WAVE TIG 355 LOWER CASE FRONT CONTROLS Refer to Figure B 3 for the location of the following controls FIGURE B 3 LOWER CASE FRONTCONTROLS 4 5 3 2 1 9 8 7 6 ...

Страница 26: ...E A six pin circular con nector for an Arc Start switch or an Amptrol remote current control 7 115 VOLT RECEPTACLE AND CIRCUIT BREAK ER A duplex 15 amp grounded NEMA 5 15R receptacle and 15 amp circuit breaker Fifteen amps of 115 volt AC power is available continu ously whenever the power is on The circuit breaker button will pop out if it trips Reset by pushing it in after the circuit breaker coo...

Страница 27: ... for rec ommended tungsten currents In the example above a 3 32 2 4 mm tungsten may be used on DC to weld near 200 amps To start the weld the operator may have to depress the Amptrol approximately 1 4 of the way down or to nearly 70 amps in order to start the arc Merely depressing the Amptrol to its 2 amp minimum position will not start the arc A similar situation occurs when the Start controls ar...

Страница 28: ...OPERATION B 13 B 13 SQUARE WAVE TIG 355 FIGURE B 4 AMPTROLS USED WITH CURRENT CONTROL IN THE LOCAL POSITION FIGURE B 5 AMPTROLS USED WITH CURRENT CONTROL IN REMOTE POSITION ...

Страница 29: ...ch has no effect in STICK mode 4 Preset the current with the Current control and the Ammeter 5 Set the desired Arc Force See CONTROLS AND SETTINGS item 11 Arc Force The Wave Balance and Afterflow controls have no effect in STICK mode 6 Turn the Start switch OFF or set the START con trols for a hot start if needed See CONTROLS AND SETTINGS item 14 Start Controls 7 Strike an arc and weld There will ...

Страница 30: ... LOCAL OR REMOTE CURRENT CONTROL START SWITCH ON START CURRENT SET HIGHER THAN PRESET CURRENT HOT START START TIME VARIABLE ALL OTHER PANEL SWITCHES OFF PRESET CURRENT PRESET CURRENT HOT START START CURRENT REMOTE AMPTROL CONTROLS FROM 2 AMPS UP TO PRESET CURRENT REMOTE AMPTROL CONTROLS FROM 2 AMPS UP TO PRESET CURRENT START TIME AFTERFLOW EFFECT OF CONTROLS ON TIG WELDING PREFLOW CLOSE ARC START ...

Страница 31: ...Y HAVE HOT START CRATER FILL SWITCH ON ALL OTHER PANEL SWITCHES OFF LOCAL OR REMOTE CURRENT CONTROL PULSE SWITCH ON PULSES PER SECOND BACKGROUND DUTY CYCLE PULSE ON ALL OTHER LOWER PANEL SWITCHES OFF SLOW FADE OUT FAST FADE OUT PRESET CURRENT PRESET CURRENT PEAK OPEN ARC START SWITCH BACKGROUND CURRENT START CRATER FILL PULSE SOFT START CRATER FILL START CURRENT REMOTE AMPTROL CONTROLS FROM 2 AMPS...

Страница 32: ...ALL OTHER LOWER PANEL SWITCHES OFF SPOT TIME IS CUT SHORT IF ARC START SWITCH IS OPENED BEFORE END OF SPOT TIME SPOT TIME SPOT TIME REMOTE AMPTROL CONTROLS CURRENT FROM 2 AMPS UP TO PRESET CURRENT START PULSE CRATER FILL SPOT SPOT START PULSE CRATER FILL EFFECT OF CONTROLS ON TIG WELDING CLOSE ARC START SWITCH WELD BEGINS OPEN ARC START SWITCH THE SPOT TIMER CAN BE USED TO TIME A PROGRAMMED SEQUEN...

Страница 33: ...0 300 290 390 23 27 11 13 18 22 8 10 1 4 6 4 750 1000 80 125 325 450 500 630 250 400 340 525 28 32 13 15 23 27 11 13 1 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shielding gases 2 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 1 Thoriated EWTh 1 2 Thoriated EWTh 2 Though not yet recognized by ...

Страница 34: ...ting the high frequency becomes available to strike the arc 11 Hold the Arc Start Switch down or operate the Amptrol until the weld is completed Release the Arc Start switch or the Amptrol to stop the arc When the Afterflow timer completes the cycle the gas and water valves close To make another weld repeat steps 10 and 11 TIG WELDING SEQUENCE OF OPERATION 4 STEP MODE Do not leave stick electrode ...

Страница 35: ...stat cools and resets will restart the welder If the primary thermostat opens the power will stay on pilot light and meters on and fans running but no more than 5 amps DC output current will be available This allows the fans to cool the machine Depending on the amount of welder overload the thermostat should reset within five minutes with the fan motors running When the primary thermostat cools an...

Страница 36: ...older and sockets for an industry standard optically isolated Solid State Relay SSR module purchased separate ly see below Solid State Relays SSRs K847 DC Can switch up to 40VDC 2 amps maximum load Package of two K847 AC Can switch up to 130VAC 2 amp maximum load Package of two Amptrol K870 or K963 Provides a remote cur rent control for most TIG welding applications Model K870 is a foot operated c...

Страница 37: ... greater safety when you are working on the Square Wave TIG 355 with INPUT POWER REMOVED 1 Remove input power to the machine 2 With a 5 16 nut driver remove the sheet metal screws that hold the right case side in place Remove the right case side 3 With a volt ohmmeter carefully check the voltage across the input power factor capacitors When input power is removed the voltage across each capacitor ...

Страница 38: ...components thorough ly See Figure D 2 for their location Main transformer Output terminals located on case front Polarity switch located on case front Rectifier assembly Control box assembly Spark gap assembly Protection PC board 3 Inspect the welder output terminals and control cables for fraying cuts and bare spots 4 Inspect the spark gap spacing at regular intervals To access the spark gap remo...

Страница 39: ...CATIONS 1 OUTPUT RECTIFIER SCR BRIDGE ASSEMBLY 2 INPUT CONTACTOR 3 RECONNECT PANEL 4 PILOT TRANSFORMER 5 FAN AND FAN MOTOR 6 INPUT POWER FACTOR CAPACITOR 7 MAIN TRANSFORMER 8 CHOKE 9 HIGH VOLTAGE TRANSFORMER 10 PC BOARDS POWER CONTROL 11 CASE FRONT 1 2 3 4 7 8 9 10 11 5 6 ...

Страница 40: ...ile welding a The Meter PC board may be defective Replace b The Control PC Board may be defective Replace 2 If machine does not weld a Current control pot may be defective Replace b The Control PC board may be defective Replace HOW TO USE THIS GUIDE Carefully read through each applicable section listed below Remember that most prob lems are caused by improper setup such as switch settings control ...

Страница 41: ...w output in TIG troubleshoot ing section 4 If TIG welding output is OK Control PC board is defec tive Replace Machine welds at very high output regard 1 Are the Start controls set correctly See Stick elec trode less of Current potentiometer setting blasts off above 2 Are the TIG welding outputs OK If not see TIG trou bleshooting section 3 If TIG welding output is OK Control PC board may be defecti...

Страница 42: ...flow period 3 Gas and High Frequency fuse F2 blown Replace fuse F2 4 Gas and High Frequency fuse F2 is too small Use 1 5 amp fuse 5 Spark Gap is too large Set to gap specified on cover plate 6 Power PC board is defective Replace Weak high frequency 1 Spark gap is set too close Set to 0 015 inches 0 381 mm gap for most applications 2 High Frequency Intensity control set too low Increase to suit 3 W...

Страница 43: ...g used Try in LOCAL Current Control at a higher current setting SEE NOTE BELOW 4 Contaminated tungsten If tungsten becomes contaminated with foreign materials grind off end of tungsten to expose fresh electrode Grind to a point for DC work and leave an end for AC work 5 Incorrect tungsten type Pure or zirconiated is recommended for AC welding thoriated is required for DC welding 6 No shielding gas...

Страница 44: ...etting the actual weld time will be the spot time plus the crater fill time The Start Current seems very hot The Start Current dial is labeled MIN to MAX of the welder output or 2 to 400 amps Always be sure to use the Start Read pushbutton to check the Start Current preset reading on the digital ammeter before welding The Pulser does not seem to operate 1 If Start Controls are used pulsing does no...

Страница 45: ...the switch is pressed Check the cable for breaks and repair or replace as necessary Check the switch and its connections 2 Be sure the 2 Step 4 Step Switch is set correctly K846 Interface Kit Solid State Relay Module output does not close 1 Is the correct type of solid state relay module installed AC when corresponding Status PC board LED lights modules work only for AC circuits and DC modules onl...

Страница 46: ... DUAL VOLTAGE MACHINE SINGLE VOLTAGE MACHINE MODE S10 LOCAL STICK CONTINUOUS REMOTE TIG OFF S11 S12 START TO GROUND PER NATIONAL ELECTRIC CODE 303 301 302 304 7 25 97C SQUARE WAVE TIG 355 WIRING DIAGRAM 2519 G 4 STEP 2 STEP S19 HIGH FREQUENCY CURRENT CONTROL 2 STEP 4 STEP ...

Страница 47: ... WAVE TIG 355 F 2 F 2 DIMENSION PRINT Square Wave TIG355 6 18 93C 17275 M S W TIG 355 K841 50 41 26 00 6 67 15 22 74 24 12 94 23 28 22 25 11 12 7 11 20 00 27 65 LOCATION OF 406 MOUNTING HOLES 43 93 34 84 45 20 3 25 Ø ...

Страница 48: ...d as recommended in the accom panying manual it may reasonably be expected to meet the Federal Communications Commission established R F energy radiation limitation The Lincoln Electric Company EQUIPMENT INSTALLATION CERTIFICATION The above identified equipment has been installed and will be operated and maintained in compliance with manufacturer s recommendations made in the accompanying oper ati...

Страница 49: ...Notes ...

Страница 50: ...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...

Страница 51: ...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...

Страница 52: ...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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