RETURN TO MAIN INDEX
IM467-B
May, 2003
SQUARE WAVE TIG 355
9951, 10056, 10389
For use with machines having Code Numbers:
9952, 10057, 10390
9953, 10058
9954, 10059
9955, 10060
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, think before you
act and be careful.
OPERATOR’S MANUAL
Copyright © 2003 Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� 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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. 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
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 available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot� when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot� parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
3.b. Insulate yourself from work and ground using dry insulation.
material to protect your skin and that of your helpers from
Make certain the insulation is large enough to cover your full
the arc rays.
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if welding
screening and/or warn them not to watch the arc nor expose
must be performed under electrically hazardous
themselves to the arc rays or to hot spatter or metal.
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
can be dangerous.
accidental contact with the workpiece or ground) use
5.a. Welding may produce fumes and gases
the following equipment:
hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder.
fumes and gases.When welding, keep
� DC Manual (Stick) Welder.
your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control.
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode,
welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic
ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�.
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical
which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection
low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded.
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical
respirator may be required. Additional precautions are
(earth) ground.
also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace
coming from degreasing, cleaning or spraying operations.
damaged insulation.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
3.g. Never dip the electrode in water for cooling.
products.
3.h. Never simultaneously touch electrically “hot� parts of
5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage
cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage
especially in confined areas, to insure breathing air is safe.
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
3.i. When working above floor level, use a safety belt to protect
equipment and the consumables to be used, including the
yourself from a fall should you get a shock.
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
3.j. Also see Items 6.c. and 8.
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar �95
iii iii
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, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact can
any other source of heat, sparks, or flame.
cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
7. Quand on ne soude pas, poser la pince à une endroit isolé de
et les précautions de sûreté specifiques qui parraissent dans ce
la masse. Un court-circuit accidental peut provoquer un
manuel aussi bien que les précautions de sûreté générales suiv-
échauffement et un risque d’incendie.
antes:
8. S’assurer que la masse est connectée le plus prés possible de
Sûreté Pour Soudage A L’Arc
la zone de travail qu’il est pratique de le faire. Si on place la
1. Protegez-vous contre la secousse électrique:
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
a. Les circuits à l’électrode et à la piéce sont sous tension
passer le courant de soudage par les chaines de levage,
quand la machine à souder est en marche. Eviter toujours
câbles de grue, ou autres circuits. Cela peut provoquer des
tout contact entre les parties sous tension et la peau nue
risques d’incendie ou d’echauffement des chaines et des
ou les vétements mouillés. Porter des gants secs et sans
câbles jusqu’� ce qu’ils se rompent.
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
9. Assurer une ventilation suffisante dans la zone de soudage.
soude dans des endroits humides, ou sur un plancher met-
Ceci est particuliérement important pour le soudage de tôles
allique ou des grilles metalliques, principalement dans
galvanisées plombées, ou cadmiées ou tout autre métal qui
les positions assis ou couché pour lesquelles une grande
produit des fumeés toxiques.
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
10. Ne pas souder en présence de vapeurs de chlore provenant
soudage et la machine à souder en bon et sûr état defonc-
d’opérations de dégraissage, nettoyage ou pistolage. La
tionnement.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
d.Ne jamais plonger le porte-électrode dans l’eau pour le
du solvant pour produire du phosgéne (gas fortement toxique)
refroidir.
ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
parce que la tension entre les deux pinces peut être le total
le code “Code for safety in welding and cutting� CSA Standard
de la tension à vide des deux machines.
W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
LES MACHINES À SOUDER À
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
TRANSFORMATEUR ET À
corps.
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi 1. Relier à la terre le chassis du poste conformement au code de
qu’un verre blanc afin de se protéger les yeux du rayon- l’électricité et aux recommendations du fabricant. Le dispositif
nement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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.
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product •â?¢â??
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 received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
� For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then
“Product Registration�. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi vi
TABLE OF CONTENTS
Page
Safety.................................................................................................................................................i-iv
Installation .............................................................................................................................Section A
Technical Specifications Square Wave TIG 355 .........................................................................A-1
Input and Output Specifications ..........................................................................................A-1
Cable and Fuse Sizes...........................................................................................................A-1
Physical Dimensions ............................................................................................................A-1
Safety Precautions......................................................................................................................A-2
Select Suitable Location .............................................................................................................A-2
Stacking................................................................................................................................A-2
Lifting .................................................................................................................................A-2
Tilting .................................................................................................................................A-2
High Frequency Precautions.......................................................................................................A-2
Input Connections.......................................................................................................................A-3
Ground Connection ..............................................................................................................A-3
Input Supply 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 Front Controls ................................................................................................B-10
Hand and Foot Amptrolâ„? Operation .................................................................................B-12
Welding Operation ....................................................................................................................B-14
Initial Start-up.....................................................................................................................B-14
Stick Welding ....................................................................................................................B-14
TIG Welding Guidelines......................................................................................................B-14
TIG Welding Sequence of Operation (2-Step Mode) .........................................................B-19
SQUARE WAVE TIG 355
vii vii
TABLE OF CONTENTS
TIG Welding Sequence of Operation (4-Step Mode) .........................................................B-19
Overload Protection..................................................................................................................B-20
Auxiliary Power .........................................................................................................................B-20
Accessories...........................................................................................................................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
SQUARE WAVE TIG 355
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - SQUARE WAVE TIG 355
INPUT - SINGLE PHASE ONLY
Input Voltages: 208 230 460 575
Input Currents
@ 350A/34 VDC 110 100 50 40
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
40% Duty Cycle 350 34 v
60% Duty Cycle 300 32 v
100% Duty Cycle 220 29 v
OUTPUT
Maximum Open Continuous
Circuit Voltage Current Range Auxiliary Power
80 Volts Max. 2-400 Amps AC and DC 115 VAC
15 Amps Continuous
RECOMMENDED INPUT WIRE AND FUSE SIZES
For Unbalanced AC TIG Welding Above 230 Amps,
For all Stick, DC TIG, and Balanced AC TIG
300/32V/60% Duty Cycle, Unbalance Based on the
Welding at 350A/34V/40% Duty Cycle Based
1990 U.S. National Electrical Code
on the 1990 U.S. National Electrical Code
Type 75°C Type 75°C
Fuse Input Type75°C Copper Ground Type 75°C Copper Ground Fuse
Input (Super Lag) Ampere Copper Wire in Wire in Conduit Copper Wire 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 (16mm ) 6 (16mm ) 134 2 (35mm ) 6 (16mm ) 175
2 2 2 2
460/60 60 50 8 (10mm ) 10 (6mm ) 67 6 (16mm ) 8 (10mm ) 80
2 2 2 2
575/60 50 40 8 (10mm ) 10 (6mm ) 54 6 (16mm ) 8 (10mm ) 70
2 2 2 2
PHYSICAL DIMENSIONS
Height Width Depth Weight
884 mm 565 mm 660 mm 232 kg
34.84 in. 22.25 in. 26.00 in. 510 lbs.
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
0° to 40°C -50° to 85°C
SQUARE WAVE TIG 355
A-2 A-2
INSTALLATION
Read this entire installation section before you TILTING
start installation.
Place the machine on a secure, level surface or on a
recommended undercarriage. Any surfaces you
place it on other than the ground must be firm, non-
SAFETY PRECAUTIONS skid, and structurally sound.
WARNING
HIGH FREQUENCY INTERFERENCE
ELECTRIC SHOCK can kill.
PROTECTION
� Do not touch electrically live parts
or electrodes with your skin or wet The spark gap oscillator in the high frequency genera-
clothing. tor, being similar to a radio transmitter, can be blamed
for many radio, TV and electronic equipment interfer-
� Insulate yourself from the work
ence problems. These problems may be the result of
and ground.
radiated interference. Proper grounding methods can
� Always wear dry insulating gloves. reduce or eliminate radiated interference.
Only qualified personnel should install, use, or service The Square Wave TIG 355 has been field tested under
this equipment. recommended installation conditions. It complies with
FCC allowable limits for radiation. For convenience, a
certificate of compliance is packed with the welder. It
SELECT SUITABLE LOCATION can be used to prove FCC RF Energy Radiation Limits
compliance if necessary. (It is the owner's responsi-
Place the Square Wave TIG 355 where clean, cooling
bility to obtain this certification.) The Square Wave TIG
air can flow freely in through the side louvers and out
355 also complies with NEMA standards for high fre-
through the rear louvers. Keep dust, dirt, and other
quency stabilized power sources.
foreign materials that can be drawn into the machine
Radiated interference can develop in the following four
to a minimum. Failure to observe these precautions
ways:
can lead to excessive operating temperatures and
nuisance shut-downs. Read the section, "High
1. Direct interference radiated from the welder.
Frequency Interference Protection" before planning
2. Direct interference radiated from the welding leads.
the installation.
3. Direct interference radiated from feedback into the
power lines.
STACKING
4. Interference from re-radiation of “pickup� by
Square Wave TIG 355s may be stacked two high. ungrounded metallic objects.
The bottom machine must be on a stable, hard, level
Keeping these contributing factors in mind, installing
surface. Be sure that the two pins in the roof of the
equipment per the following instructions should mini-
bottom machine fit into the holes in the base of the
mize problems.
top machine.
1. Keep the welder power supply lines as short as
LIFTING
possible and completely enclose them in rigid
metallic conduit or equivalent shielding for a mini-
WARNING mum distance of 50 feet (15.2m). There should be
good electrical contact between this conduit and
CYLINDER MAY EXPLODE if damaged. the welder. Both ends of the conduit should be
connected to a driven ground and the entire length
� Do not lift the welder with a cylinder attached.
should be continuous.
2. Keep the work and electrode leads as short as pos-
The Square Wave TIG 355 weighs 510 lbs. (232 kg) sible and as close together as possible. Lengths
without a gas cylinder. Lift the machine by the lift should not exceed 25 ft (7.6m). Tape the leads
bail only. Never lift the machine with a cylinder together when practical.
attached.
SQUARE WAVE TIG 355
A-3 A-3
INSTALLATION
3. Be sure the torch and work cable rubber coverings FIGURE A.1 � REAR PANEL
are free of cuts and cracks that allow high fre-
quency leakage. Cables with high natural rubber 2
content, such as Lincoln Stable-Arc® better resist
high frequency leakage than neoprene and other
3
synthetic rubber insulated cables.
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 fol-
lowing methods.
a) A metal underground water pipe in direct con-
tact with the earth for ten feet or more.
b) A 3/4� (19mm) galvanized pipe or a 5/8�
(16mm) solid galvanized iron, steel or copper
rod driven at least eight feet into the ground.
The ground should be securely made and the
grounding cable should be as short as possible
1. WARNING DECAL
using cable of the same size as the work cable, or
2. INPUT POWER ENTRY
larger. Grounding to the building frame electrical
3. RECONNECT PANEL COVER
conduit or a long pipe system can result in re-radi-
ation, effectively making these members radiating
GROUND CONNECTION
antennas.
The frame of the welder must be
6. Keep all access panels and covers securely in
grounded. A ground terminal marked
place. with the symbol is located at the bot-
tom of the input box for this purpose.
7. All electrical conductors within 50 ft (15.2m) of the
See your local and national electrical
welder should be enclosed in grounded, rigid
codes for proper grounding methods.
metallic conduit or equivalent shielding. Flexible
Also follow other grounding instructions given in the
metallic conduit is generally not suitable.
section “High Frequency Interference Protection.�
8. When the welder is enclosed in a metal buidling, INPUT SUPPLY CONNECTION
several good earth driven electrical grounds (as in
Be sure the voltage, phase, and frequency of the input
5 (b) above) around the periphery of the building
power is as specified on the welder nameplate.
are recommended.
Failure to observe these recommended installation
WARNING
procedures can cause radio or TV interference
problems and result in unsatisfactory welding per-
ELECTRIC SHOCK can kill.
formance resulting from lost high frequency
� Have a qualified electrician install
power.
and service this equipment.
� Turn the input power off at the fuse
INPUT CONNECTIONS box before working on this equip-
ment.
Be sure the voltage, phase, and frequency of the input
� Do not touch electrically hot parts.
power is as specified on the rating plate, located on
the front of the machine.
Have a qualified electrician connect the input power
Welder supply line entry provision is in the case rear
leads to L1 and L2 of the input contactor in accor-
panel with a removable cover over the input connec-
dance with all local codes and national electrical
tion panel area. See Figure A.1.
codes. Use a single phase line or one phase of a two
or three phase line. Refer to the connection diagram
located on the inside of the cover of the Reconnect
Panel. Also see Figure A.2.
SQUARE WAVE TIG 355
A-4 A-4
INSTALLATION
FIGURE A.2 � INPUT SUPPLY CONNECTIONS
Refer to Figure A.2 for the following procedure.
WARNING Welders are shipped connected for the highest input
voltage listed on the rating plate. To change this con-
nection for a different input voltage, reconnect both
ELECTRIC SHOCK can kill.
the power strap (P) and control lead (C) to their
� Do not touch electrically live parts
respective terminals corresponding to the input volt-
or electrodes with your skin or wet
age used. Designations on reconnect panel, LOW,
clothing.
MID and HIGH, correspond to the nameplate input
voltages of a triple voltage welder. Dual voltage
� Insulate yourself from the work and ground.
welders use only LOW and HIGH. Single voltage
� Always wear dry insulating gloves.
welders use only HIGH.
EXAMPLE: On a 208/230/460 volt welder, LOW is
208V, MID is 230V, and HIGH is 460V.
RECONNECT PROCEDURE
Fuse the input circuit with the recommended super lag
On multiple input voltage welders, be sure the recon- fuses or delay type1 circuit breakers. Choose an input
nect panel is connected according to the following and grounding wire size according to local or national
instructions for the voltage being supplied to the codes or refer to Tables A.1 and A.2. Using fuses or
welder. circuit breakers smaller than recommended may result
in “nuisance� shut-offs from welder inrush currents
even if not welding at high currents.
CAUTION
Unbalanced AC TIG welding draws higher input cur-
Failure to follow these instructions can cause immedi- rents than those for stick, DC TIG, or Balanced AC TIG
ate failure of components within the welder. welding. The welder is designed for these higher input
currents. However, where unbalanced AC TIG welding
above 230 amps is planned, the higher input currents
require larger input wire sizes and fuses. See Table
A.2.
Also called “inverse time� or “thermal/magnetic� circuit breakers.
1
These circuit breakers have a delay in tripping action that decreases
as the magnitude of the current increases.
SQUARE WAVE TIG 355
A-5 A-5
INSTALLATION
The Square Wave TIG 355 should be permanently
wired into the power system. Plugs or connectors are
not recommended.
TABLE A.1
RECOMMENDED INPUT WIRE AND FUSE SIZES
For all Stick, DC TIG, and Balanced AC TIG Welding
Based on the 1990 U.S. National Electrical Code(2) 40% Duty Cycle
Input Ampere Type 75°C
Input Rating on Wire in Conduit Grounding Wire Fuse Size
Volt/Freq. Nameplate AWG Copper Cond. AWG Copper Cond. (Super Lag)
208/60 110 4 6 150
230/60 100 6 6 125
460/60 50 8 10 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 2 6 175
460/60 67 6 8 80
200/50 154 1 6 200
220/50 140 2 6 200
440/50 70 6 8 90
Article 630 of the 1990 U.S. National Electrical Code allows the rated ampacity of the supply conductors to be determined by multiplying
(2)
the nameplate rating by the appropriate multiplier, depending on the duty cycle of the welder.
SQUARE WAVE TIG 355
A-6 A-6
INSTALLATION
OUTPUT CONNECTIONS WARNING
Observe the safety precautions necessary for handling
and using compressed gas containers. Contact your
WARNING
supplier for specific information.
ELECTRIC SHOCK can kill.
� Keep the electrode holder, TIG FIGURE A.3 � FRONT PANEL
torch and cables insulation in
good condition and in place.
� Do not touch electrically live parts
or electrode with skin or wet
clothing.
� Insulate yourself from work and ground.
� Turn the power off pushbutton on the Square Wave
TIG 355 “off� before connecting or disconnecting
output cables or other equipment.
See Figure A.3 for the location of the work and elec-
trode terminals, the gas and optional water solenoids,
and the Remote Receptacle.
TIG TORCH CONNECTION
TIG welding torches come with 15 ft (4.6m) and 25 ft
(7.6m) cables. Use the shorter length whenever pos-
sible to minimize possible radio interference problems.
With power source off, connect the torch cable to the
“Electrode� terminal on the welder. Connect a sepa-
1. REMOTE RECEPTACLE
rate work cable to the “Work� terminal of the welder. 2. WATER AND GAS
See Table A.3 for recommended work cable sizes. SOLENOIDS
Both work and electrode cables should be routed 3. WORK (LEFT) AND
ELECTRODE TERMINALS
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 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.
TABLE A.3
CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE AND WORK CABLE
Lengths up to 100 to 200 ft 200 to 250 ft
Machine Size 100 ft (30 m) (30 to 61 m) (61 to 76 m)
350 Amp
40% Duty Cycle #1 (45mm2) 1/0 (55mm2) 2/0 (70mm2)
SQUARE WAVE TIG 355
A-7 A-7
INSTALLATION
DO NOT operate a water-cooled torch unless water is STICK ELECTRODE CABLE
flowing. Water doesn’t flow until the solenoid is actu- CONNECTION
ated.
Turn the Power switch Off. Run the electrode and
If using a water-cooled torch with a Magnum water work cables through the strain relief holes below the
cooler, connect the cooler water outlet to the “Water welding output terminals and connect the cables to
Valve In� fitting. Connect the TIG torch inlet to the the proper terminals. This strain relief prevents dam-
“Water Valve Out� fitting. age to the welding output terminals if the cables are
pulled excessively. Select cable size according to
If using a water-cooled torch with a free-running water
Table A.3
supply, install a water line between the welder “Water
Inlet� and the supply. Include a strainer in the water
supply line to prevent dirt particles from obstructing
water flow in the valve and cooling chamber of the TIG
torch. Failure to do so could result in water valve mal-
WARNING
function and overheating of the water-cooled torch.
Connect the torch water line to the welder “Water Out�
Do not connect a TIG torch and stick electrode cable
fitting. Use a nonmetallic drain line from the electrode
at the same time. They will both be electrically HOT
connection to the drain or water recirculating pump.
whenever the output terminals are energized.
For other water coolers or torches, consult the manu-
facturer’s instructions for the water cooler or TIG torch
being used.
SQUARE WAVE TIG 355
B-1 B-1
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section of operating
instructions before operating the machine.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts or
electrodes with your skin or wet 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 additional Safety Guidelines detailed in
the beginning of this manual.
SQUARE WAVE TIG 355
B-2 B-2
OPERATION
GENERAL DESCRIPTION DESIGN FEATURES AND ADVANTAGES
� Designed to NEMA EW-1 and International IEC-974
The Square Wave TIG 355 is a constant current, single
Standards.
range square wave AC/DC TIG (GTAW) arc welding
power source with built-in high frequency stabilization. � Single output range of 2-400 amps covers the
It also has stick (SMAW) capability. The Square Wave majority of TIG welding applications.
TIG 355 gives the operator full control of the welding
� Solid State Output Contactor: no noise, no parts to
current plus the ability to preset weld and start cur-
wear.
rents. Preflow and postflow timers are included for
shielding gas and cooling water control. Altogether � Digital Ammeter and Voltmeter for precise readings
the many features of the machine allow part or all of a from 2-400 amps welding.
weld cycle to be preset or "programmed," which sim-
� Welding current limit can be preset from 2-400
plifies the TIG welding process.
amps and is displayed on the ammeter when not
The Square Wave TIG 355 includes advanced features welding.
such as Auto-Balanceâ„? 2-Step/4-Step Arc Start
� Auto Balance� circuitry automatically provides the
Switch Operation, start controls, crater controls, spot
proper amount of cleaning and penetration when
timer, and status LEDs. Preflow and postflow timers
AC TIG welding. Manual AC wave balance adjust-
allow control of shielding gas and cooling water.
ment is also possible.
� 2-Step/4-Step Arc Start switch capability.
RECOMMENDED PROCESSES
� Spot control for 2-Step Arc Start switch mode.
The Square Wave TIG 355 is recommended for TIG
� TIG Pulser with On/Off selection, and Pulses Per
(GTAW) and stick (SMAW) welding processes within its
Second adjustment. Background current and duty
output capability of 2 to 400 amps on both AC and DC
cycle are automatically adjusted according to the
polarity. It is compatible with all Magnum TIG acces-
peak welding current.
sories as well as many industry standard TIG torches,
hoses, and water coolers. (See the Accessories sec- � Crater Fill control for current fade-out at the end of
tion of this manual.) a weld.
� Adjustable preflow time from 0 to 10 seconds.
Preflow time is eliminated if welding restarts during
OPERATIONAL FEATURES AND gas afterflow of previous weld. This avoids unnec-
CONTROLS essary delays when making repeated welds.
The following operational controls are standard on the � Adjustable afterflow time control.
Square Wave TIG 355: Local/Remote current control
� Locate/Remote current selection.
switch, Stick/TIG mode selection switch, TIG 2-
Step/TIG 4-Step mode selection switch, High � Stick/TIG selection.
Frequency Continuous/Start/Off switch, Peak Current
� Arc Force control of added current when electrode
control, Volts/Amps switch for the digital ammeter
shorts to the work in stick mode.
reading, AC Wave Balance control, Afterflow timer for
shielding gas and water flow, Arc Force current control � Continuous/Start/Off High Frequency selection.
for stick welding, Preflow timer for shielding gas and
� DC+/AC/DC- Polarity switch.
water flow, Spot Time Controls, Start current/time
controls, Pulse controls (pulses per second, back- � Power Factor Correction for lower input currents
ground % peak current, pulse % on), and Crater Fill and smaller input wire sizes.
controls (fade-out, % peak current).
� Remote Receptacle for Amptrol� or Arc Start
The following additional features are also standard: switch.
Digital ammeter selectable for either volts or amps;
� Low Voltage Arc Start switch circuit (24 VAC) for
Status Indicator LEDs for gas and water, high frequen-
maximum operator safety.
cy, arc established, start, peak, background, crater fill.
� Gas and optional water valves: Inlet and outlet fit-
tings conform to Compressed Gas Association
(CGA) standards.
� Built-In High Frequency Generator.
SQUARE WAVE TIG 355
B-3 B-3
OPERATION
� 115 Volt receptacle with 15 amp circuit breaker. WELDING CAPABILITY
� Excellent arc starting and stability up through 400 The Square Wave TIG 355 is NEMA Class II (40) Power
amps. Source rated 350 amps at 34 volts, 40% duty cycle.
The duty cycle is based upon a 10 minute time period.
� High resistance to AC arc rectification.
(For 40% duty cycle, it is 4 minutes on and 6 minutes
� No tungsten spitting within current range of elec- off.) The overload capacity is 375 amps at 35 volts,
trode. 30% duty cycle.
� Compact size, requires only a 22.25 in x 26 in (565 The “Lincoln Plus� rating of 300 amps at 40 volts pro-
mm 660 mm) footprint. vides additional voltage to overcome voltage drops in
long cables when stick welding at high currents.
� Strain relief holes in base for welding cables, gas
and water hoses and control cables.
� Easy access for input connections. Connections LIMITATIONS
are simple strip and clamp of input wires (no lugs
� The Square Wave TIG 355 is not recommended for
required).
arc gouging. The machine's output capacity is too
� Low fan noise at idle. limited.
� Modular construction for easy servicing. � The Square Wave TIG 355 is not recommended for
AC TIG welding with high concentrations of helium
� Unused controls are automatically locked out to
shielding gas. Starting problems and arc rectifica-
simplify setup. Examples: the AC Wave Balance
tion may occur.
control has no effect in DC; the High Frequency and
gas and water valves do not operate in Stick mode; � The Square Wave TIG 355 is not recommended for
TIG Pulser is locked out in the Stick mode. pipe thawing.
� Recessed panels protect controls, output terminals,
gas and water fittings.
� Large safety margins and protective circuits protect
rectifiers from transient voltages and high currents.
� Line voltage compensated.
� Thermostatically protected.
� Electronic over current protection.
SQUARE WAVE TIG 355
B-4 B-4
OPERATION
CONTROLS AND SETTINGS
UPPER CASE FRONT CONTROLS
Controls on the upper case front control panel are
used for manual TIG and stick welding. Their func-
tions are described below. Some controls are active in
both TIG and stick welding, while others are active in
TIG only. Refer to Figure B.1 for control locations.
FIGURE B.1 � UPPER CASE FRONT CONTROLS
1 2 10
4 5
3 6 7 8 9 11
17
15 16
14
13
12
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-BALANCEâ„? 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. STATUS INDICATOR LEDs
SQUARE WAVE TIG 355
B-5 B-5
OPERATION
NOTE: If the Crater Fill switch (Item 16) is ON,
UPPER CASE FRONT CONTROL PANEL
welding will continue after the Arc Start switch is
The upper case front panel controls are used for man- pressed and released the second time. (See
ual TIG and stick welding. Crater Fill Controls.)
1. CURRENT CONTROL SWITCH NOTE: If the arc goes out while welding in the 4-
Step mode, the machine will try to re-establish an
A two-position toggle switch:
arc for a period of two seconds. The output con-
LOCAL (PANEL): Current is controlled by the tactor will remain closed, and the High Frequency,
machine settings; remote Amptrol has no affect if in the Start Only or continuous mode, will be
on current. activated. If an arc does not re-establish within
two seconds, the weld cycle is automatically
REMOTE: Current is controlled by a remote
ended.
Amptrol up to the current set on the machine.
4. HIGH FREQUENCY SWITCH
2. MODE SWITCH
A three-position toggle switch: (Locked out in
A two-position toggle switch:
STICK mode).
STICK: For stick electrode welding (SMAW), this
CONTINUOUS: High frequency will come on after
position makes the Stick Arc Force control active.
the gas Preflow time and remain on until the weld
This switch locks out high frequency, the gas and
is stopped.
water valves, and the AC Wave Balance control.
The STICK position also locks out the Spot Time, START : High Frequency will come on for 1-2 sec-
Start Time and Crater Fill controls. The Pulse con- onds after an arc is established, then go off.
trols are locked out except when an Arc Start (When AC TIG welding, the high frequency will
switch connected to the Remote receptacle is stay on until after the Start period and come on
closed. again during the Crater Fill period.)
TIG: For TIG welding (GTAW), this position locks OFF: No high frequency.
out the Stick Arc Force control. It makes all other
5. DIGITAL VOLTMETER/AMMETER
controls active. To start and stop the welding
sequence and to get output current, an Amptrol or Displays the output voltage of the welder when the
Arc Start switch must be used when this switch is VOLTS/AMPS switch (Item 7) is held in the
in the TIG position. “VOLTS� position.
3. 2-STEP/4-STEP SWITCH When the VOLTS/AMPS SWITCH IS IN THE
“AMPS� position, this display functions as an
A two-position toggle switch: (Locked out in the
ammeter.
STICK mode.)
When you are not welding, the ammeter displays
2-STEP: For use with an Arc Start switch or an
the value preset by the Peak Current control.
Amptrol remote current control. The Arc Start
switch must be held down during the entire weld When you are not welding and the Start Current
cycle. Pressing the Arc Start switch starts the Display pushbutton is pressed, the ammeter will
Preflow cycle, and releasing the switch ends the display the preset Start (Item 14). (See Start
weld cycle. Controls)
NOTE: If the Crater Fill switch (Item 16) is ON, NOTE: The ammeter display is an indicator of the
welding will continue after the Arc Start switch is preset current. Actual welding current will be
released. (See Crater Fill controls.) slightly different.
4-STEP: For use with an Arc Start switch only. The While you are welding, the ammeter displays the
Arc Start switch must be pressed and released to actual welding current. The ammeter is accurate
start the weld cycle. Pressing and releasing the within ±3% of its reading or ±2 amps, whichever is
Arc Start switch a second time ends the weld greatest. The ammeter displays RMS current.
cycle. This eliminates the need to continuously (RMS current is the actual “heating value� of the
hold down the Arc Start switch during a weld. If arc.) NOTE: Some types of ammeters will not
the Preflow timer (Item 12) is being used, the Arc accurately read true RMS currents, particularly
Start switch must be held down during the Preflow when AC TIG welding aluminum. AC only amme-
time. The Arc switch can be released once an arc ters may read as much as 40% low when measur-
is established. ing AC TIG welding currents.
SQUARE WAVE TIG 355
B-6 B-6
OPERATION
6. PEAK CURRENT CONTROL .
CAUTION
Presets the maximum welding current the
machine will produce, from 2 through 400 amps.
Use only the amount of “cleaning� required. Greater
The preset current is displayed on the digital
amounts of positive current will heat the tungsten
ammeter when you are not welding.
more and possibly cause it to melt or “spit.� Also, the
NOTE: The ammeter display is an indicator of the arc is usually more flared and less stable with more
preset current. Actual welding current will be positive “cleaning� current.
slightly different.
If you use an Amptrol, it will control the current
PENETRATION (Above �3� on the dial): Provides
from 2 amps up to the current preset by the Peak
more negative current than positive current. The
Current control. See the section, “Hand and Foot
“cleaning� effect will be reduced, but the arc plas-
Amptrol Operation� for proper use of hand and
ma will be more concentrated and more easily
foot Amptrols.
directed to where the heat is needed. The
If pulsing, the peak current is the current set and reduced amount of positive current allows the
controlled by the Peak Current control (Item 6) and tungsten to run cooler at a given current than
the Amptrol. when set balanced.
7. VOLTS/AMPS SWITCH In general, use just enough “cleaning� to remove
oxides and to give good wetting of the puddle.
A two-position, spring-loaded toggle switch for
selecting either arc voltage or welding current/pre- 9. AUTO BALANCEâ„? LED
set current to be displayed on the digital meter.
Illuminates only when the Auto Balance function is
To read the arc voltage, you must hold the switch active. The welder must be in the AC TIG mode,
in the “Volts� position. This spring-loaded switch with the AC Wave Balance control fully clockwise.
always returns to the “AMPS� position when
10. AFTERFLOW
released.
This control adjusts the amount of time the gas
8. AC WAVE BALANCE
and water valves stay open after the end of a weld.
This control is active only in AC TIG mode. It con- Minimum time is approximately 5 seconds; maxi-
trols the amounts of positive and negative current mum is approximately 55 seconds. Use enough
in the AC output. It has no effect on stick or DC Afterflow time to protect the hot tungsten with gas
TIG welding. shielding until it cools. Too short of a time will
cause the tungsten to oxidize and become conta-
AUTO BALANCEâ„?: This setting provides automat-
minated. When in doubt, set a longer time, then
ic adjustment of the AC wave balance, and it is the
reduce it to a time that still gives good protection.
preferred balance setting for most welding condi-
tions. This setting gives the ideal amount of clean- PREFLOW
ing and penetration, based on the welding current
All machines have an adjustable Preflow time.
output. When the control is set to the Auto
Balance position, the Auto Balance LED (Item 9) If a new weld is started during the Afterflow time of
will light. This feature operates only in the AC TIG a previous weld, the Preflow time is bypassed,
mode. since gas shielding is already present. This allows
new welds to start immediately, with no preflow
For those procedures when manual adjustment of
delay.
the Wave Balance control is necessary, use the
following as a guide: 11. ARC FORCE
BALANCED: The amounts of positive and negative This control is active only in Stick mode. It con-
are the same. trols the amount of current added to the welding
current when the electrode shorts to the work.
CLEANING (Below �3� on the dial): Provides more
positive current than negative current. Since the At Minimum, no extra short circuit current is
positive current produces the “cleaning� or oxide added. The arc will be softer and will have less
removal on aluminum, this setting is used for spatter but may be more prone to sticking.
heavily oxidized aluminum.
SQUARE WAVE TIG 355
B-7 B-7
OPERATION
At Maximum, the arc will be more forceful and less Press and hold in this pushbutton to display the
prone to sticking but will produce more spatter. Start Current preset by the Start Current control.
(The Volts/Amps switch (Item 7) must be in the
12. PREFLOW
“AMPS� position to read preset current.)
This control adjusts the amount of time the gas
Start Current Control
and water valves are open before the arc starts. It
is adjustable from 0 to 10 seconds. Locked out if the Start switch is off.
The Preflow time occurs only if the valves were Presets the current that will be provided at the
closed (no gas flow) when the Arc Start switch or start of the weld. The current can be preset from
Amptrol was pressed. If a new weld is started 2 to 400 amps. The position of the amptrol has no
while the gas valve is still on during the Afterflow effect on the initial current. The present Start
time of a previous weld, the Preflow time is Current is displayed on the Ammeter when the
bypassed since gas shielding is already present. pushbutton is pressed before welding.
This allows new welds to start immediately with no
A “hot� start is used to quickly heat the tungsten
preflow delay.
and work, usually on DC TIG welding. Set the
Note that since the arc cannot start during the Start Current higher than what the welding current
Preflow time, a long Preflow setting can cause will be. After the time is set on the Start Time con-
complaints about arc starting. In general, a trol, the current will step down to the current set
Preflow time of 0.5 seconds is satisfactory for and controlled by the Peak Current control (Item 6)
most applications. and the Amptrol.
13. SPOT CONTROLS A “soft� start is used to preheat the tungsten and
work, usually on AC TIG welding. Set the Start
Spot Switch � A two-position toggle switch:
Current lower than what the welding current will
Recommended for use in the 2-step Arc Start be. The arc will establish at the Start Current and
Switch mode only. then ramp up to the current set and controlled by
the Peak Current control (Item 6) and the Amptrol.
ON: Spot Time control is active. Once the arc is
The time to get up to welding current is set by the
established, the Spot time begins. At the end of
Start Time control. During the ramp up, the
the Spot time (or if the Arc Start switch/Amptrol is
Amptrol will affect the current that the ramp is
released sooner), the arc stops. (If Crater Fill [Item
going toward and therefore the rate at which the
16] is on, downslope begins.)
current increases.
OFF: Locks out the Spot Time control.
Start Time Control
Spot Time Control: Not active if the Spot switch
Locked out if the Start switch is off. Adjusts the
is off. Adjusts weld time from 0.1 to 5 seconds.
Start Time from approximately 0.1 to 10 seconds.
Weld time is the time from when the arc is fully
established until the arc is turned off (or when 15. PULSE CONTROLS
Crater Fill downslope is started). The Arc Start
Pulse Switch � A two-position toggle switch:
switch or Amptrol must be held down during the
Spot time; if it is released before the end of the ON: Pulsing will begin as soon as an arc is estab-
Spot time, the arc will be turned off (or Crater Fill lished and will continue until the weld is complet-
started). ed. If you are using Start Controls, pulsing begins
after the Start Current. If you are using Crater Fill,
14. START CONTROLS
pulsing will continue during the downslope period.
Start Switch � A two-position toggle switch:
OFF: Locks out Pulse controls.
ON: Start Current control is active. At the begin-
Pulses per Second Control � Controls the num-
ning of the weld, current will be the value preset by
ber of pulses per second from approximately 0.1
the Start Current control. Th position of the
to 10 pps. 0.1 pulses per second is slow pulsing
Amptrol has no effect on this current.
(one pulse every 10 seconds); 10 pulses per sec-
OFF: Locks out Start Current and Time controls. ond is fast pulsing.
Start Current Display Pushbutton Background % Peak Current Control �
Controls the background (low pulse) current from
zero to 100% of the peak current set and con-
trolled by the Peak Current control (Item 6) and the
Amptrol.
SQUARE WAVE TIG 355
B-8 B-8
OPERATION
Example: The Peak Current control is preset at 50 OFF: Locks out Crater Fill controls.
amps and the Amptrol is partially down, giving a
Fade-out Control � Controls how slowly the cur-
peak current of 30 amps. If the Background
rent fades out. The FAST setting will cause current
Current control is set at 50%, the Background (low
to ramp down from the welding current toward 2
pulse) current will be 15 amps.
amps in approximately 1/2 second; the SLOW set-
The Amptrol raises and lowers the Peak current. ting, in approximately 20 seconds. The time for
Since Background current is always a percentage downslope to the Crater Fill Current level depends
of Peak current, the Amptrol also raises and low- on the difference between the weld current and
ers the Background current. the Crater Fill Current.
Pulse % On � Controls the percentage of the Crater Fill % Peak Current Control � Controls
pulse cycle that is at the Peak current. the final Crater Fill current from zero to 100% of
the weld current preset on the Peak Current con-
Example: You are pulsing at 1 Pulse per second
trol.
with a 30% Pulse % On setting. The welding cur-
rent would be at the Peak current for 0.3 seconds Example: WIth a Crater Fill % Current setting of
and at the Background current for the remainder 20% and a weld current preset at 100 amps, the
of the cycle, 0.7 seconds. current will fade from 100 amps to 20 amps and
then dwell at 20 amps for about 1-1/2 seconds
16. CRATER FILL CONTROLS
before the arc goes out.
Use the Crater Fill controls to automatically control
The final Crater Fill current dwell time is approxi-
current fade-out at the end of a weld. LOCAL cur-
mately 1-1/2 seconds, regardless of Crater Fill
rent control (Item 1) MUST be used when Crater
control settings.
Fill is used.
17. STATUS INDICATOR LEDs � Seven Light
Crater Fill Switch � A two-position toggle
Emitting Diodes (LEDs) which light when their
switch.
function is active.
ON: Crater Fill Fade-out will begin when the Arc
� GAS & WATER LED is on when the solenoid
Start Switch or Amptrol is released (2-Step mode)
valves are open, from the beginning of Preflow
or pressed and released a second time (4-Step
to the end of Afterflow.
mode). If used with Spot Time (item 13), Crater Fill
begins at the end of the Spot Time. The current � HIGH FREQUENCY LED is on when the high
control (item 1) switch must be in LOCAL when frequency circuit is on.
using Crater Fill.
FIGURE B.2 � STATUS INDICATOR LIGHT SEQUENCE
SQUARE WAVE TIG 355
SQUARE WAVE TIG 355
B-9 B-9
OPERATION
� ARC ESTABLISHED LED goes on when the arc NOTE: An LED will light in response to the control cir-
is fully established and goes out if the arc goes cuit command, even if other components do not work.
out. For example, if the gas supply is turned off or the gas
solenoid valve malfunctions or the fuse is blown, the
� START LED is on from the time the arc is estab-
gas will not flow even though the Gas and Water LED
lished until current begins to go up (soft start) or
lights up. Another example is the High Frequency LED
down (hot start). Note that the Start LED is off
which can light, yet there will not be high frequency
during upslope if a soft start is used.
due to a blown fuse or defective high frequency circuit
� PEAK LED goes on after the Start period. If the or spark gaps set too large.
Pulse switch is on, the Peak LED goes off dur-
The Status Indicator LEDs are useful for understanding
ing the Background periods. The Peak LED and
which functions are active during a weld sequence
Background LED will alternate when pulsing.
and for how long. They are useful for setting times of
� BACKGROUND LED is on during the the controls on the Function Panel. See Figure B.2.
Background (low pulse) period of pulsing.
The Status Indicator LED circuit board includes a
� CRATER FILL LED is on during the Fade-Out receptacle for plugging in the circuit board included
downslope and final current periods. with the Optional Interface Kit.
SQUARE WAVE TIG 355
B-10 B-10
OPERATION
LOWER CASE FRONT CONTROLS
Refer to Figure B.3 for the location of the following controls.
FIGURE B.3 � LOWER CASE FRONTCONTROLS
1
2
3
5
4
9
6
8
7
SQUARE WAVE TIG 355
B-11 B-11
OPERATION
1. POWER ON/OFF � A momentary start/stop 6. REMOTE RECEPTACLE � A six-pin circular con-
pushbutton, which controls the input contactor. If nector for an Arc Start switch or an Amptrol
the input power supply goes off or if the thermo- remote current control.
stat in the welder trips, the start pushbutton must
7. 115 VOLT RECEPTACLE AND CIRCUIT BREAK-
be pressed to restart the welder.
ER � A duplex 15 amp grounded NEMA 5-15R
2. PILOT LIGHT � Indicates when the input contac- receptacle and 15 amp circuit breaker. Fifteen
tor is energized (power is on). 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
CAUTION pushing it in after the circuit breaker cools and the
overload has been removed.
Do not switch polarity under load.
8. HIGH FREQUENCY INTENSITY CONTROL AND
SPARK GAP � This control changes the high fre-
quency intensity. Use the lowest intensity which
still gives good arc starting to minimize Radio
3. POLARITY SWITCH � Selects DC-/AC/DC+
Frequency Interference (RFI). The spark gap is set
4. FUSE F1 � 0.5 amp control circuit fuse protects at the factory to the normal setting marked on the
the control transformer from overloads. Input cover plate. Instructions for larger or smaller gap
overvoltage protection circuitry will blow this fuse settings are also on the cover plate.
to protect electronic components if the input volt-
9. GAS AND OPTIONAL WATER VALVES �
age to the welder is too high (more than 40% over
Solenoid valves that open at the beginning of the
rated voltage). If this fuse blows, the digital meters
Preflow time and close at the end of the Afterflow
will not light and the input contactor will not latch
time.
when the Power On/Off Start pushbutton is
pressed and released. The gas valve inlet and outlet are standard 5/18-18
right-hand female fittings. The water valve inlet
5. FUSE F2 � 1.5 amp gas, water, and high fre-
and outlet are standard 5/8-18 left-hand female fit-
quency fuse protects the circuitry that drives the
tings. The fittings conform to CGA (Compressed
gas and water valves and the high frequency sup-
Gas Association) standards. Use a water line
ply transformer. If this fuse blows, the valves and
strainer to prevent particles from jamming the
high frequency will not work. However, the LEDs
water valve.
for Gas and Water and High Frequency will still
light.
SQUARE WAVE TIG 355
B-12 B-12
OPERATION
HAND AND FOOT AMPTROL OPERATION
Both the Hand and Foot Amptrol (optional kits K870 or A similar situation occurs when the Start controls are
K963) work in a similar manner. They are meant to be used. For example, a 3/32� (2.4 mm) tungsten is again
used for remote current control when Remote Current used for welding DC- up to 200 amps (preset on the
control is selected. The TIG 2-Step mode must be ammeter). A Start current of 50 amps is set on the
selected when using an Amptrol for remote current Start Level control. When you depress the Amptrol,
control. As explained below, Amptrols can also be the start circuitry sets the output current to 50 amps.
used as arc start switches if Local Current control is If the Amptrol is kept near the minimum position, at the
selected. end of the start period the output current will drop to 2
amps, causing the arc to go out in most cases.
For simplicity, the following explanation will refer only
Depress the Amptrol at least 1/4 of the way down, or
to “Amptrols,� meaning both Foot and Hand models.
to around 70 amps, so that the tungsten remains lit
The term “minimum� refers to a Foot pedal in the “up�
when the start period ends.
position, as it would be with no foot pressure, or a
Hand Amptrol in the relaxed position, with no thumb The same holds true for a “hot� start, or one in which
pressure. “Maximum� refers to a fully depressed Foot the Start current is set to a current higher than the cur-
Amptrol, or a fully extended Hand Amptrol. rent preset on the ammeter. Again, at the end of the
start period, the Amptrol must be depressed far
The Amptrol is capable of controlling the output cur-
enough so that the machine output will be high
rent from 2 amps to whatever current is preset on the
enough to keep the arc lit.
ammeter. For example, if the ammeter is preset for
200 amps and the Current Control switch is in the The best technique when using the start controls and
Remote position, the Amptrol, when depressed just an Amptrol is to press the Amptrol to maximum at the
past its minimum position, will cause the Square Wave beginning of the weld, wait until the end of the start
TIG 355 to weld at 2 amps. At the Amptrol’s maximum period, and then back off on the amptrol only if the
position, the output would be near 200 amps. See current is too high.
Figure B.4.
If the Current Control switch is set to the Local posi-
tion, an Amptrol can be used as an arc start switch.
Depressing the amptrol just past minimum will cause
CAUTION
the Amptrol’s built-in arc start switch to close, and
Since the full output of the current setting is available backing off completely causes the built-in start switch
when the Amptrol is fully depressed, care must be to open. The Amptrol will have no effect on the weld-
taken not to set a current which will exceed the current ing current when used as an arc start switch. See
carrying capacity of the tungsten. When in doubt, use Figure B.5.
a lower current setting first, then increase.
It is important to note that, for many applications, the
tungsten will not start an arc at only 2 amps. To start
an arc reliably, it is important to depress the Amptrol
far enough so that the machine output current is near
the tungsten operating range. (See Table B.2 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.
SQUARE WAVE TIG 355
B-13 B-13
OPERATION
FIGURE B.4 � AMPTROLS USED WITH CURRENT CONTROL IN THE LOCAL POSITION
FIGURE B.5 � AMPTROLS USED WITH CURRENT CONTROL IN REMOTE POSITION
SQUARE WAVE TIG 355
B-14 B-14
OPERATION
WELDING OPERATION Select STICK mode. (High Frequency switch has
no effect in STICK mode.)
INITIAL START-UP 4. Preset the current with the Current control and the
Ammeter.
Be sure the Square Wave TIG 355 has been installed
correctly with respect to location, high frequency pro- 5. Set the desired Arc Force. (See CONTROLS AND
tection, input power, and output connections. SETTINGS, item 11, “Arc Force.�) (The Wave
Balance and Afterflow controls have no effect in
If you are TIG welding, connect a K870 or K963
STICK mode.)
Amptrol or a K814 Arc Start switch to the Remote
Receptacle. Check that the gas supply is on. Check 6. Turn the Start switch OFF, or set the START con-
for the correct type and size of tungsten electrode, gas trols for a hot start if needed. (See CONTROLS
cone size and torch size. If you are using a water AND SETTINGS, item 14, “Start Controls.�)
cooled torch, check that the water supply is on.
7. Strike an arc and weld. (There will be a buzzing
Press the Start (green) Power pushbutton. The input sound from the arc if you are AC welding, due to
contactor will pull in, the pilot light will come on, the the faster rate of current reversal of the Square
meter displays will light up, and the fans will start. In Wave.
TIG mode, the gas and water valves will open for one
TIG WELDING GUIDELINES
Afterflow period to purge the lines. The ammeter will
display the preset current (if there is no load on the
Recommended tungsten electrode sizes, stickouts,
welder output terminals). The voltmeter will read zero
currents, cup or nozzle sizes and gas flow are shown
in TIG mode, or from 60 to 70 in STICK mode.
in Table B.2. SINCE TIG APPLICATIONS CAN VARY,
Select the Electrode Polarity needed (DC-/AC/DC+) . THIS TABLE IS INTENDED AS A GUIDE ONLY.
Set the controls by going from left to right across the Aluminum Welding: Set the Electrode Polarity switch
top row and then the bottom row, choosing the correct to AC, the High Frequency switch to CONTINUOUS,
setting for each. Note that the bottom row of controls and the Mode switch to TIG. Make all other control
includes on/off switches to easily lock out the controls settings to suit the size tungsten and current. In gen-
within blocks (Spot, Start, Pulse, or Crater Fill) without eral, pure or zirconiated tungsten electrode is best for
changing the settings. Also, note that some of the aluminum and should have a “balled� end not exceed-
controls are automatically locked out internally if they ing the diameter of the tungsten. A buzzing sound will
do not apply in STICK mode or do not apply in TIG occur in the arc when AC TIG welding aluminum. We
mode. This reduces the number of controls which recommend that you set the AC Wave Balance control
must be set. See Table B.1 for examples of the effects to the Auto Balance position. For more information
of the Function controls on TIG welding. see CONTROLS AND SETTINGS, item 8, “AC Wave
Balance.�
STICK WELDING
Stainless or Mild Steel Welding: Set the Electrode
1. Remove the Amptrol or Arc Start switch from the Polarity switch to DC-, the High Frequency switch to
Remote Receptacle. START, and the Mode switch to TIG. In general, 1% or
2% thoriated tungsten electrode is best for stainless or
2. Turn the welder on. The pilot light on the front
mild steel and should have the end ground to a point.
panel indicates when the power is on.
If there is difficulty starting the arc, the tunsten may be
3. Select LOCAL current control; contaminated, or it may be too large to get up to oper-
ating temperature.
Note: Starting difficulties may often be due to not
pressing the Amptrol far enough. When the
Amptrol is just “cracked,� the minimum current
(2 amps) is produced. Pressing the Amptrol
more at the start of the weld will often solve
starting problems.
SQUARE WAVE TIG 355
B-15 B-15
OPERATION
TABLE B.1
SPECIFIC EFFECTS OF CONTROLS
(illustrated in the 2-Step Mode for clarity)
START SWITCH
START SWITCH
WELD BEGINS
CLOSE ARC
OPEN ARC
EFFECT OF CONTROLS ON TIG WELDING
PREFLOW
PRESET
CURRENT
LOCAL CURRENT CONTROL
ALL LOWER PANEL
SWITCHES OFF
AFTERFLOW
PRESET
REMOTE CURRENT CONTROL
CURRENT
ALL LOWER PANEL
SWITCHES OFF
REMOTE AMPTROL CONTROLS
FROM 2 AMPS UP TO
PRESET CURRENT
START TIME
START CURRENT
LOCAL OR REMOTE CURRENT CONTROL
PRESET START SWITCH ON
CURRENT
START CURRENT SET HIGHER THAN
HOT START
PRESET CURRENT (HOT START)
START TIME: VARIABLE
ALL OTHER PANEL SWITCHES OFF
REMOTE AMPTROL CONTROLS
FROM 2 AMPS UP TO
PRESET CURRENT
SQUARE WAVE TIG 355
B-16 B-16
OPERATION
START SWITCH
START SWITCH
WELD BEGINS
CLOSE ARC
OPEN ARC
EFFECT OF CONTROLS ON TIG WELDING
MAX START
TIME
START
LOCAL OR REMOTE CURRENT CONTROL
TIME
PRESET
MIN
START SWITCH ON
CURRENT
SOFT START
START CURRENT SET LOWER THAN
CURRENT
START
PRESET CURRENT (SOFT START)
START TIME: VARIABLE
ALL OTHER PANEL SWITCHES OFF
REMOTE AMPTROL CONTROLS
FROM 2 AMPS UP TO
PRESET CURRENT
CURRENT
PRESET
LOCAL CURRENT CONTROL
CRATER FILL SWITCH ON
CRATER FILL
% CURRENT
CRATER FILL
CRATER FILL % CURRENT VARIABLE
SLOW
FADE-OUT VARIABLE
FADE-OUT
FAST FADE-OUT ALL OTHER LOWER PANEL SWITCHES
OFF
-3 SEC.
CRATER FILL TIME
LOCAL CURRENT CONTROL
START & CRATER FILL
START SWITCH ON
PRESET
(SOFT START SHOWN; MAY HAVE HOT
CURRENT
START)
CRATER FILL SWITCH ON
ALL OTHER PANEL SWITCHES OFF
START
CRATER FILL
CURRENT
% CURRENT
SWITCH
START
OPEN
LOCAL OR REMOTE CURRENT CONTROL
ARC
PULSE SWITCH ON
PULSES PER SECOND
PRESET
BACKGROUND % DUTY CYCLE
CURRENT
PULSE
(PEAK) PULSE % ON
ALL OTHER LOWER PANEL SWITCHES
BACKGROUND
OFF
% CURRENT
REMOTE AMPTROL CONTROLS
FROM 2 AMPS UP TO
PRESET CURRENT
SQUARE WAVE TIG 355
B-17 B-17
OPERATION
START SWITCH
START SWITCH
WELD BEGINS
CLOSE ARC
OPEN ARC
EFFECT OF CONTROLS ON TIG WELDING
START TIME
START & PULSE & CRATER FILL
START CURRENT
LOCAL CURRENT CONTROL
START SWITCH ON
PRESET
CRATER FILL
% CURRENT
(SHORT HOT START SHOWN)
CURRENT
PULSE SWITCH ON
CRATER FILL SWITCH ON
(SLOW FADE-OUT SHOWN)
SPOT SWITCH OFF
BACKGROUND
% CURRENT
LOCAL OR REMOTE
SPOT SWITCH ON
START SWITCH
ALL OTHER LOWER PANEL SWITCHES
START SWITCH
CLOSE ARC
OFF
CLOSE ARC
AFTER SPOT TIME
START SWITCH
SPOT TIME SPOT TIME
OPEN ARC
(SPOT TIME IS CUT SHORT IF ARC
PRESET
SPOT
START SWITCH IS OPENED BEFORE
CURRENT
PREFLOW
END OF SPOT TIME)
REMOTE AMPTROL CONTROLS CURRENT
FROM 2 AMPS UP TO PRESET CURRENT
SPOT & START PULSE & CRATER FILL
THE SPOT TIMER CAN BE USED TO TIME A PROGRAMMED SEQUENCE OF START AND/OR
PULSE UP TO 5 SECONDS LONG, OPTIONALLY FOLLOWED BY CRATER FILL. IF CRATER FILL
IS USED, FADE-OUT BEGINS AT THE END OF THE SPOT TIME.
SQUARE WAVE TIG 355
B-18 B-18
OPERATION
TABLE B.2
TYPICAL CURRENT RANGES(1) FOR TUNGSTEN ELECTRODES(2)
AC Approximate Argon
Gas Flow Rate
Unbalanced Wave Balanced Wave
DCEN (-) DCEP (+) C.F.H. (l/min)
Tungsten 1%, 2% 1%, 2%
Electrode 1%, 2% 1%, 2% Thoriated Thoriated TIG Torch
Diameter Thoriated Thoriated Pure Tungsten Pure Tungsten Stainless Nozzle
in. (mm) Tungsten Tungsten Tungsten Zirconated Tungsten Zirconiated Aluminum Steel Size (4), (5)
(3)
.010 (.25) 2-15 2-15 2-15 2-15 � 3-8 (2-4) 3-8 (2-4) 4,5,6
(3)
0.020 (.50) 5-20 5-15 5-20 10-20 5-20 5-10 (3-5) 5-10 (3-5)
(3)
0.040 (1.0) 15-80 10-60 15-80 20-30 20-60 5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 50-100 70-150 30-80 60-120 5-10 (3-5) 9-13 (4-6) 5,6
3/32 (2.4) 150-250 15-30 100-160 140-235 60-130 100-180 13-17 (6-8) 11-15 (5-7) 6,7,8
1/8 (3.2) 250-400 25-40 150-210 225-325 100-180 160-250 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 200-275 300-400 100-240 200-320 21-25 (10-12) 13-17 (6-8) 8,10
3/16 (4.8) 500-750 55-80 250-350 400-500 190-300 290-390 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 the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.
(3) DCEP is not commonly used in these sizes.
(4) TIG torch nozzle “sizes� are in multiples of 1/16ths of an inch:
# 4 = 1/4 in. (6mm)
# 5 = 5/16 in. (8mm)
# 6 = 3/8 in. (10mm)
# 7 = 7/16 in. (11mm)
#8 = 1/2 in. (12.5mm)
#10 = 5/8 in. (16mm)
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high
temperatures and high duty cycles. Currents above 350 amps require metal nozzles on water cooled torches.
SQUARE WAVE TIG 355
B-19 B-19
OPERATION
hose and torch. After a time determined by the
TIG WELDING SEQUENCE OF
Preflow control setting, the high frequency
OPERATION (2-STEP MODE)
becomes available to strike the arc.
WARNING 11. Hold the Arc Start Switch down or operate the
Amptrol until the weld is completed. Release the
Do not leave stick electrode welding cable connected.
Arc Start switch or the Amptrol to stop the arc.
It will be electrically “hot� when TIG welding.
When the Afterflow timer completes the cycle, the
gas and water valves close. To make another
weld, repeat steps 10 and 11.
1. Connect an Amptrol or Arc Start switch to the
Remote Receptacle.
2. Turn the welder, water supply (if equipped) and
TIG WELDING SEQUENCE OF
gas supply on. The pilot light on the front panel
OPERATION (4-STEP MODE)
indicates when the power is on.
WARNING
3. Select REMOTE or LOCAL current control
(REMOTE requires an Amptrol).
Do not leave stick electrode welding cable connected.
Select TIG mode. It will be electrically “hot� when TIG welding.
Select CONTINUOUS or START high frequency.
Select AC or DC- electrode polarity. See Table B.3
for recommended polarity settings. 1. Connect an Arc Start switch to the Remote
Receptacle.
2. Turn the welder, water supply (if so equipped) and
TABLE B.3
gas supply on. The pilot light on the front panel
RECOMMENDED SETTINGS FOR TIG WELDING
indicates when the power is on.
Electrode High Frequency
3. Select LOCAL current control. Select TIG mode.
Type of Welding Polarity Switch
Select CONTINUOUS or START high frequency.
Stainless Steel DC- Start Select AC or DC- electrode polarity (See Table
B.3 for recommended polarity settings).
Aluminum and
Magnesium AC Continuous 4. Preset the maximum current with the Peak
Current control and the Ammeter.
Other Metals DC- Start
5. (Arc Force Control has no effect in TIG mode.)
6. If in AC, set AC Wave Balance control. (See CON-
4. Preset the maximum current with the Current con-
TROLS AND SETTINGS, item 8, “AC Wave
trol and the Ammeter.
Balance. This control has no effect in DC.)
5. (Arc Force control has no effect in TIG mode.)
7. Set Afterflow time.
6. If in AC, set AC Wave Balance control. (See CON-
8. Set Function Panel controls as needed. (See
TROLS AND SETTINGS, item 8, “AC Wave
CONTROLS AND SETTINGS, “Lower Case Front
Balance.� This control has no effect in DC.)
Controls�)
7. Set Afterflow time.
9. Press the Arc Start switch and set the gas
8. Set Function Panel controls as needed. (See flowmeter. The welder is now ready for welding.
CONTROLS AND SETTINGS.)
10. Position the tungsten electrode at the start of the
9. Press the Arc Start switch or Amptrol and set the weld at a 65° to 75° angle with the horizontal so
gas flowmeter. The welder is now ready for weld- that the electrode is approximately 1/8� (4 mm)
ing. above the workpiece. Press the Arc Start switch.
This opens the gas and water valves to automati-
10. Position the tungsten electrode at the start of the
cally purge air from the hose and torch. After a
weld at a 65° to 75° angle with the horizontal so
time determined by the Preflow control setting,
that the electrode is approximately 1/8� (3.2 mm)
the high frequency becomes available to strike the
above the workpiece. Press the Arc Start switch
arc.
or operate the Amptrol. This opens the gas and
water valves to automatically purge air from the
SQUARE WAVE TIG 355
B-20 B-20
OPERATION
11. Hold the Arc Start switch down until an arc is AUXILIARY POWER
established. At this point, the Arc Start Switch
ALL MACHINES
can be released, and the weld will continue.
Press and release the Arc Start switch a second
The Square Wave TIG 355 provides 15 amps of 115
time to stop the arc. When the Afterflow timer
volt AC power at a standard NEMA 5-15R receptacle,
completes the cycle, the gas and water valves
located on the lower case back of the machine. This
close. To make another weld, repeat steps 10
circuit is protected from shorts and overloading by a
and 11.
15 amp circuit breaker, located next to the receptacle.
Note: Starting difficulties may often be due to not The auxiliary circuit is intended for running water cool-
pressing the Amptrol far enough. When the Amptrol is ers and small power tools, whose current draw is with-
just “cracked,� the minimum current (2 amps) is pro- in the 15 amp rating.
duced. Pressing the Amptrol more at the start of the
weld will often solve starting problems.
CAUTION
Note that some types of equipment, especially pumps
OVERLOAD PROTECTION and motors, have starting currents significantly higher
than their running currents. These higher starting cur-
The Square Wave TIG 355 has thermostatic protection
rents may cause the circuit breaker to open. If this sit-
from overloads, loss of cooling, and high ambient tem-
uation occurs, the user should avoid using the Square
peratures. When the welder is subjected to an over-
Wave TIG 355 auxiliary for that equipment.
load or loss of cooling, a thermostat will open.
If the secondary thermostat opens, the effect will be
the same as pushing the Stop power pushbutton: the
power will go off, the pilot light and meters will go out,
and the fans will stop. Pressing the Start power push-
button after the thermostat 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 and
resets, normal output current will be available.
FEB97
SQUARE WAVE TIG 355
C-1 C-1
ACCESSORIES
OPTIONS/ACCESSORIES
The following options/accessories are available for Solid State Relays (SSRs):
your Square Wave TIG 355 from your local Lincoln
K847-DC � Can switch up to 40VDC, 2 amps
Electric Distributor.
maximum load. Package of two.
Undercarriage (K841) � Includes a platform, wheels,
K847-AC � Can switch up to 130VAC, 2 amp
and brackets for supporting the welder and two gas
maximum load. Package of two.
cylinders.
Amptrol� (K870 or K963) � Provides a remote cur-
Pump Mounting Platform (K827) � Mounts on top of
rent control for most TIG welding applications. Model
the welder to provide a mounting surface suitable for
K870 is a foot operated control; model 812 is hand
water recirculating pumps.
operated. Both models plug into the remote control
Arc Start Switch (K814) � Starts the welding receptacle. A separate switch on the Amptrol starts
sequence if remote control for TIG welding is not the welding sequence. When the Current Control
desired. Plugs into the Remote Receptacle. The switch on the welder is set in the LOCAL position, the
Current Control switch must be in the LOCAL position Amptrol works as an arc start switch only; it does not
when using the Arc Start switch; only a minimum cur- control current. (Current is controlled by the rheostat
rent (2 amp) is available in REMOTE. Includes 25 ft. on the front panel.) When the Current Control switch
(7.6 m) cable. on the welder is set to the REMOTE position, current
is controlled by the Amptrol, in a range from 2 amps up
Interface Kit (K846) � Mounts to the back of the LED
to the current set on the control panel. For a more
status PC board. Provides six isolated circuits that
detailed explanation of Amptrol operation, see the
can be closed to provide status indication when each
Operation Section of this manual.
of the following functions is active: High Frequency,
Arc Established, Start, Pulse Peak, Pulse Background,
and Crater Fill. Each circuit occupies two positions on
a terminal strip and consists of a fuse, fuse holder, and
sockets for an industry standard, optically isolated
Solid State Relay (SSR) module (purchased separate-
ly, see below).
Use of the Synergic 7 wire feeder requires appropriate input cable assembly, wire stand, and drive roll kit. Refer to Synergic 7 Operator’s
1
Manual for available options.
SQUARE WAVE TIG 355
D-1 D-1
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
� 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.
INPUT POWER FACTOR
CAPACITOR DISCHARGE
PROCEDURE
This procedure ensures that the power factor capaci-
tors are discharged, for 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 should be zero. (Normally, the capaci-
tors discharge through the primary winding in the
main transformer.)
4. If capacitor voltage is zero, you may begin working
on the Square Wave TIG 355.
SQUARE WAVE TIG 355
D-2 D-2
MAINTENANCE
5. If any voltage is present, DISCHARGE EACH INDI- 2. Periodically blow out dust and dirt from the inside
VIDUAL CAPACITOR as follows: of the machine with a low pressure air system. Be
sure to clean the following components thorough-
a. Obtain a 500 Ohm resistor. Grip the 500 ohm
ly. See Figure D.2 for their location.
resistor with insulated gloves and insulated
gripping pliers and hold the resistor across the � Main transformer
terminals on each capacitor for 20 seconds. � Output terminals (located on case front)
See Figure D.1. � Polarity switch (located on case front)
� Rectifier assembly
b. With the volt/ohmmeter, recheck each capac-
� Control box assembly
itor for voltage.
� Spark gap assembly
6. After all the capacitors are discharged completely, � Protection PC board
check for broken capacitor leads or an open pri-
3. Inspect the welder output terminals and control
mary winding on the main transformer, which
cables for fraying, cuts, and bare spots.
would have prevented the capacitors from dis-
charging normally. 4. Inspect the spark gap spacing at regular intervals.
To access the spark gap, remove the nameplate
located on the lower right section of the output
ROUTINE AND PERIODIC panel. Maintain the gap marked on the
machine cover plate. Please note the following:
MAINTENANCE
� If more intensity is needed than is available with
the "High Frequency" set to MAXIMUM,
WARNING increase the spark gap according to the inter-
vals on the cover plate. (To minimize RFI prob-
To avoid receiving a high frequency shock, keep elec- lems, use the smallest possible spark gap set-
trode holders, TIG torches and cable insulation in ting that still provides good welding.)
good condition.
� Do not dress or refinish the spark gap contacts.
Replace the electrodes if the contact surfaces
become irregular or completely eroded.
1. Disconnect power supply lines to the machine
before performing periodic maintenance. 5. The fan motors have sealed ball bearings and
require no maintenance.
FIGURE D.1 � POWER FACTOR CAPACITOR DISCHARGE DETAILS
SQUARE WAVE TIG 355
D-3 D-3
MAINTENANCE
FIGURE D.2 � GENERAL COMPONENT LOCATIONS
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
2
1
3
4
5
6
7
8
10
9
11
SQUARE WAVE TIG 355
E-1 E-1
TROUBLESHOOTING
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed throughout this manual.
WARNING
ELECTRIC SHOCK can kill. If you believe the setup is correct and the trouble still exists,
� Do not touch electrically live parts such
first check for the obvious: input power, blown fuses, loose
as output terminals or internal wiring.
PC board connectors, broken wires and the like. The sections
listed below are intended to help you find the less obvious
� Turn the input power off at the fuse box
sources of trouble.
before working on equiptment.
� Only qualified personnel should General Troubleshooting
perform this installation.
Stick Welding Trouble
HOW TO USE THIS GUIDE: Carefully read through each
TIG Welding Trouble
applicable section listed below. Remember that most prob-
lems are caused by improper setup, such as switch settings, Lower Panel Controls Trouble
control settings, electrode sizes, improper shielding gases, Accessory Troubles
etc.
GENERAL MACHINE TROUBLE
SYMPTOM CAUSE AND REMEDY
Machine will not turn on. 1. Input supply lines not “hot�. Check input supply line fuses.
2. Blown control circuit fuse (F1). Replace.
3. Thermostat (secondary) has opened. Allow machine to cool
before restarting.
Control circuit fuse (F1) keeps blowing. 1. Machine reconnect panel hooked up for wrong voltage.
Connect per connection diagram in this manual.
2. Fuse is too small. Use 1/2 amp fuse.
3. Shorted control transformer T5. Replace.
4. Defective Power, Meter, Control, or Protection PC board.
Replace PC boards one by one in this order until fuse no
longer blows.
Digital meter does not light, but welder 1. Defective Meter PC board. Replace.
turns on as indicated by the Pilot Light 2. Defective Control PC board. Replace.
and fan operation.
Accessories plugged into 115 volt recep- 1. Is accessory defective? Plug it into a known “hot� receptacle
tacle do not work. to check if it works.
2. Circuit Breaker CB1 is open. Before resetting the Circuit
Breaker, find out why it opened. Is the accessory exceeding
the 15 amp maximum load? Is the accessory defective?
Cannot preset a current, but meter lights up. 1. Set control knob to 12 o’clock position. Switch Start function
OFF. Machine should weld at approximately 80 amps. If
machine welds okay but ammeter does not display the weld-
ing current while 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.
WARNING
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 precautions detailed in the Safety
Section of this manual to avoid electrical shock or danger while troubleshooting this equipment.
___________________________________________________________________________________________________________________________________
SQUARE WAVE TIG 355
TROUBLESHOOTING
E-2 E-2
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed throughout this manual.
STICK WELDING
SYMPTOM CAUSE AND REMEDY
Machine shuts off in Stick mode. 1. Welder has overheated and secondary thermostat has
opened. Allow welder to cool before attempting to turn
on. Be sure to provide adequate ventilation around
welder to prevent recurrence.
Stick electrode “blasts off� when touched 1. Weld current is set too high for electrode size. Reduce
weld
to workpiece. current.
2. Start Switch is “On�, and Start Current is set too high
for electrode size. Either turn Start Switch OFF, or
reduce Start Current.
3. Arc Force control is set too high. Turn to minimum.
Arc seems too hot, and reducing current 1. Arc Force control is set too high. Turn to minimum.
potentiometer does not help. 2. Start Switch is ON and Start Current is set too high.
Start time may be set too long. Reduce or turn Start
Switch OFF.
Machine welds at very low output, regard- 1. Current Control switch is in REMOTE. Switch to
LOCAL.
less of Current potentiometer setting. 2. Start Switch is ON, and Start Current is set too low for
the electrode size. Either turn Start Switch OFF, or set
Start Current to proper level for the electrode size.
3. Does machine have correct output in TIG mode? If not,
see “Machine welds at low 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
defective. Replace.
Arc Force control has no effect. 1. The effect of the Arc Force Control will be less notice-
able at high welding currents. Weld at low current (less
than 150 amps) and check Arc Force effect.
2. If no effects are seen at low currents, the Arc Force
control potentiometer may be defective. Replace.
3. Control PC board may be defective. Replace.
Gas and water do not flow even though Gas Machine is operating properly; gas and water solenoids, as
well as
and Water LED is lit in Stick mode. the high frequency circuit, are disabled in the Stick mode.
WARNING
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 precautions detailed in the Safety
Section of this manual to avoid electrical shock or danger while troubleshooting this equipment.
___________________________________________________________________________________________________________________________________
SQUARE WAVE TIG 355
E-3 E-3
TROUBLESHOOTING
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.
SQUARE WAVE TIG 355
E-4 E-4
TROUBLESHOOTING
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed throughout this manual.
TIG WELDING (Continued)
SYMPTOM CAUSE AND REMEDY
Machine has gas flow and high frequency but no 1. Turn High Frequency Switch OFF. Look at the two LED’s in
open circuit voltage when the Arc Start Switch the upper left corner of the Power PC board. They should
or Amptrol is pressed. glow when the Arc Start Switch is pressed.
If the LED’s do glow, leads 232A and 233A may be reversed
on the primary of control transformer T5 in control box. Turn
the machine off. Reverse the leads. Turn back on and check
for open circuit voltage. If this does not fix the problem,
restore wires 232A and 233A to their original positions.
If the LED’s do not glow, the Power PC board may be defec-
tive. Replace. If the problem still exists, the Control PC board
may be defective. Replace.
Difficulty in getting tungsten to “light off�. 1. Current Control switch is in REMOTE but machine is being
used with an Arc Start Switch and no Amptrol. Set switch to
LOCAL.
2. Start switch is ON, and Start Current is set too low for tung-
sten size. Either turn Start switch OFF, or increase Start
Current to proper level for tungsten size.
3. Current control is set too low. Amptrol is not being pressed
far enough for the tungsten size being 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 (or not enough). Adjust gas flow for 10 to
30 CFH (4.7 to 14.1 l/min) for most applications.
Machine welds only at minimum output when 1. Current Control switch is in REMOTE but machine is being
the Current Control switch is in the REMOTE used with an Arc Start Switch and no Amptrol. Set switch to
position. LOCAL.
2. Use LOCAL Current Control. If problem goes away, Amptrol
may be defective. Replace or repair Amptrol.
3. Current Control switch may be defective. Replace.
4. Can machine be preset for currents from 2 to 400 amps? If
not, see “Cannot preset a current� in General
Troubleshooting section.
Arc goes out soon after it is lit. 1. Current Control is set too low, or Amptrol is not being
pressed far enough for the tungsten size being used. SEE
NOTE BELOW.
2. In AC, use Continuous High Frequency.
NOTE: STARTING DIFFICULTIES MAY OFTEN BE DUE TO NOT PRESSING THE AMPTROL FAR ENOUGH.
WHEN THE AMPTROL IS JUST “CRACKED�, THE MINIMUM CURRENT (2 AMPS) IS PRODUCED. PRESSING
THE AMPTROL MORE AT THE START OF THE WELD WILL OFTEN SOLVE STARTING PROBLEMS. Refer to
page 23 for proper use of amptrols.
SQUARE WAVE TIG 355
E-5 E-5
TROUBLESHOOTING
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed throughout this manual.
TIG WELDING (Continued)
SYMPTOM CAUSE AND REMEDY
Tungsten is eroding quickly. 1. Current potentiometer is set too high for tungsten size.
Reduce welding current or increase tungsten size.
2. In AC, Wave Balance control may be set too far towards
CLEANING. Turn Balance pot towards PENETRATION, or
increase tungsten size.
Tungsten seems to “spit� when Arc Start Switch High welding current is thermally “shocking� the cold
or Amptrol is pressed at high currents. tungsten causing pieces of the end to spall off. Turn Start
Switch ON, and set Start Current to a value lower than the
welding current to give a “soft� start.
LOWER PANEL CONTROLS
SYMPTOM CAUSE AND REMEDY
Machine does not always wait for Preflow time Machine is operating correctly; it does not go through a
when starting arc. Preflow period if the Arc Start Switch or Amptrol is pressed
during the Afterflow period.
The Spot Time does not last as long as the When in the 2-Step mode, be sure to keep the Arc Start Switch or
nameplate setting. Amptrol pressed until the Spot Time is completed. Releasing the
Arc Start Switch before the Spot Timer has timed out will cause
the arc to go out.
The Spot Time lasts much longer than the The Crater Fill switch should be turned OFF. If it is left ON,
nameplate setting. 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 not begin until the
end of the start time, which can be as much as 10 seconds.
2. Check the Pulses Per Second control. If it is set near mini-
mum, each pulse may be as long as ten seconds. Set all
three of the pulse controls near the midpoints to see the
Pulser’s effects.
3. The Pulse % On control may be set at either extreme. If that
is the case, the pulses may be too short to be seen, depend-
ing on the settings of the Current and Background % Current
controls. Set all three of the pulse controls near the mid-
points to see the Pulser’s effects.
When using Crater Fill, the arc goes out 1. The Crater Fill % Current control may be set too low for the
before the final Crater Fill Current level tungsten being used. Increase the Crater Fill % Current con-
is reached. trol until the final Crater Fill current is within the tungsten’s
operating range.
2. If using the Pulser in conjunction with the Crater Fill, the
Background % Current may be too low for the tungsten as
the current is downsloping in Crater Fill. The best solution is
to increase the Background % Current level.
3. If welding with AC use CONTINUOUS High Frequency. The
high frequency will stabilize the arc as the current goes
down.
SQUARE WAVE TIG 355
E-6 E-6
TROUBLESHOOTING
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed throughout this manual.
ACCESSORIES
SYMPTOM CAUSE AND REMEDY
K870 Foot Amptrol or K963 Hand Amptrol.
Amptrol does not control welder output with 1. Check continuity between pins D and E in the cable connec-
Current Control switch in REMOTE and tor. There should be an open circuit when the Amptrol is not
Mode switch in TIG. pressed and a short circuit when it is pressed part way. If this
is not the case, check the Amptrol cable for breaks. The
microswitch in the Amptrol may not be operating properly.
Repair or replace as necessary.
2. Using an ohmmeter, check the resistance between pins A
and B in the Amphenol connector. The resistance should be
10K ohms when the pedal is up, and near zero ohms when
the pedal is fully depressed. An open circuit would indicate a
bad cable or defective potentiometer. Check for breaks and
repair or replace the damaged cable or potentiometer.
K814 Arc Start Switch
Arc Start Switch does not start welder output 1. Check continuity between pins D and E of the cable
in TIG Mode and LOCAL Current Control. connector. There should be an open circuit when the switch
is not pressed, and a short circuit when 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 only for
DC circuits.
2. Is the corresponding fuse (F1 for CR1, F2 for CR2, etc.)
blown? If so, find cause and replace with a 4 amp fuse.
3. Are the Interface and Status PC boards correctly mated to
one another? Be sure that all 10 pins on P701 are inserted
into J602 on the Status PC board.
4. Is harness connector P601 plugged into J701 on the
Interface PC board?
5. Is Terminal Strip (TS701) wired correctly (terminals 3 and 4
for CR1, terminals 5 and 6 for CR2, etc.)?
6. Is DC polarity of terminal strip connection correct? Odd num-
bers (+), even numbers (�).
7. Defective solid state relay. Replace.
Solid State Relay Module output seems to 1. High Frequency pickup may be a problem. Reroute leads
make contact at wrong times. going to Interface terminal strip away from welding cables
which carry high frequency.
2. Use shielded cables to make connections to the Interface PC
board terminal strip. Ground the shield to terminal 1 or 2 on
TS701.
3. Be sure that the white ground lead is on the Interface PC
board tab terminal and is connected to the welder chassis
screw.
SQUARE WAVE TIG 355
WIRING DIAGRAM - Square Wave TIG355
F-1
SINGLE VOLTAGE MACHINE
DUAL VOLTAGE MACHINE
TO GROUND PER NATIONAL ELECTRIC CODE
DIAGRAMS
SQUARE WAVE TIG 355
4 STEP
STICK CONTINUOUS
LOCAL
START
REMOTE
304
OFF
2 STEP
TIG 302
303
HIGH
CURRENT 301
FREQUENCY
2 STEP/4 STEP
MODE
CONTROL
S11
S10 S19 S12
SQUARE WAVE TIG 355
WIRING DIAGRAM
2519
7-25-97C G
F-1
DIMENSION PRINT - Square Wave TIG355
F-2
50.41 23.28
26.00 6.67 22.25
15.22 11.12
.74
3.25
S.W. TIG 355
34.84
45.20
DIAGRAMS
SQUARE WAVE TIG 355
K841
7.11
* * *
24.12 .94 20.00
43.93 27.65
LOCATION OF MOUNTING HOLES.
Ø .406
*
6-18-93C
17275
M
F-2
F-3 F-3
EQUIPMENT MANUFACTURER’S CERTIFICATION
Type of Equipment
Model Number
Code Number
Serial Number
Operating Instruction Manual Number
This certificate indicates manufacturer’s conformity to FCC Rules & Regulations. User’s
compliance with these regulations requires he fill out this certificate & attach it to the
equipment or other location where it will be conveniently available for inspection.
The High Frequency Generator of the above identified equipment has been tested
under field test condition standards recommended by the Joint Industry Committee on
High Frequency Stabilized Arc Welding Machines. It was found to comply with the
Federal Communications Commission established maximum allowable R. F. energy
radiation limit of 10 micro volts per meter at a distance of 1 mile.
If this equipment is installed, operated and maintained 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-
ating manual.
Certifying Signature & Title
Date
THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO U.S.A. S14929 (9-2-83E)
Notes
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND 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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� World's Leader in Welding and Cutting Products �
� 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
|