Lincoln Electric IM467-B User Manual
SQUARE WAVE TIG 355
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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.
IM467-B
May, 2003
For use with machines having Code Numbers: 9951, 10056, 10389
9952, 10057, 10390
9953, 10058
9954, 10059
9955, 10060
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
Copyright © 2003 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
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.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
i
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
SAFETY
ii
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
vapors
to
5.e. Also see item 1.b.
Mar ‘95
iii
SAFETY
iii
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
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.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
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
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons 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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product •••
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___________________________________________________________________________
vv
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
“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:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
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 Amptrol™ 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 all Stick, DC TIG, and Balanced AC TIG
Welding at 350A/34V/40% Duty Cycle Based
on the 1990 U.S. National Electrical Code
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 (16mm2) 6 (16mm2) 134 2 (35mm2) 6 (16mm2) 175
460/60 60 50 8 (10mm2) 10 (6mm2) 67 6 (16mm2) 8 (10mm2)80
575/60 50 40 8 (10mm
Fuse Input Type75°C Copper Ground Type 75°C Copper Ground Fuse
2
Type 75°C Type 75°C
) 10 (6mm2) 54 6 (16mm2) 8 (10mm2)70
For Unbalanced AC TIG Welding Above 230 Amps,
300/32V/60% Duty Cycle, Unbalance Based on the
1990 U.S. National Electrical Code
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
start installation.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrodes with your skin or wet
clothing.
• Insulate yourself from the work
and ground.
• Always wear dry insulating gloves.
Only qualified personnel should install, use, or service
this equipment.
SELECT SUITABLE LOCATION
Place the Square Wave TIG 355 where clean, cooling
air can flow freely in through the side louvers and out
through the rear louvers. Keep dust, dirt, and other
foreign materials that can be drawn into the machine
to a minimum. Failure to observe these precautions
can lead to excessive operating temperatures and
nuisance shut-downs. Read the section, "High
Frequency Interference Protection" before planning
the installation.
TILTING
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, nonskid, and structurally sound.
HIGH FREQUENCY INTERFERENCE
PROTECTION
The spark gap oscillator in the high frequency generator, being similar to a radio transmitter, can be blamed
for many radio, TV and electronic equipment interference problems. These problems may be the result of
radiated interference. Proper grounding methods can
reduce or eliminate radiated interference.
The Square Wave TIG 355 has been field tested under
recommended installation conditions. It complies with
FCC allowable limits for radiation. For convenience, a
certificate of compliance is packed with the welder. It
can be used to prove FCC RF Energy Radiation Limits
compliance if necessary. (It is the owner's responsibility to obtain this certification.) The Square Wave TIG
355 also complies with NEMA standards for high frequency stabilized power sources.
Radiated interference can develop in the following four
ways:
1. Direct interference radiated from the welder.
2. Direct interference radiated from the welding leads.
STACKING
Square Wave TIG 355s may be stacked two high.
The bottom machine must be on a stable, hard, level
surface. Be sure that the two pins in the roof of the
bottom machine fit into the holes in the base of the
top machine.
LIFTING
WARNING
CYLINDER MAY EXPLODE if damaged.
• Do not lift the welder with a cylinder attached.
The Square Wave TIG 355 weighs 510 lbs. (232 kg)
without a gas cylinder. Lift the machine by the lift
bail only. Never lift the machine with a cylinder
attached.
SQUARE WAVE TIG 355
3. Direct interference radiated from feedback into the
power lines.
4. Interference from re-radiation of “pickup” by
ungrounded metallic objects.
Keeping these contributing factors in mind, installing
equipment per the following instructions should minimize problems.
1. Keep the welder power supply lines as short as
possible and completely enclose them in rigid
metallic conduit or equivalent shielding for a minimum distance of 50 feet (15.2m). There should be
good electrical contact between this conduit and
the welder. Both ends of the conduit should be
connected to a driven ground and the entire length
should be continuous.
2. Keep the work and electrode leads as short as possible and as close together as possible. Lengths
should not exceed 25 ft (7.6m). Tape the leads
together when practical.
A-3 A-3
INSTALLATION
3. Be sure the torch and work cable rubber coverings
are free of cuts and cracks that allow high frequency leakage. Cables with high natural rubber
content, such as Lincoln Stable-Arc®better resist
high frequency leakage than neoprene and other
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 following 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
using cable of the same size as the work cable, or
larger. Grounding to the building frame electrical
conduit or a long pipe system can result in re-radiation, effectively making these members radiating
antennas.
6. Keep all access panels and covers securely in
place.
7. All electrical conductors within 50 ft (15.2m) of the
welder should be enclosed in grounded, rigid
metallic conduit or equivalent shielding. Flexible
metallic conduit is generally not suitable.
8. When the welder is enclosed in a metal buidling,
several good earth driven electrical grounds (as in
5 (b) above) around the periphery of the building
are recommended.
FIGURE A.1 – REAR PANEL
2
3
1. WARNING DECAL
2. INPUT POWER ENTRY
3. RECONNECT PANEL COVER
GROUND CONNECTION
The frame of the welder must be
grounded. A ground terminal marked
with the symbol is located at the bottom of the input box for this purpose.
See your local and national electrical
codes for proper grounding methods.
Also follow other grounding instructions given in the
section “High Frequency Interference Protection.”
INPUT SUPPLY CONNECTION
Be sure the voltage, phase, and frequency of the input
power is as specified on the welder nameplate.
Failure to observe these recommended installation
procedures can cause radio or TV interference
problems and result in unsatisfactory welding performance resulting from lost high frequency
power.
INPUT CONNECTIONS
Be sure the voltage, phase, and frequency of the input
power is as specified on the rating plate, located on
the front of the machine.
Welder supply line entry provision is in the case rear
panel with a removable cover over the input connection panel area. See Figure A.1.
SQUARE WAVE TIG 355
WARNING
ELECTRIC SHOCK can kill.
• Have a qualified electrician install
and service this equipment.
• Turn the input power off at the fuse
box before working on this equipment.
• Do not touch electrically hot parts.
Have a qualified electrician connect the input power
leads to L1 and L2 of the input contactor in accordance with all local codes and national electrical
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.
A-4 A-4
INSTALLATION
FIGURE A.2 – INPUT SUPPLY CONNECTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrodes with your skin or wet
clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
RECONNECT PROCEDURE
On multiple input voltage welders, be sure the reconnect panel is connected according to the following
instructions for the voltage being supplied to the
welder.
CAUTION
Failure to follow these instructions can cause immediate failure of components within the welder.
Refer to Figure A.2 for the following procedure.
Welders are shipped connected for the highest input
voltage listed on the rating plate. To change this connection for a different input voltage, reconnect both
the power strap (P) and control lead (C) to their
respective terminals corresponding to the input voltage used. Designations on reconnect panel, LOW,
MID and HIGH, correspond to the nameplate input
voltages of a triple voltage welder. Dual voltage
welders use only LOW and HIGH. Single voltage
welders use only HIGH.
EXAMPLE: On a 208/230/460 volt welder, LOW is
208V, MID is 230V, and HIGH is 460V.
Fuse the input circuit with the recommended super lag
fuses or delay type
and grounding wire size according to local or national
codes or refer to Tables A.1 and A.2. Using fuses or
circuit breakers smaller than recommended may result
in “nuisance” shut-offs from welder inrush currents
even if not welding at high currents.
Unbalanced AC TIG welding draws higher input currents than those for stick, DC TIG, or Balanced AC TIG
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.
1
Also called “inverse time” or “thermal/magnetic” circuit breakers.
These circuit breakers have a delay in tripping action that decreases
as the magnitude of the current increases.
1
circuit breakers. Choose an input
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
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
(2)
40% Duty Cycle
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
(2)
Article 630 of the 1990 U.S. National Electrical Code allows the rated ampacity of the supply conductors to be determined by multiplying
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
ELECTRIC SHOCK can kill.
• Keep the electrode holder, TIG
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 electrode terminals, the gas and optional water solenoids,
and the Remote Receptacle.
TIG TORCH CONNECTION
WARNING
Observe the safety precautions necessary for handling
and using compressed gas containers. Contact your
supplier for specific information.
FIGURE A.3 – FRONT PANEL
TIG welding torches come with 15 ft (4.6m) and 25 ft
(7.6m) cables. Use the shorter length whenever possible to minimize possible radio interference problems.
With power source off, connect the torch cable to the
“Electrode” terminal on the welder. Connect a separate work cable to the “Work” terminal of the welder.
See Table A.3 for recommended work cable sizes.
Both work and electrode cables should be routed
through the cable strain relief holes provided in the
base directly below the welding ouput terminals.
Connect the TIG torch gas and water fittings to the
welder fittings. any torch with fittings that conform to
Compressed Gas Association (CGA) standards can be
used.
The welder fittings have the following threads: Gas
Inlet and Outlet: 5/8”-18 right-hand female; Water inlet
and 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
1. REMOTE RECEPTACLE
2. WATER AND GAS
SOLENOIDS
3. WORK (LEFT) AND
ELECTRODE TERMINALS
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 (45mm
2
) 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
flowing. Water doesn’t flow until the solenoid is actuated.
If using a water-cooled torch with a Magnum water
cooler, connect the cooler water outlet to the “Water
Valve In” fitting. Connect the TIG torch inlet to the
“Water Valve Out” fitting.
If using a water-cooled torch with a free-running water
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 malfunction and overheating of the water-cooled torch.
Connect the torch water line to the welder “Water Out”
fitting. Use a nonmetallic drain line from the electrode
connection to the drain or water recirculating pump.
For other water coolers or torches, consult the manufacturer’s instructions for the water cooler or TIG torch
being used.
STICK ELECTRODE CABLE
CONNECTION
Turn the Power switch Off. Run the electrode and
work cables through the strain relief holes below the
welding output terminals and connect the cables to
the proper terminals. This strain relief prevents damage to the welding output terminals if the cables are
pulled excessively. Select cable size according to
Table A.3
WARNING
Do not connect a TIG torch and stick electrode cable
at the same time. They will both be electrically HOT
whenever the output terminals are energized.
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 clothing.
• 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 combustibles.
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
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