Page 2 - SAFETY; WARNING; ARC WELDING can be hazardous.; ELECTRIC SHOCK can kill.
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY i i SQUARE WAVE TIG 355 WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understan...
Page 3 - ii
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY ii ii SQUARE WAVE TIG 355 WELDING SPARKS cancause fire or explosion. 4.a. Remove fire hazards from the weld-ing area. If this is not possible,cover them to prevent the weldingsparks from starting a fire.Re...
Page 4 - iii
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iii iii SQUARE WAVE TIG 355 FOR ENGINEpowered equipment. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. 7.b. Operate engines in ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iv iv SQUARE WAVE TIG 355 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que le...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
MASTER TABLE OF CONTENTS FOR ALL SECTIONS v v SQUARE WAVE TIG 355 Page Safety .................................................................................................................................................i-iv Installation ..............................................................
Page 7 - TABLE OF CONTENTS; Installation; Lifting
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Section A-1 SQUARE WAVE TIG 355 Installation Technical Specifications Square Wave TIG 355 ......................................................................
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS - SQUARE WAVE TIG 355; Input Currents; RATED OUTPUT; 5 Amps Continuous; RECOMMENDED INPUT WIRE AND FUSE SIZES; PHYSICAL DIMENSIONS; OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-2 A-2 SQUARE WAVE TIG 355 TECHNICAL SPECIFICATIONS - SQUARE WAVE TIG 355 INPUT - SINGLE PHASE ONLY Input ...
Page 9 - SAFETY PRECAUTIONS; SELECT SUITABLE LOCATION; STACKING; CYLINDER MAY EXPLODE if damaged.; TILTING
Read this entire installation section before youstart installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wetclothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. Only qualified person...
Page 10 - INPUT CONNECTIONS; GROUND CONNECTION; FIGURE A.1 – REAR PANEL
3. Be sure the torch and work cable rubber coveringsare free of cuts and cracks that allow high fre-quency leakage. Cables with high natural rubbercontent, such as Lincoln Stable-Arc ® better resist high frequency leakage than neoprene and othersynthetic rubber insulated cables. 4. Keep the torch in...
Page 11 - FIGURE A.2 – INPUT SUPPLY CONNECTIONS; • Do not touch electrically live parts; RECONNECT PROCEDURE; circuit breakers. Choose an input
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-5 A-5 SQUARE WAVE TIG 355 FIGURE A.2 – INPUT SUPPLY CONNECTIONS ELECTRIC SHOCK can kill. • Do not touch e...
Page 13 - OUTPUT CONNECTIONS; • Keep the electrode holder, TIG; TIG TORCH CONNECTION; Lengths up to
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OUTPUT CONNECTIONS ELECTRIC SHOCK can kill. • Keep the electrode holder, TIG torch and cables insulation ingood conditio...
Page 15 - Operation
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - OPERATION SECTION - Operation ............................................................................................................................... Section B Safety Instructions .......
Page 16 - OPERATION; OPERATING INSTRUCTIONS
OPERATION B-2 B-2 SQUARE WAVE TIG 355 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATING INSTRUCTIONS Read and understand this entire section of operatinginstruc...
Page 17 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES
GENERAL DESCRIPTION The Square Wave TIG 355 is a constant current, singlerange square wave AC/DC TIG (GTAW) arc weldingpower source with built-in high frequency stabilization.It also has stick (SMAW) capability. The Square WaveTIG 355 gives the operator full control of the weldingcurrent plus the ab...
Page 19 - CONTROLS AND SETTINGS; UPPER CASE FRONT CONTROLS; FIGURE B.1 – UPPER CASE FRONT CONTROLS
CONTROLS AND SETTINGS UPPER CASE FRONT CONTROLS Controls on the upper case front control panel areused for manual TIG and stick welding. Their func-tions are described below. Some controls are active inboth TIG and stick welding, while others are active inTIG only. Refer to Figure B.1 for control lo...
Page 20 - UPPER CASE FRONT CONTROL PANEL; CURRENT CONTROL SWITCH
UPPER CASE FRONT CONTROL PANEL The upper case front panel controls are used for man-ual TIG and stick welding. 1. CURRENT CONTROL SWITCH A two-position toggle switch: LOCAL (PANEL): Current is controlled by themachine settings; remote Amptrol has no affecton current. REMOTE: Current is controlled by...
Page 21 - AUTO BALANCE; LED; All machines have an adjustable Preflow time.; CAUTION
6. PEAK CURRENT CONTROL Presets the maximum welding current themachine will produce, from 2 through 400 amps.The preset current is displayed on the digitalammeter when you are not welding. NOTE: The ammeter display is an indicator of thepreset current. Actual welding current will beslightly differen...
Page 22 - Spot Switch — A two-position toggle switch:; Start Switch — A two-position toggle switch:; Start Current Control; Locked out if the Start switch is off.; Start Time Control
At Maximum, the arc will be more forceful and lessprone to sticking but will produce more spatter. 12. PREFLOW This control adjusts the amount of time the gasand water valves are open before the arc starts. Itis adjustable from 0 to 10 seconds. The Preflow time occurs only if the valves wereclosed (...
Page 23 - • GAS & WATER LED is on when the solenoid; FIGURE B.2 – STATUS INDICATOR LIGHT SEQUENCE
Example: The Peak Current control is preset at 50amps and the Amptrol is partially down, giving apeak current of 30 amps. If the BackgroundCurrent control is set at 50%, the Background (lowpulse) current will be 15 amps. The Amptrol raises and lowers the Peak current.Since Background current is alwa...
Page 25 - LOWER CASE FRONT CONTROLS; Refer to Figure B.3 for the location of the following controls.; FIGURE B.3 – LOWER CASE FRONTCONTROLS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION B-11 B-11 SQUARE WAVE TIG 355 LOWER CASE FRONT CONTROLS Refer to Figure B.3 for the location of the following ...
Page 26 - Do not switch polarity under load.
1. POWER ON/OFF — A momentary start/stoppushbutton, which controls the input contactor. Ifthe input power supply goes off or if the thermo-stat in the welder trips, the start pushbutton mustbe pressed to restart the welder. 2. PILOT LIGHT — Indicates when the input contac-tor is energized (power is ...
Page 27 - HAND AND FOOT AMPTROL OPERATION
HAND AND FOOT AMPTROL OPERATION Both the Hand and Foot Amptrol (optional kits K870 orK812) work in a similar manner. They are meant to beused for remote current control when Remote Currentcontrol is selected. The TIG 2-Step mode must beselected when using an Amptrol for remote currentcontrol. As exp...
Page 28 - FIGURE B.5 – AMPTROLS USED WITH CURRENT CONTROL IN REMOTE POSITION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION B-14 B-14 SQUARE WAVE TIG 355 FIGURE B.4 – AMPTROLS USED WITH CURRENT CONTROL IN THE LOCAL POSITION FIGURE B.5...
Page 29 - WELDING OPERATION; STICK WELDING; Remove the Amptrol or Arc Start switch from the; TIG WELDING GUIDELINES; Note: Starting difficulties may often be due to not
WELDING OPERATION INITIAL START-UP Be sure the Square Wave TIG 355 has been installedcorrectly with respect to location, high frequency pro-tection, input power, and output connections. If you are TIG welding, connect a K870 or K812Amptrol or a K814 Arc Start switch to the RemoteReceptacle. Check th...
Page 30 - SPECIFIC EFFECTS OF CONTROLS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION B-16 B-16 SQUARE WAVE TIG 355 TABLE B.1 SPECIFIC EFFECTS OF CONTROLS (illustrated in the 2-Step Mode for clari...
Page 33 - TYPICAL CURRENT RANGES
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION B-19 B-19 SQUARE WAVE TIG 355 TABLE B.2 TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES (2) DCEN (-) DCEP (...
Page 35 - Hold the Arc Start switch down until an arc is; OVERLOAD PROTECTION; If the; AUXILIARY POWER; ALL MACHINES
11. Hold the Arc Start switch down until an arc is established. At this point, the Arc Start Switchcan be released, and the weld will continue.Press and release the Arc Start switch a secondtime to stop the arc. When the Afterflow timercompletes the cycle, the gas and water valvesclose. To make anot...
Page 36 - Accessories
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories................
Page 37 - ACCESSORIES
OPTIONS/ACCESSORIES The following options/accessories are available foryour Square Wave TIG 355 from your local LincolnElectric Distributor. Undercarriage (K841) – Includes a platform, wheels,and brackets for supporting the welder and two gascylinders. Pump Mounting Platform (K827) – Mounts on top o...
Page 38 - Maintenance
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions.....................
Page 39 - MAINTENANCE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC MAINTENANCE D-2 D-2 SQUARE WAVE TIG 355 WARNING SAFETY PRECAUTIONS • Only Qualified personnel should perform this mainte...
Page 40 - FIGURE D.1 – POWER FACTOR CAPACITOR DISCHARGE DETAILS
5. If any voltage is present, DISCHARGE EACH INDI- VIDUAL CAPACITOR as follows: a. Obtain a 500 Ohm resistor. Grip the 500 ohm resistor with insulated gloves and insulatedgripping pliers and hold the resistor across theterminals on each capacitor for 20 seconds.See Figure D.1. b. With the volt/ohmme...
Page 41 - FIGURE D.2 – GENERAL COMPONENT LOCATIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC MAINTENANCE D-4 D-4 SQUARE WAVE TIG 355 FIGURE D.2 – GENERAL COMPONENT LOCATIONS 1. OUTPUT RECTIFIER/SCR BRIDGE ASSEMBLY...
Page 42 - Theory of Operation
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS -THEORY OF OPERATION SECTION- Theory of Operation ............................................................................................................. Section E General Description .......
Page 43 - THEORY OF OPERATION
HIGH VOLTAGE TRANSFORMER CIRCUIT REMOTE RECEPTACLE GAS/WATER SOLENOIDS FANS 115VAC RECEPTACLE INPUT CONTACTOR RE CO NN ECT POWER FACTOR CAPACITORS FEED - THRU BOARD CONTROL BOARD POWER BOARD SNUBBER BOARD MAIN TRANSFORMER AC AC DC- DC+ POLARITY SWITCH SHUNT C H O K E BY-PASS BOARDS WORK ELECTRODE HI...
Page 44 - FIGURE E.3 – OUTPUT RECTIFICATION AND FEEDBACK CONTROL
OUTPUT RECTIFICATION ANDFEEDBACK CONTROL The AC output from the main transformer secondary isrectified and controlled through the SCR bridge.Output current is sensed at the shunt as a low voltagesignal and fed back to the control board. The controlboard compares the commands of the control panels,pa...
Page 45 - FIGURE E.4 – HIGH VOLTAGE/HIGH FREQUENCY CIRCUIT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC THEORY OF OPERATION E-4 E-4 SQUARE WAVE TIG 355 HIGH VOLTAGE/HIGH FREQUENCY CIRCUIT The control board signals the power ...
Page 46 - DC WELDING OUTPUT; FIGURE E.5 – DC WELDING OUTPUT CIRCUIT; FIGURE E.5a – SCR BRIDGE AND CHOKE CONFIGURATION FOR DC WELDING
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC THEORY OF OPERATION E-5 E-5 SQUARE WAVE TIG 355 DC WELDING OUTPUT When the polarity switch is placed in either DC posi-t...
Page 47 - AC WELDING OUTPUT; FIGURE E.6 – AC WELDING OUTPUT CIRCUIT; FIGURE E.6a – SCR BRIDGE AND CHOKE CONFIGURATION FOR AC WELDING
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC THEORY OF OPERATION E-6 E-6 SQUARE WAVE TIG 355 AC WELDING OUTPUT Rotating the polarity switch to the AC positionchanges...
Page 48 - SCR OPERATION; FIGURE E.7 – SCR OPERATION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC THEORY OF OPERATION E-7 E-7 SQUARE WAVE TIG 355 SCR OPERATION A silicon controlled rectifier (SCR) is a three-terminalde...
Page 49 - PROTECTIVE CIRCUITS; THERMAL PROTECTION
PROTECTIVE CIRCUITS Protective circuits are designed into the Square WaveTIG 355 to sense trouble and shut down the machinebefore the trouble damages the internal machine com-ponents. Both thermal protection and current over-load are included. THERMAL PROTECTION Thermostats protect the machine from ...
Page 50 - Troubleshooting & Repair Section; Abnormal Open Circuit Voltage – (AC TIG Mode, One
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS -TROUBLESHOOTING & REPAIR SECTION- Troubleshooting & Repair Section ....................................................................................... Section F How to Use Troublesh...
Page 51 - TROUBLESHOOTING & REPAIR; HOW TO USE TROUBLESHOOTING GUIDE; The
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-2 F-2 SQUARE WAVE TIG 355 HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be p...
Page 52 - PC BOARD TROUBLESHOOTING PROCEDURES AND REPLACEMENT
ELECTRIC SHOCK can kill. Have an electrician install and ser-vice this equipment. Turn themachine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PCboard failures. These problems can sometimes betraced to poor electrical connection...
Page 53 - TROUBLESHOOTING GUIDE; Observe Safety Guidelines; OUTPUT PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-4 F-4 SQUARE WAVE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the...
Page 57 - FUNCTION PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-8 F-8 SQUARE WAVE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the...
Page 60 - TIG MODE PROBLEMS; The machine must be in TIG
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-11 F-11 SQUARE WAVE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in t...
Page 61 - High Frequency Signal Test.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-12 F-12 SQUARE WAVE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in t...
Page 67 - Check the Crater Fill Fade Out
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-18 F-18 SQUARE WAVE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in t...
Page 68 - STICK WELDING PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-19 F-19 SQUARE WAVE TIG 355 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in t...
Page 69 - PURPOSE FOR THE PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INPUT POWER FACTOR CAPACITOR VOLTAGE CHECK AND DISCHARGE PROCEDURE Service and repair should be performed by only Lincol...
Page 70 - TEST PROCEDURE; FIGURE F.1 – POWER FACTOR CAPACITOR DISCHARGE DETAILS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SQUARE WAVE TIG 355 F-21 F-21 INPUT POWER FACTOR CAPACITOR VOLTAGE CHECK AND DISCHARGE PROCEDURE (continued) TROUBLESHOO...
Page 71 - ARC START TRIGGER CIRCUIT TEST; TEST DESCRIPTION
ARC START TRIGGER CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid ...
Page 73 - FIGURE F.3 – ARC START TRIGGER CIRCUIT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SQUARE WAVE TIG 355 F-24 F-24 ARC START TRIGGER CIRCUIT TEST (continued) TROUBLESHOOTING & REPAIR FIGURE F.3 – ARC S...
Page 74 - POWER BOARD TEST
POWER BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-trical sh...
Page 75 - SQUARE WAVE POWER
F-26 F-26 POWER BOARD TEST (continued) FIGURE F.4 - POWER BOARD TEST POINTS TROUBLESHOOTING & REPAIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the screws and carefully lower the front controlpanel. 3. On the power board, locate the test points ...
Page 76 - POWER BOARD VOLTAGE TEST CHART
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-27 F-27 POWER BOARD VOLTAGE TEST CHART TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 Check Points IJ4 to 2J4 4J4 to...
Page 77 - INPUT CONTACTOR TEST
INPUT CONTACTOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid electri-ca...
Page 78 - ELECTRICAL ARCING can injure.
F-29 F-29 INPUT CONTACTOR TEST (continued) FIGURE F.5 - INPUT CONTACTOR TEST POINTS TROUBLESHOOTING & REPAIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the machine top and sides. 3. Locate the two leads, #243 and #244, con- nected to the input c...
Page 81 - PILOT TRANSFORMER TEST
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SQUARE WAVE TIG 355 PILOT TRANSFORMER TEST Service and repair should be performed by only Lincoln Electric factory train...
Page 82 - FIGURE F.7 - PILOT TRANSFORMER CONNECTIONS
F-33 F-33 PILOT TRANSFORMER TEST (continued) FIGURE F.7 - PILOT TRANSFORMER CONNECTIONS TROUBLESHOOTING & REPAIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the machine top and sides. 3. Locate terminals X1 and X2 connected to the pilot transform...
Page 83 - FEED-THRU PC BOARD TEST
FEED-THRU PC BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-tr...
Page 85 - VIEW FROM EDGE OF BOARD; FEED THROUGH
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SQUARE WAVE TIG 355 F-36 F-36 FEED-THRU PC BOARD TEST (continued ) TROUBLESHOOTING & REPAIR FIGURE F.9 - FEED-THRU P...
Page 86 - FEED THRU PC BOARD RESISTANCE TEST POINTS; Check Points
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-37 F-37 FEED-THRU PC BOARD TEST (continued ) FEED THRU PC BOARD RESISTANCE TEST POINTS TROUBLESHOOTING & REPAIR Ch...
Page 87 - PROTECTION PC BOARD TEST
PROTECTION PC BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-t...
Page 88 - FIGURE F.11- PROTECTION PC BOARD LOCATION AND MOUNTING DETAILS; SQUARE W
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-39 F-39 PROTECTION PC BOARD TEST (continued) FIGURE F.11- PROTECTION PC BOARD LOCATION AND MOUNTING DETAILS TROUBLESHO...
Page 89 - PROTECTION PC BOARD RESISTANCE TEST POINTS CHART; Test Points
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SQUARE WAVE TIG 355 F-40 F-40 PROTECTION PC BOARD TEST (continued) PROTECTION PC BOARD RESISTANCE TEST POINTS CHART TROU...
Page 90 - MAIN TRANSFORMER TEST
MAIN TRANSFORMER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-tric...
Page 91 - FIGURE F.12 - MAIN TRANSFORMER LOCATION AND WIRING DETAILS
F-42 F-42 MAIN TRANSFORMER TEST (continued) FIGURE F.12 - MAIN TRANSFORMER LOCATION AND WIRING DETAILS TROUBLESHOOTING & REPAIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the machine top and sides. 3. Perform the power factor capacitor dis- char...
Page 92 - Secondary and Auxiliary
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SQUARE WAVE TIG 355 F-43 F-43 MAIN TRANSFORMER TEST (continued) TROUBLESHOOTING & REPAIR 7. Check the voltages at th...
Page 94 - FIGURE F.13 - LOCATION OF CONTROL BOARD AND CONTROL TRANSFORMER; machine case top and sides.; Check for 120VAC at the primary leads
F-45 F-45 CONTROL TRANSFORMER (T5) VOLTAGE TEST (continued) FIGURE F.13 - LOCATION OF CONTROL BOARD AND CONTROL TRANSFORMER TROUBLESHOOTING & REPAIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16” nut driver, remove the machine case top and sides. 3. Locate plug J4 on the ...
Page 95 - END VIEW
F-46 F-46 CONTROL TRANSFORMER (T5) VOLTAGE TEST (continued) FIGURE F.14 – PLUG P4 DETAILS TROUBLESHOOTING & REPAIR 6. Check fuse F1 (0.5 amp). Test the resis- tance from 6J15, on the feed-thru PCboard, to the #265 lead at the control trans-former. Also check the resistance from7J15, on the feed-...
Page 96 - CONTROL PC BOARD TEST
CONTROL PC BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-tric...
Page 97 - FIGURE F.15 – CONTROL PC BOARD LOCATION; Locate the test points on the control PC
F-48 F-48 CONTROL PC BOARD TEST (continued) FIGURE F.15 – CONTROL PC BOARD LOCATION TROUBLESHOOTING & REPAIR TEST PROCEDURE 1. Remove input power to the machine. 2. With the 5/16” nut driver, remove the screws and carefully lower the case frontcontrol panel. 3. Locate the test points on the cont...
Page 98 - FIGURE F.16 – CONTROL PC BOARD PLUG DETAILS; Check the test points for the appropriate; CONTROL
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-49 F-49 CONTROL PC BOARD TEST (continued) FIGURE F.16 – CONTROL PC BOARD PLUG DETAILS PLUG J13 LOCATION RESISTOR TEST ...
Page 100 - STATIC SCR TEST
STATIC SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-trical sho...
Page 101 - FIGURE F.17 – POWER PC BOARD PLUG LOCATIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-52 F-52 STATIC SCR TEST (continued) FIGURE F.17 – POWER PC BOARD PLUG LOCATIONS TROUBLESHOOTING & REPAIR TEST PROC...
Page 102 - FIGURE F.18 – SCR TEST POINTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-53 F-53 STATIC SCR TEST (continued) FIGURE F.18 – SCR TEST POINTS TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 SCR...
Page 103 - ACTIVE SCR TEST
ACTIVE SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-trical sho...
Page 105 - FIGURE F.20 – SCR TEST POINTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-56 F-56 ACTIVE SCR TEST (continued) FIGURE F.20 – SCR TEST POINTS TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 SCR...
Page 106 - BATTERY TEST; Connect the SCR into the test circuit as
F-57 F-57 ACTIVE SCR TEST (continued) FIGURE F.21 - SILICON CONTROLLED RECTIFIER TEST SETUP. TROUBLESHOOTING & REPAIR SILICON CONTROLLEDRECTIFIER TEST (Heat Sink Mounted Units) To test the SCRs, construct the circuit outlinedin Figure F.21. One 6V lantern battery can beused. Resistor tolerances ...
Page 107 - volts; SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM; DC STICK MODE; HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-58 F-58 TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 CH1 0 volts 2 ms 50 volts SCOPE SETTINGS Volts/Div .............
Page 108 - AC STICK MODE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-59 F-59 TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 CH1 0 volts 2 ms 50 volts SCOPE SETTINGS Volts/Div .............
Page 109 - DC TIG MODE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-60 F-60 TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 CH1 0 volts 2 ms 50 volts SCOPE SETTINGS Volts/Div .............
Page 110 - AC TIG MODE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-61 F-61 TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 CH1 0 volts 2 ms 50 volts SCOPE SETTINGS Volts/Div .............
Page 111 - TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-62 F-62 TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 CH1 0 volts 2 ms 20 volts SCOPE SETTINGS Volts/Div .............
Page 113 - ABNORMAL OPEN CIRCUIT VOLTAGE – DC TIG MODE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-64 F-64 TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 CH1 0 volts 2 ms 50 volts SCOPE SETTINGS Volts/Div .............
Page 114 - ABNORMAL OPEN CIRCUIT VOLTAGE – AC TIG MODE; ONE OUTPUT SCR NOT FUNCTIONING
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-65 F-65 TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 CH1 0 volts 2 ms 50 volts SCOPE SETTINGS Volts/Div .............
Page 115 - CONTROL PC BOARD REMOVAL AND REPLACEMENT; DESCRIPTION
CONTROL PC BOARD REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and...
Page 117 - POWER PC BOARD REMOVAL AND REPLACEMENT
POWER PC BOARD REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and t...
Page 118 - PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-69 F-69 POWER PC BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.23 - POWER PC BOARD TROUBLESHOOTING & REPAIR P...
Page 119 - INPUT CONTACTOR REMOVAL AND REPLACEMENT
INPUT CONTACTOR REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and ...
Page 120 - FIGURE F.24 – INPUT CONTACTOR CONNECTIONS
F-71 F-71 INPUT CONTACTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.24 – INPUT CONTACTOR CONNECTIONS TROUBLESHOOTING & REPAIR PROCEDURE 1. Remove input power to the machine. 2. With the 5/16" nut driver, remove the case top and sides. 3. Perform the Input Power Factor Capacitor Voltage Ch...
Page 121 - Attach small lead H1 to the L1 terminal.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-72 F-72 INPUT CONTACTOR REMOVAL AND REPLACEMENT (continued) TROUBLESHOOTING & REPAIR 13. Replacement: Mount the co...
Page 122 - FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT
FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety ...
Page 123 - FIGURE F.25- FAN MOTOR AND BLADE MOUNTING DETAILS
F-74 F-74 FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (continued) FIGURE F.25- FAN MOTOR AND BLADE MOUNTING DETAILS TROUBLESHOOTING & REPAIR PROCEDURE The following procedure allows you to removeand replace either of the two fans on theSquare Wave TIG 355. 1. Remove the input power to the machin...
Page 124 - OUTPUT RECTIFIER REMOVAL AND REPLACEMENT
OUTPUT RECTIFIER REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and...
Page 125 - FIGURE F.26 – OUTPUT RECTIFIER CONNECTION DETAILS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-76 F-76 TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 OUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) FIGURE F...
Page 127 - SCR REMOVAL AND AND REPLACEMENT
SCR REMOVAL AND AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid...
Page 128 - Perform the Output Rectifier Removal; SPECIAL INSTRUCTIONS
F-79 F-79 SCR REMOVAL AND AND REPLACEMENT (continued) TROUBLESHOOTING & REPAIR The unclamping and clamping procedure out-lined below is critical for the prevention of iner-nal SCR damage. Failure to follow this proce-dure may result in subsequent damage of theSCR. Handle all SCRs with care. PROC...
Page 130 - NOTE: This procedure can only be used; FIGURE F.29 – SCR CLAMP ASSEMBLY DETAILS – 1/2” WIDE SPRING
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-81 F-81 TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 5) Re-inspect the SCR for proper seating. 6) Clamp the cap sc...
Page 131 - ) Place a piece of sleeving around; FIGURE F.30 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-82 F-82 TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 B. PROCEDURE FOR THE 5/8 INCH WIDE SPRING: 1) Place a piece o...
Page 132 - Install the output rectifier heat sink assem-; FIGURE F.31 – SCR CLAMP ASSEMBLY DETAILS – 5/8” WIDE SPRING
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-83 F-83 TROUBLESHOOTING & REPAIR SQUARE WAVE TIG 355 Clamping procedure for 1/4-20 capscrews. Note: This procedure...
Page 133 - RETEST AFTER REPAIR; INPUT AMPS AT RATED MACHINE OUTPUT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mech...
Page 134 - AC and DC True RMS Meter – Fluke 8922A or equivalent
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-85 F-85 SQUARE WAVE TIG 355 RETEST AFTER REPAIR (continued) OUTPUT CURRENT RANGE 2 - 400 ...
Page 136 - NOTES
NOTES SQUARE WAVE TIG 355 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 137 - ELECTRICAL DIAGRAMS; Wiring Diagram
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-2 SQUARE WAVE TIG 355 Wiring Diagram D U A L V O L T A G E M A C H I N E S I N G L E V O L T A G E...
Page 138 - Machine Schematic
NOTE: This diagram is for reference only. It may not be totally applicable to every code covered by this manual. G-3 ELECTRICAL DIAGRAMS SQUARE WAVE TIG 355 Machine Schematic SHUNT (+) SHUNT (-) BACKGROUND RECTIFIER (+) PRIMARY THERMOSTAT PRIMARY THERMOSTAT BACKGROUND RECTIFIER (-) BACKGROUND RESIST...
Page 144 - IDENTIFICATION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC G-9 ELECTRICAL DIAGRAMS SQUARE WAVE TIG 355 Protection PC Board (M16062) Layout G-9 NOTE: Lincoln Electric assumes no re...
Page 146 - I T E M; B Y P A S S
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC G-11 ELECTRICAL DIAGRAMS SQUARE WAVE TIG 355 Bypass PC Board (M15299) Layout G-11 NOTE: Lincoln Electric assumes no resp...
Page 149 - L E D D I S P L A Y; M E T E R
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC G-14 ELECTRICAL DIAGRAMS SQUARE WAVE TIG 355 Meter PC Board (M15893) Layout G-14 NOTE: Lincoln Electric assumes no respo...
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