Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
– 2 – FOR ENGINEpowered 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 out...
Page 5 - PRÉCAUTIONS DE SÛRETÉ
– 5 – SAFETY 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 secous...
Page 6 - Thank You; This statement appears where the information; must be followed to avoid minor personal injury or damage to; CAUTION; Please Examine Carton and Equipment For Damage Immediately
– 6 – Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manua...
Page 7 - TABLE OF CONTENTS; Page; Safety
– 7 – TABLE OF CONTENTS Page Safety .....................................................................................................................2-6 Installation ................................................................................................................8-12 Technical Spe...
Page 8 - INSTALLATION; T E C H N I C A L S P E C I F I C AT I O N S - S QUA R E WAV E T I G 2 5 5; For all Stick, DC TIG, and Balanced AC TIG; Code; AC and DC; INPUT - SINGLE PHASE ONLY; PHYSICAL DIMENSIONS
– 8 – INSTALLATION T E C H N I C A L S P E C I F I C AT I O N S - S QUA R E WAV E T I G 2 5 5 For all Stick, DC TIG, and Balanced AC TIG Welding at 255A/30V/40% Duty Cycle Based on the 1993 US. National Electrical Code For Unbalanced AC TIG Welding Above 180 Amps, 255A/16V/40% Duty Cycle, Auto Balan...
Page 9 - Safety Precautions; STACKING
– 9 – INSTALLATION Read entire installation section before startinginstallation. Safety Precautions SELECT SUITABLE LOCATION Place the welder where clean cooling air can freelycirculate in through the rear louvers and out throughthe side louvers. Dirt, dust or any foreign material thatcan be drawn i...
Page 10 - FIGURE 1 - REAR PANEL; INPUT CONNECTIONS
– 10 – INSTALLATION 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 thefollowing methods: a) A m e t a l u n d e r g r o u n d w a t e r p i p e i n d i r e c t...
Page 11 - TABLE 1; circuit breakers. Choose an input; FIGURE 2 - FRONT PANEL; TIG TORCH CONNECTION; OUTPUT CONNECTIONS
– 11 – INSTALLATION TABLE 1 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable Machine Size Lengths up to 100 ft 100 to 200 ft 200 to 250 ft 255 Amp 40% Duty Cycle #2 (35mm2) #1 (45mm2) 1/0 (55mm2) Welders are shipped connected for the highest inputvoltage as listed on the rating Pl...
Page 12 - DO NOT; operate a water-cooled torch unless water is; STICK ELECTRODE CABLE CONNECTION
– 12 – INSTALLATION DO NOT operate a water-cooled torch unless water is flowing. Water doesn’t flow until solenoid is actuated. If using a water-cooled torch with a Magnum watercooler, connect the cooler water outlet to the ‘WaterValve In” fitting. Connect the TIG torch inlet to the“Water Valve Out”...
Page 13 - OPERATION; OPERATING INSTRUCTIONS; General Warnings; SAFETY INSTRUCTIONS
– 13 – ELECTRIC SHOCKcan kill. • Do not touch electrically live parts or electrode with skin or wetclothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASEScan be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes fro...
Page 14 - ON; HF
– 14 – ON 2 A TIG 2-STEP TIG 4-STEP STICK CURRENT CONTROL OUTPUT LOCAL CURRENT CONTROL REMOTE CURRENT CONTROL INCREASE OUTPUT DECREASE HIGH FREQUENCY CONTINUOUS HIGH FREQUENCY START ONLY HIGH FREQUENCY OFF CLEAN (INCREASE POSITIVE POLARITY) PENETRATE (INCREASE NEGATIVE POLARITY) TIG PULSER AFTERFLOW...
Page 16 - GENERAL DESCRIPTION; Operational Features and Controls; • Single output range of 5-315 amps covers the
– 16 – • Welding current limit can be preset from 5 to 315 amps and is displayed on the Ammeter when notwelding. • Auto Balance circuitry automatically provides the proper amount of cleaning and penetration when AC TIG welding. Manual AC wave balance adjust-ment is also possible. • 2-Step/4-Step Arc...
Page 18 - CONTROL PANEL KEYS; CONTROLS AND SETTINGS; FIGURE 3 - CONTROL PANEL KEYS
– 18 – OPERATION 4. AC WAVE BALANCE: These keys are active inthe AC TIG mode only. They are used to set theamount of cleaning and/or penetration producedd u r i n g a n A C T I G w e l d . A u t o B a l a n c e ™automatically sets the AC Wave Balance accordingto the welding current. If manual adjust...
Page 19 - B. VOLTMETER: This meter displays open circuit; CASE FRONT CONTROLS; CONTROL PANEL: The display is divided into five; FIGURE 5 - CASE FRONT CONTROLS
– 19 – OPERATION A. AC/DC INDICATOR: This symbol represents the output polarity of the 255 . . . either AC or DC. ACis shown in Figure 4A; DC is shown in Figure 4B. B. VOLTMETER: This meter displays open circuit voltage as well as welding voltage, as measuredon the output studs of the Square Wave TI...
Page 20 - WELDING OPERATION; TIG Welding
– 20 – TABLE 2 RECOMMENDED POLARITY SETTINGS FOR TIG WELDING Type of Welding Electrode Polarity High Frequency Setting Stainless Steel Aluminum & Magnesium Other Metals DC- AC DC- START CONTINUOUS START OPERATION WELDING OPERATION TIG Welding Familiarize yourself with the Controls and DisplaySec...
Page 21 - TABLE 3
– 21 – OPERATION 7. If welding with AC polarity, select Auto Balance™.This gives the optimum ratio between cleaning andpenetration, automatically adjusted for the outputcurrent. If manual adjustment of the AC WaveBalance is desired, select Manual Balance, andadjust the wave balance with the Cleaning...
Page 22 - Press and release the Arc Start Switch, and set; ADVANCED TIG WELDING FEATURES; AC Wave Balance and Auto BalanceTM
– 22 – OPERATION 9. Set the Afterflow time with the Seconds Up/Downkeys. Afterflow time provides shielding gas flow(and cooling water, if used) after the weld. Useshort Afterflow times with low currents and smalltungstens, long afterflow times at high outputcurrents with large tungstens. 10. Press a...
Page 23 - OVERLOAD PROTECTION; TIG Pulser; STICK WELDING; ALL MACHINES; BALANCED (0): T h e a m o u n t s o f p o s i t i v e a n d
– 23 – OPERATION 50/60Hz MACHINES - (Codes 10024 thru 10026 & 10134) Square Wave TIG 255 machines rated for 50/60Hzoperation provide 2 amps of 220 volt AC power at ac o n t i n e n t a l E u r o p e a n ( S c h u k o ) t y p e r e c e p t a c l e ,located on the lower case back of the machine. T...
Page 24 - ACCESSORIES; OPTIONS / ACCESSORIES; • Magnum Cooler Horizontal TIG Mounting Bracket; UNDERCARRIAGE FUNCTION
– 24 – ACCESSORIES OPTIONS / ACCESSORIES • Hand Amptrol (K963) • Foot Amptrol (K870) • Arc Start Switch (K814) • Magnum Cooler Horizontal TIG Mounting Bracket (K559-2) • Undercarriage (K932-1) UNDERCARRIAGE FUNCTION The Square Wave TIG 255 is designed to be usedw i t h a L i n c o l n K 9 3 2 - 1 U ...
Page 25 - ELECTRIC SHOCK can kill.; Keep TIG torch and cables in good condition.; MAINTENANCE
– 25 – MAINTENANCE ELECTRIC SHOCK can kill. • Only qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse boxbefore working on thisequipment. • Do not touch electrically hot parts. To avoid receiving a high frequency shock, keep theTIG torch ...
Page 26 - FIGURE 6 - GENERAL ASSEMBLY EXPLODED VIEW
– 26 – MAINTENANCE 38 1 5 22 11 2 6 4 28 3 2 FIGURE 6 - GENERAL ASSEMBLY EXPLODED VIEW 1. MAIN TRANSFORMER 5. CONTROL BOX ASSEMBLY 2. OUTPUT STUDS 6. SPARK GAP ASSEMBLY 3. POLARITY SWITCH 7. PROTECTION PC BOARD - 4. RECTIFIER ASSEMBLY (Mounted to rear of control box assembly)
Page 27 - TROUBLESHOOTING; How To Use Troubleshooting Guide; Step 2. PERFORM EXTERNAL RECOMMENDED
– 27 – TROUBLESHOOTING How To Use Troubleshooting Guide This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairsperformed on this equipment may result in danger to the technician and machine operator and will invalidate yourfactory warranty. For your safe...
Page 28 - Troubleshooting Guide; Major Physical or Electrical; OUTPUT PROBLEMS
– 28 – TROUBLESHOOTING Troubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS(SYMPTOMS) Major Physical or Electrical Damage is Evident. Machine is Dead - No Output - No FanNo Displays. Fan runs - Display and controlpanel dark. No output frommachine in eith...
Page 29 - Machine regularly over heats -
– 29 – TROUBLESHOOTING Observe Safety Guidelinesdetailed in the beginning of this manual. Troubleshooting Guide PROBLEMS(SYMPTOMS) Machine regularly over heats - thermostat opens, PL1 (yellow lighton front panel) glows. The fan runsbut machine has no output and nodisplay. Machine makes a very loudbu...
Page 30 - FUNCTION PROBLEMS
– 30 – TROUBLESHOOTING Troubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS(SYMPTOMS) The yellow light (PL1) on the front panel is not lit. One or more keypad lights (LEDS)are dark and cannot be lit whentheir respective keys are pressed -machine is opera...
Page 31 - Machine output is intermittently; TIG MODE PROBLEMS
– 31 – TROUBLESHOOTING Observe Safety Guidelinesdetailed in the beginning of this manual. Troubleshooting Guide PROBLEMS(SYMPTOMS) Machine output is intermittently lost. Gas flow and high frequencyare also interrupted. Arc “Flutters” when TIG welding. Lack of penetration in AC TIGwelding. Black area...
Page 32 - Machine has low output when in; TIG WELDING PROBLEMS
– 32 – TROUBLESHOOTING Troubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS(SYMPTOMS) Machine has low output when in TIG 4-Step Mode. Weak high frequency - machinehas normal welding output. The display shows zero amps, butindicates open circuit voltage(a...
Page 33 - No high frequency. Machine is in
– 33 – TROUBLESHOOTING Observe Safety Guidelinesdetailed in the beginning of this manual. Troubleshooting Guide PROBLEMS(SYMPTOMS) No high frequency. Machine is in the TIG Mode and has normaloutput. No gas or water flow when arc startswitch or amptrol is activated in theTIG Mode. Machine has output ...
Page 34 - Stick electrode “Blasts Off” when; STICK WELDING PROBLEMS
– 34 – TROUBLESHOOTING Troubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS(SYMPTOMS) Stick electrode “Blasts Off” when arc is struck. Cannot adjust AC Wave Balancewhen welding in the Stick Mode. Machine welds at a very low outputregardless of the preset...
Page 35 - WIRING DIAGRAM; ram for a particular code is pasted inside
– 35 – WIRING DIAGRAM 231 TO GROUND PER NATIONAL ELECTRIC CODE 229 PIEZO BUZZER (-) (+) C1 (1,3) (1,2) (1,1) (2,2) (2,1) (3,1) (4,1) (4,2) (5,1) (5,2) TO KEYPAD MATRIX X1 240 230 230D 230B 50/60 HZ 237 238 236A C2 232 230C MACHINES ONLY 230E 236 235 232B 229A 23 9A 239 23 5A 238A R3 R4 52A 4-19-96D ...
Page 37 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P l ...
Page 40 - WARRANTY; IN; STATEMENT OF WARRANTY:; LIMITED WARRANTY; WARRANTY SUPERSEDED
▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ WARRANTY P E R F O R M A N C E P L U S P R O T E C T I O N L IN C OL N ELEC TR IC 3 Y E A R I N C L U D I N G : PA R T S & L A B O R S22127-2 • Sales and Service through Subsidiaries and Distributors Worldwide • 22801 St. Clair Ave. Cleveland, O...
