Lincoln Electric Welding System IM520 B User Manual
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IM520-B  
January, 1997  
SQUARE WAVE TIG 255  
For use with machines having Code Number 10022 thru 10026 & 10134, 10451,10452,10453.  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be  
increased by proper installation ...  
and thoughtful operation on your  
part. DO NOT INSTALL,  
OPERATE OR REPAIR THIS  
EQUIPMENT  
WITHOUT  
READING THIS MANUAL AND  
THE SAFETY PRECAUTIONS  
CONTAINED THROUGHOUT.  
And, most importantly, think  
before you act and be careful.  
OPERATOR’S MANUAL  
World's Leader in Welding and Cutting Products  
Premier Manufacturer of Industrial Motors  
Sales and Service through Subsidiaries and Distributors Worldwide  
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100  
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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 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 Diesel Engines  
The Above For Gasoline 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.  
1.h. To avoid scalding, do not remove the  
FOR ENGINE  
powered equipment.  
radiator pressure cap when the engine is  
hot.  
1.a. Turn the engine off before troubleshooting and maintenance  
work unless the maintenance work requires it to be running.  
____________________________________________________  
1.b.Operate engines in open, well-ventilated  
areas or vent the engine exhaust fumes  
outdoors.  
ELECTRIC AND  
MAGNETIC FIELDS  
____________________________________________________  
may be dangerous  
1.c. Do not add the fuel near an open flame  
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.  
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:  
____________________________________________________  
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.  
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  
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.  
side, the work cable should also be on your right side.  
2.d.4. Connect the work cable to the workpiece as close as  
possible to the area being welded.  
___________________________________________________  
1.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.  
2.d.5. Do not work next to welding power source.  
Mar ‘95  
– 2 –  
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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
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.  
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.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
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.  
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.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
• AC Welder with Reduced Voltage Control.  
ventilation and/or exhaust at the arc to keep  
fumes and gases away from the breathing zone. When  
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.  
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.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating  
products.  
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.  
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.  
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.  
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.  
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.  
5.e. Also see item 1.b.  
Mar ‘95  
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SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
the welding sparks from starting a fire.  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
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.  
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.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
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.  
•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.  
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 though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
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.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
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.  
FOR ELECTRICALLY  
powered equipment.  
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.  
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.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
– 4 –  
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SAFETY  
zones où l’on pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
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:  
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.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
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.  
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.  
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.  
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.  
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.  
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.  
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.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi 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.  
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.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la  
debrancher à l’interrupteur à la boite de fusibles.  
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.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
Mar. ‘93  
– 5 –  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank 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.  
Model Name & Number _____________________________________  
Code & Serial Number _____________________________________  
Date of Purchase _____________________________________  
Whenever you request replacement parts for or information on this equipment always supply the information  
you have recorded above.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or  
loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to  
this equipment.  
– 6 –  
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TABLE OF CONTENTS  
Page  
.....................................................................................................................2-6  
Safety  
Installation................................................................................................................8-12  
Technical Specifications ............................................................................................8  
Input and Output Specifications  
Cable and Fuse Sizes  
Physical Dimensions  
Location .....................................................................................................................9  
Machine Grounding....................................................................................................9  
Input Connections....................................................................................................10  
Output Connections .................................................................................................11  
Operation................................................................................................................13-23  
Safety Instructions ...................................................................................................13  
Graphic Symbols ................................................................................................14-15  
General Description .................................................................................................16  
Design Features and Advantages............................................................................16  
Welding Capability ...................................................................................................17  
Limitations................................................................................................................17  
Controls and Settings...............................................................................................18  
Hand and Foot Amptrol Operation...........................................................................20  
Welding Operation..............................................................................................20-23  
Tig Welding Guidelines.......................................................................................20  
Tig Welding Sequence of Operation (2 Step Mode) ...........................................21  
Tig Welding Sequence of Operation (4 Step Mode) ...........................................22  
Advanced Tig Welding Features.........................................................................22  
Stick Welding ......................................................................................................23  
Auxillary Power ........................................................................................................23  
Overload Protection .................................................................................................23  
Accessories.................................................................................................................24  
Maintenance...........................................................................................................25-26  
Safety Precautions...................................................................................................25  
Routine and Periodic Maintenance..........................................................................25  
General Assembly Exploded View...........................................................................26  
Troubleshooting ....................................................................................................27-34  
How To Use Troubleshooting Guide........................................................................27  
Troubleshooting Guide .......................................................................................28-34  
Wiring Diagrams ....................................................................................................35-36  
Parts Manual .................................................................................................APPENDIX  
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INSTALLATION  
TECHNICAL SPECIFICATIONS - SQUARE WAVE TIG 255  
INPUT - SINGLE PHASE ONLY  
Standard  
Voltage  
Input Current at  
Rated Output (1)  
81/74/37  
Code  
Number  
10022  
10023  
10024  
10452  
10453  
10451  
208/230/460/1/60  
230/460/575/1/60  
200/240/400/1/50/60  
220/380/440/1/50/60  
380/415/500/1/50/60  
220/380/415/1/50/60  
74/37/30  
85/77/44  
77/45/39  
45/41/33  
77/45/41  
RATED OUTPUT  
Duty Cycle  
40% Duty Cycle  
NEMA Class II (40)  
60% Duty Cycle  
100% Duty Cycle  
Volts at Rated Amperes  
Amps  
255  
30  
28  
26  
200  
150  
OUTPUT  
Welding Current Range  
(Continuous)  
Auxiliary Power  
Constant Open  
Circuit Voltage  
Stick OCV: 76  
TIG OCV: 53  
115 Volts AC, 10 Amps  
5-315 Amps  
AC and DC  
220Volts AC, 2 Amps  
(50/60 Hz. machines only)  
RECOMMENDED INPUT WIRE AND FUSE SIZES  
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  
Balance Based on the 1993 U.S. National  
Electrical Code  
Type 75°C  
Type 75°C  
Fuse  
(Super Lag)  
or Breaker  
Size  
Input  
Type 75°C  
Copper Wire in  
Conduit AWG  
(IEC) Sizes  
Copper Ground  
Wire in Conduit  
AWG (IEC)  
Copper Ground  
Wire in Conduit  
AWG (IEC)  
Type 75°C  
Copper Wire in  
Conduit AWG  
(IEC) Sizes  
Ampere  
Input  
Rating on  
Nameplate  
Input  
Voltage /  
Frequency  
Amperes  
Sizes  
Sizes  
2
2
2
2
125  
100  
50  
81  
74  
37  
30  
85  
77  
46  
43  
41  
39  
34  
6 (16mm )  
102  
92  
46  
37  
105  
96  
55  
53  
51  
48  
42  
6 (16mm )  
208/60  
230/60  
6 (16mm )  
4 (25mm )  
2
2
2
2
6 (16mm )  
6 (16mm )  
8 (10mm )  
4 (25mm )  
2
2
2
2
10 (6mm )  
10 (6mm )  
460/60  
10 (6mm )  
8 (10mm )  
2
2
2
2
50  
10 (6mm )  
10 (6mm )  
575/60  
10 (6mm )  
10 (6mm )  
2
2
2
2
125  
100  
70  
6 (16mm )  
6 (16mm )  
200/50/60  
220/50/60  
380/50/60  
400/50/60  
415/50/60  
440/50/60  
500/50/60  
6 (16mm )  
4 (25mm )  
2
2
2
2
6 (16mm )  
8 (10mm )  
8 (10mm )  
4 (25mm )  
2
2
2
2
8 (10mm )  
8 (10mm )  
8 (10mm )  
8 (10mm )  
2
2
2
2
60  
10 (6mm )  
10 (6mm )  
10 (6mm )  
8 (10mm )  
2
2
2
2
60  
10 (6mm )  
10 (6mm )  
10 (6mm )  
8 (10mm )  
2
2
2
2
60  
10 (6mm )  
10 (6mm )  
10 (6mm )  
8 (10mm )  
2
2
2
2
50  
10 (6mm )  
10 (6mm )  
10 (6mm )  
10 (6mm )  
PHYSICAL DIMENSIONS  
Height  
Width  
Depth  
Weight  
30.5 in.  
19.0 in.  
(Lift bail, add 3.5 in)  
30.0 in.  
300 lbs  
(137 kg)  
775 mm  
485 mm  
760 mm  
(Lift bail, add 90 mm)  
(1)  
Unbalanced TIG welding above 180 amps will draw higher input currents; see Supply Connections section.  
– 8 –  
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INSTALLATION  
Read entire installation section before starting  
installation.  
MACHINE GROUNDING AND HIGH  
FREQUENCY INTERFERENCE  
PROTECTION  
Safety Precautions  
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.  
WARNING  
ELECTRIC SHOCK can kill.  
• Only qualified personnel should  
perform this installation.  
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.  
• Turn the input power OFF at the  
disconnect switch or fuse box  
before working on this  
equipment.  
• Do not touch electrically hot  
parts.  
• Always connect the Square Wave  
TIG 255 grounding terminal  
(located on the bottom of the  
input connection box) to a good  
electrical earth ground.  
Radiated interference can develop in the following  
four ways:  
1. Direct interference radiated from the welder.  
2. Direct interference radiated from the welding leads.  
SELECT SUITABLE LOCATION  
3. Direct interference radiated from feedback into the  
power lines.  
Place the welder where clean cooling air can freely  
circulate in through the rear louvers and out through  
the side louvers. Dirt, dust or any foreign material that  
can be drawn into the welder should be kept at a  
minimum. Failure to observe these precautions can  
result in excessive operating temperatures and  
nuisance shut-downs.  
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.  
STACKING  
Square Wave TIG 255’s cannot be stacked.  
TILTING  
Each machine must be placed on a secure, level  
surface, either directly or on a recommended  
undercarriage. The machine may topple over if this  
procedure is not followed.  
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.  
ENVIRONMENTAL PROTECTION  
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.  
Square Wave TIG 255 power sources carry an IP21  
protection rating. They are rated for use in rain-  
sheltered environments.  
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INSTALLATION  
4. Keep the torch in good repair and all connections  
See Figure 1 for the location of the rating plate, the  
entry hole, and the reconnect panel.  
tight to reduce high frequency leakage.  
FIGURE 1 - REAR PANEL  
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  
contact with the earth for ten feet or more.  
1
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.  
2
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.  
3
4
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.  
1. RATING PLATE  
2. INPUT ENTRY &  
RECONNECT PANEL  
3. 220V RECEPTACLE & BREAKER  
(50/60 HZ MACHINE ONLY)  
4. 115V RECEPTACLE & BREAKER  
8. When the welder is enclosed in a metal building,  
several good earth driven electrical grounds (as in  
5 (b) above) around the periphery of the building  
are recommended.  
Have a qualified electrician connect the input leads to  
L1 and L2 of the input panel in accordance with all  
local codes and national electrical codes, and the  
connection diagram located on the inside of the cover.  
Use a single phase line or one phase of a two or three  
phase line.  
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.  
On multiple input voltage welders, be sure the  
reconnect panel is connected per the following  
instructions for the voltage being supplied to the  
welder.  
INPUT CONNECTIONS  
Be sure the voltage, phase, and frequency of the input  
power is as specified on the rating plate, located on  
the rear of the machine.  
CAUTION  
Welder supply line entry provision is in the case rear  
panel with a removable cover over the input  
connection panel area. Entry is through a 1.7 in  
(43mm) diameter hole in the case back. European  
machines have a plastic bushing good for 3 - 10mm2  
conductors. For larger input conductors a customer  
supplied plastic bushing should be used if required by  
local or national code specifications.  
Failure to follow these instructions can cause  
immediate failure of components within the welder.  
___________________________________________  
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INSTALLATION  
Welders are shipped connected for the highest input  
voltage as listed on the rating Plate. To change this  
connection for a different input voltage, reconnect the  
power strap (P) to the terminal 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.  
FIGURE 2 - FRONT PANEL  
1
4
2
3
L9119-1  
DC  
I
POWER  
EXAMPLE: On a 208/230/460 volt welder, LOW is  
208V, MID is 230V, and HIGH is 460V.  
AC  
DO NOT SWITCH  
WHILE WELDING  
O
DC  
WARNING  
L9119-2  
GAS  
ELECTRODE  
WATER  
WORK  
REMOTE  
IN  
OUT  
IN  
OUT  
Fuse the input circuit with the recommended super lag  
1
fuses or delay type circuit breakers. Choose an input  
and grounding wire size according to local or national  
codes, refer to Specification page at the beginning of  
this chapter. 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.  
7
8
6
5
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 180 amps is planned, the higher input  
currents require larger input wire sizes and fuses.  
Refer to Specification page at the beginning of this  
chapter.  
1. CONTROL AND DISPLAY AREA 5. OPTIONAL WATER SOLENOID  
2. POWER SWITCH  
3. THERMOSTATIC  
PROTECTION LIGHT  
4. POLARITY SWITCH  
6. GAS SOLENOID  
7. WORK (LEFT) AND  
ELECTRODE STUDS  
8. REMOTE RECEPTACLE  
TIG TORCH CONNECTION  
TIG welding torches come with 12.5 ft (3.8m) 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” stud on the welder. Connect  
a separate work cable to the “Work” stud of the  
welder. See Table 1 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 output terminals.  
The Square Wave TIG 255 should be permanently  
wired into the power system. No plugs or connectors  
are necessary.  
OUTPUT CONNECTIONS  
WARNING  
To avoid receiving a high frequency shock, keep the  
TIG torch and cables in good condition.  
___________________________________________  
TABLE 1  
Cable Sizes for Combined Lengths of Copper  
Electrode and Work Cable  
Lengths up to  
See Figure 2 for the location of the work and  
electrode terminals, the gas and optional water  
solenoids, and the Remote Receptacle.  
Machine Size  
100 ft  
100 to 200 ft  
200 to 250 ft  
255 Amp  
40% Duty Cycle  
2
2
2
#2 (35mm )  
#1 (45mm )  
1/0 (55mm )  
TIG torches include the necessary gas and, when  
designed for water cooling, water hoses. Connect the  
fittings on these hoses to the welder fittings. Any torch  
conforming to Compressed Gas Association (CGA)  
standards can be connected.  
1
Also  
called  
“inverse  
time”  
or  
“thermal/magnetic”  
delay  
magnitude  
circuit breakers; circuit breakers which have  
in tripping action that decreases as the  
of the current increases.  
a
– 11 –  
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INSTALLATION  
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.  
WARNING  
Observe the safety precautions necessary for  
handling and using compressed gas containers.  
Contact your supplier for specific information.  
___________________________________________  
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 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 conditions, 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 1.  
WARNING  
Do not connect a TIG torch and stick electrode cable  
at the same time. They will both be electrically HOT  
whenever the output contactor is energized.  
___________________________________________  
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OPERATION  
OPERATING INSTRUCTIONS  
General Warnings  
SAFETY INSTRUCTIONS  
WARNING  
ELECTRIC SHOCK  
can kill.  
• Do not touch electrically live parts  
or electrode with skin or wet  
clothing.  
• Insulate yourself from 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.  
– 13 –  
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OPERATION  
GRAPHIC SYMBOLS THAT APPEAR ON  
THIS MACHINE OR IN THIS MANUAL  
AFTERFLOW /  
AFTERFLOW  
TIME  
TIG 2-STEP  
TIG 4-STEP  
&
2
CONTINUOUS  
HIGH  
FREQUENCY  
STICK  
START ONLY  
HIGH  
FREQUENCY  
CURRENT  
CONTROL  
OUTPUT  
OFF  
ON  
LOCAL  
CURRENT  
CONTROL  
REMOTE  
CURRENT  
CONTROL  
CLEAN  
(INCREASE  
POSITIVE  
POLARITY)  
&
&
INCREASE  
PENETRATE  
(INCREASE  
NEGATIVE  
POLARITY)  
OUTPUT  
A
DECREASE  
TIG PULSER  
HIGH  
HF  
FREQUENCY  
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OPERATION  
GRAPHIC SYMBOLS THAT APPEAR ON  
THIS MACHINE OR IN THIS MANUAL (CONT.)  
AC WAVE  
BALANCE  
GAS OUTPUT  
PULSED PER  
SECOND  
f
GAS INPUT  
OVER  
TEMPERATURE  
ELECTRODE  
CONNECTION  
INPUT  
POWER  
PROTECTIVE  
GROUND  
DC+  
POLARITY  
&
&
SINGLE PHASE  
TRANSFORMER  
AC & DC  
DC-  
POLARITY  
RECTIFIER  
POWER  
SOURCE  
DO NOT  
SWITCH  
WHILE  
TIG (GTAW)  
WELDING  
WARNING  
SINGLE  
PHASE  
WATER  
(COOLANT)  
OUTPUT  
WORK  
CONNECTION  
WATER  
(COOLANT)  
INPUT  
AC POLARITY  
– 15 –  
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OPERATION  
GENERAL DESCRIPTION  
• Welding current limit can be preset from 5 to 315  
amps and is displayed on the Ammeter when not  
welding.  
The Square Wave TIG 255 is a constant current,  
single range square wave AC/DC TIG (GTAW) arc  
welding power source with built-in high frequency  
stabilization. It also has stick (SMAW) capability. It is  
available from the factory in one model only; there are  
no factory installed options, only variations in input  
voltage and frequency.  
• 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 Start Switch Capability.  
The Square Wave TIG 255 includes advanced  
features such as Auto-Balance™, 2-Step/4-Step Arc  
Start Switch operation and a TIG pulser. In addition,  
fixed preflow and variable afterflow timers are  
included for shielding gas and cooling water control.  
• TIG Pulser with On/Off Selection, and Pulses Per  
Second adjustment. Background current and duty  
cycle are automatically adjusted according to the  
peak welding current.  
• Fixed preflow time of 0.5 seconds. Preflow time is  
eliminated if welding restarts during gas afterflow of  
previous weld. This avoids unnecessary delays  
when making repeated welds.  
Recommended Processes And  
Equipment  
• Adjustable afterflow time control.  
• Local/Remote current selection.  
• Stick/TlG selection.  
The Square Wave TIG 255 is recommended for the  
TIG (GTAW) and stick (SMAW) welding processes  
within its output capacity of 5 to 315 amps, on both  
AC and DC polarity. It is compatible with all Magnum  
TIG accessories (see Accessory section in this  
manual), as well as many industry standard  
items, such as TIG torches, hoses, and water coolers.  
• Continuous/Start/Off High Frequency selection.  
• DC+/AC/DC- Polarity Switch.  
•
Power Factor Correction for lower input currents and  
smaller input wire sizes.  
Operational Features and Controls  
The Square Wave 255 has the following controls as  
standard: TIG 2-Step/TlG 4-Step/Stick mode  
• Remote Receptacle for Amptrol or Arc Start Switch.  
selection, Local/Remote current control selection,  
Continuous/Start Only/Off high frequency selection,  
Auto/Manual AC wave balance selection with the  
manual wave balance adjustment, TIG pulser On/Off  
selection with frequency adjustment, afterflow  
adjustment, and DC+/DC-/AC polarity selection.  
• Low Voltage Arc Start Switch Circuit (24 V AC) for  
maximum operator safety.  
• Gas and optional Water Valves: Inlet & outlet fittings  
conform to Compressed Gas Association (CGA)  
standards.  
• Built-in High Frequency Generator.  
Design Features and Advantages  
• 115 Volt Receptacle with 10 amp Circuit Breaker.  
• Designed to NEMA EW-1 & International IEC-974  
Standards.  
• 220 Volt European (Schuko) type receptacle with 2  
amp circuit breaker for water coolers (50/60Hz  
machines only).  
• Single output range of 5-315 amps covers the  
majority of all TIG welding applications.  
• Excellent arc starting and stability up through 315  
amps.  
• Solid State Output Contactor: no noise, no parts to  
wear.  
• High resistance to AC arc rectification.  
• No tungsten spitting within current range of  
electrode.  
• Digital Ammeter and Voltmeter for precise readings  
from 5 to 315 amps welding.  
• Compact size, requires only a 19 in x 30 in  
(485 mm x 760 mm) footprint.  
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OPERATION  
• Strain relief holes in base for welding cables, gas  
and water hoses and control cables.  
• Easy access for input connections. Connections  
are simple strip and clamp of input wires (no lugs  
required).  
• Low fan noise at idle.  
• Modular construction for easy servicing.  
• Simple keypad layout allows even novice users to  
operate with minimal instruction.  
• Unused controls are automatically locked out to  
simplify setup. Examples: the AC wave balance  
control has no effect in DC; the High Frequency and  
gas and water valves do not operate in Stick mode;  
TIG Pulser is locked out in the Stick mode.  
• Recessed panels protect controls, output terminals  
gas and water fittings.  
• Large safety margins and protective circuits protect  
rectifiers from transient voltages and high currents.  
• Submersion dipping of assembled transformer,  
choke, rectifier in special sealing/insulating material  
gives added protection against moisture and  
corrosive atmospheres.  
• Line Voltage Compensated.  
• Thermostatically Protected.  
• Electronic Over Current Protection.  
• Hinged Cover over Output Panel.  
Welding Capability  
The Square Wave TIG 255 is rated at 255 amps, 30  
volts, at 40% duty cycle on a ten minute basis. It is  
capable of higher duty cycles at lower output currents.  
If the duty cycle(s) are exceeded, a thermal protector  
will shut off the output until the machine cools to a  
reasonable operating temperature.  
Limitations  
Arc Gouging cannot be performed with the Square  
Wave TIG 255.  
The Square Wave TIG 255 is not recommended for  
pipe thawing.  
– 17 –  
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OPERATION  
CONTROLS AND SETTINGS  
All operator controls and adjustments are located on the case front of the Square Wave TIG 255. Refer to Figures  
3 and 4 and corresponding explanations.  
FIGURE 3 - CONTROL PANEL KEYS  
7
G2612  
AC/DC OUTPUT CAPACITY: 255 AMPS 30 VOLTS 40% DUTY CYCLE  
THE LINCOLN ELECTRIC COMPANY  
CLEVELAND, OHIO USA  
AC WAVE BALANCE  
CURRENT CONTROL  
TIG PULSER  
WELD MODE  
HF HIGH FREQUENCY  
2
AFTERFLOW  
TIG 2-STEP  
LOCAL  
REMOTE  
CONTINUOUS  
SECONDS  
OFF  
ON  
HF  
AUTO-  
MANUAL  
BALANCE  
BALANCE  
AMPS  
TIG 4-STEP  
START ONLY  
HF  
PULSES PER SECOND  
CLEAN  
2
f
STICK  
A
PENETRATE  
OFF  
LINCOLN  
R
ELECTRIC  
6
2
4
1
5
3
1. WELD MODE KEYS  
5. TIG PULSER KEYS  
6. AFTERFLOW KEYS  
7. DISPLAY  
2. CURRENT CONTROL KEYS  
3. HIGH FREQUENCY KEYS  
4. AC WAVE BALANCE KEYS  
CONTROL PANEL KEYS  
4. AC WAVE BALANCE: These keys are active in  
the AC TIG mode only. They are used to set the  
amount of cleaning and/or penetration produced  
during an AC TIG weld. Auto Balance™  
automatically sets the AC Wave Balance according  
to the welding current. If manual adjustment is  
desired, the Manual Balance key can be pressed,  
and the balance adjusted from +5 (cleaning) to -10  
(penetration) with the Cleaning and Penetration  
keys. Read the Advanced Features section for a  
complete explanation of the AC Wave Balance.  
The keys are grouped into six areas, described below  
and in Figure 3. Some areas are active in both TIG  
and Stick, while others are active in TIG only. The red  
LED indicator lights are used to tell which functions  
are active, and the display (Item 1) is used to check  
the settings of the up/down keys.  
1. WELD MODE KEYS: These keys select the Weld  
Mode desired: TIG 2-Step, TIG 4-Step, or Stick.  
Read the complete Operating Instructions section  
for more information on TIG 2-Step and  
TIG 4-Step.  
5. TIG PULSER: These keys are active in the TIG  
mode only. The On/Off keys turn the TIG Pulser  
on and off. The Pulses Per Second keys adjust  
the pulsing frequency up and down, from 0.5 to 10  
pulses per second. Read the Advanced Features  
section for more information on the TIG Pulser.  
2. CURRENT CONTROL: This area contains the  
Local/Remote keys, as well as the Amps Up/Amps  
Down keys. These keys are used to set the  
welding current from 5 to 315 amps, as well as to  
select Local or Remote control. Local control  
allows the current to be adjusted only with the  
Amps Up/Amps Down keys. Remote control  
allows the use of a hand or foot operated remote  
control. Read the complete Operating Instructions  
section for more information on Local and Remote.  
6. AFTERFLOW: These keys are active in the TIG  
mode only. They must adjust the afterflow time  
from 5 to 50 seconds for shielding gas and cooling  
water flow through solenoids located on the case  
front. As the Afterflow time is adjusted, the  
Afterflow time, in seconds, is shown in the  
Momentary Display.  
3. HIGH FREQUENCY: These keys are active in the  
TIG mode only. Select from Continuous, Start  
Only, or Off. Read the TIG Welding Section for  
information on High Frequency.  
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OPERATION  
7. CONTROL PANEL: The display is divided into five  
sections. See Figures 4A and 4B.  
E. BAR GRAPH DISPLAY: This area provides a  
graphical display of values shown on the Ammeter  
and on the Momentary Display. When the  
Momentary Display is blank (as in Figure 4A), the  
Bar Graph Display represents values shown on the  
ammeter. When a low value is shown on the  
ammeter, only a few “bars” will appear on the left  
hand side of the Bar Graph Display. As the  
ammeter value increases, more and more “bars”  
will appear. Whenever a value increases, more  
and more “bars” will appear. Whenever a value  
appears in the Momentary Display, the Bar Graph  
Display will represent the Momentary Display  
value, not the ammeter value.  
FIGURE 4A - DISPLAY  
C
D
A
B
E
CASE FRONT CONTROLS  
Refer to Figure 5 for the location of the following  
controls:  
A. AC/DC INDICATOR  
B. VOLTMETER  
C. AMMETER  
D. MOMENTARY DISPLAY  
E. BAR GRAPH  
1. POWER SWITCH: Controls the input power to the  
Square Wave TIG 255.  
FIGURE 4B - DISPLAY  
2. OVER TEMPERATURE LIGHT: A yellow light  
which only lights when an over temperature  
situation occurs. See the Maintenance Section for  
more information on the thermostatic protection.  
3. POLARITY SWITCH: Selects DC+, AC or DC-  
welding polarity. Do not switch under load.  
FIGURE 5 - CASE FRONT CONTROLS  
A. AC/DC INDICATOR: This symbol represents the  
output polarity of the 255 . . . either AC or DC. AC  
is shown in Figure 4A; DC is shown in Figure 4B.  
B. VOLTMETER: This meter displays open circuit  
voltage as well as welding voltage, as measured  
on the output studs of the Square Wave TIG 255.  
3
1
2
L9119-1  
DC  
C. AMMETER: The ammeter can display preset  
current (for setting the welding current before  
welding) and actual welding current (the value of  
the welding current during a weld). Read the  
complete Operating Instructions section for more  
information on the ammeter.  
I
POWER  
AC  
DO NOT SWITCH  
WHILE WELDING  
O
DC  
WARNING  
L9119-2  
GAS  
ELECTRODE  
WATER  
WORK  
REMOTE  
IN  
OUT  
IN  
OUT  
D. MOMENTARY DISPLAY: This area is blank under  
most conditions; see Figure 4A. Different values  
may be displayed here as certain keypad keys are  
pressed. See Figure 4B; the TIG Pulser is being  
adjusted, so the Pulse Frequency, 2.0 Hz, is being  
displayed. Information in the Momentary Display  
lasts for five seconds after a key is pressed. Read  
the complete Operating Instructions section for  
more information on the values that appear in the  
Momentary Display.  
1.  
2.  
POWER SWITCH  
THERMOSTATIC  
PROTECTION LIGHT  
POLARITY SWITCH  
3.  
– 19 –  
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OPERATION  
HAND AND FOOT AMPTROL ACCESSORY  
OPERATION  
WELDING OPERATION  
TIG Welding  
Both the Hand and Foot Amptrol work in a similar  
manner. They are meant to be used for remote current  
control when Remote Current Control is selected.  
The TIG 2-Step mode must be selected when using  
an Amptrol for remote current control. As explained  
below, Amptrols can also be used as arc start  
switches if Local Current Control is selected.  
Familiarize yourself with the Controls and Display  
Section before attempting operation of the Square  
Wave TIG 255.  
TIG Welding Guidelines  
TIG welding can be done in either the TIG 2-Step or  
the TIG 4-Step Weld Mode. TIG 2-Step is typically  
used with Hand or Foot Amptrols, with Remote  
Current control. TIG 4-Step is typically used with Arc  
Start switches and Local Current Control, because it  
provides a very brief current upslope, and a 5-second  
current downslope. TIG 4-Step also functions like a  
trigger interlock, making it unnecessary to hold down  
the Arc Start switch during a weld. Note, on later  
versions, TIG 4-Step was made available for use with  
Remote Current Control with the release of ROM  
version S21228-4 (initiated on Control board G2150-3  
on codes 10022 and higher). This feature requires  
that the remote control devise in use must have  
separate Arc Start and Output Control mechanisms.  
Read the TIG Welding Sequence of Operation  
sections for more details on 2-Step and 4-Step  
Operation.  
For simplicity, the following explanation will refer only  
to “Amptrols”, meaning both Foot and Hand models.  
The term “minimum” refers to a Foot pedal in the “up”  
position, as it would be with no foot pressure, or a  
Hand Amptrol in the relaxed position, with no thumb  
pressure. “Maximum” refers to a fully depressed Foot  
Amptrol, or a fully extended Hand Amptrol.  
The Amptrol is capable of controlling the output  
current from 5 amps to the preset current displayed on  
the ammeter. For example, if the ammeter is preset  
for 200 amps and the Current Control switch is in the  
REMOTE position, the Amptrol, when depressed just  
past its minimum position, will cause the Square  
Wave TIG 255 to weld at 5 amps. At the Amptrols  
maximum position, the output would be near 200  
amps.  
It is important to note that, for many applications, the  
tungsten will not start an arc at only 5 amps. To start  
an arc reliably, it is important to depress the Amptrol  
far enough so that the machine output current is near  
the tungsten operating range. In the example above, a  
3/32” tungsten may be used on DC- to weld near 200  
amps. To start the weld, the operator may have to  
depress the Amptrol approximately 1/4 of the way  
down, or to nearly 50 amps, in order to start the arc.  
Merely depressing the Amptrol to its 5 amp minimum  
position will not start the arc.  
TABLE 2  
RECOMMENDED POLARITY  
SETTINGS FOR TIG WELDING  
Electrode  
Polarity  
High Frequency  
Setting  
Type of Welding  
Stainless Steel  
DC-  
AC  
START  
CONTINUOUS  
START  
Aluminum & Magnesium  
Other Metals  
DC-  
If the Current Control switch is set to the LOCAL  
position, an Amptrol can be used as an arc start  
switch. Depressing the Amptrol just past minimum will  
cause the Amptrols built-in arc start switch to close,  
and backing off completely causes the built-in start  
switch to open. The Amptrol will have no effect on the  
welding current when used as an arc start switch.  
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OPERATION  
TABLE 3  
TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES (2)  
AC  
Approximate Argon  
Gas Flow Rate  
C.F.H. (1/min.)  
+
-
DCEN (  
)
DCEP (  
)
Unbalanced Wave  
Balanced Wave  
1%, 2%  
1%, 2%  
Tungsten  
Electrode  
Diameter  
in. (mm)  
1%, 2%  
Thoriated  
Tungsten  
1%, 2%  
Thoriated  
Tungsten  
Thoriated  
Tungsten  
Zirconiated  
Thoriated  
Tungsten  
Zirconiated  
TIG Torch  
Nozzle  
Pure  
Tungsten  
Pure  
Tungsten  
Stainless  
Steel  
Size(4), (5)  
Aluminum  
(3)  
(3)  
(3)  
.010 (.25)  
0.020 (.50)  
0.040 (1.0)  
2-15  
5-20  
15-80  
2-15  
5-15  
10-60  
2-15  
5-20  
15-80  
2-15  
10-20  
20-30  
---  
5-20  
20-60  
3-8  
(2-4) 3-8  
(2-4) #4, #5, #6  
5-10 (3-5) 5-10 (3-5)  
5-10 (3-5) 5-10 (3-5)  
1/16 (1.6)  
3/32 (2.4)  
70-150  
10-20  
50-100  
70-150  
30-80  
60-120  
5-10 (3-5) 9-13 (4-6)  
#5, #6  
150-250  
250-400  
15-30  
25-40  
100-160  
150-210  
140-235  
225-325  
60-130  
100-180  
100-180  
160-250  
13-17 (6-8) 11-15 (5-7) #6, #7, #8  
15-23 (7-11)  
1/8  
(3.2)  
11-15 (5-7)  
5/32 (4.0)  
3/16 (4.8)  
400-500  
500-750  
40-55  
55-80  
80-125  
200-275  
250-350  
325-450  
300-400  
400-500  
500-630  
100-240  
190-300  
250-400  
200-320  
290-390  
340-525  
13-17 (6-8)  
18-22 (8-10)  
23-27(11-13)  
#8, #10  
21-25 (10-12)  
23-27 (11-13)  
28-32 (13-15)  
1/4  
(6.4) 750-1000  
(1)  
(2)  
When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gasses.  
Tungsten electrodes are classified as follows by the American Welding Society (AWS):  
Pure . . . . . . . . . . . . . . . EWP  
1% Thoriated . . . . . . . . EWTh-1  
2% Thoriated . . . . . . . . EWTh-2  
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.  
DCEP is not commonly used in these sizes.  
TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:  
(3)  
(4)  
#4 = 1/4 in.  
#5 = 5/16 in.  
#6 = 3/8 in.  
#7 = 7/16 in.  
#8 = 1/2 in.  
#10 = 5/8 in.  
(6 mm)  
(8 mm)  
(10 mm)  
(11 mm)  
(12.5 mm)  
(16 mm)  
(5)  
TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot  
withstand high temperatures and high duty cycles.  
TIG WELDING SEQUENCE OF OPERATION  
(2-STEP MODE)  
7. If welding with AC polarity, select Auto Balance™.  
This gives the optimum ratio between cleaning and  
penetration, automatically adjusted for the output  
current. If manual adjustment of the AC Wave  
Balance is desired, select Manual Balance, and  
adjust the wave balance with the Cleaning and  
Penetration keys. See the Advanced Features  
section for more information on setting and using  
the AC Wave Balance.  
1. Connect an Arc Start Switch or an Amptrol to the  
Remote Receptacle.  
2. Turn on the welder, gas supply and water supply (if  
so equipped). The Control Panel Display and  
red LEDS will illuminate when the power is on.  
3. Select the TIG 2-Step Weld Mode.  
8. Select TIG Pulser On or Off. If the TIG Pulser is  
on, adjust the pulse frequency with the Pulses Per  
Second Up/Down keys. See the Advanced  
Features section for more information on setting  
and using the TIG Pulser.  
4. Select Local (if using an Arc Start Switch) or  
Remote (if using an Amptrol) current control. Set  
the output current using the Amps Up/Down keys.  
The output current setting will be displayed on the  
Ammeter.  
9. Set the Afterflow time with the Seconds Up/Down  
keys. Afterflow time provides shielding gas flow  
(and cooling water, if used) after the weld. Use  
short Afterflow times with low currents and small  
tungstens, use long afterflow times at high output  
currents with large tungstens.  
5. Select Continuous High Frequency if welding with  
AC polarity, or Start Only High Frequency if  
welding with DC- polarity. High Frequency Off can  
be used for scratch start welding.  
6. Select AC or DC- electrode polarity. See Table 2.  
– 21 –  
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OPERATION  
9. Set the Afterflow time with the Seconds Up/Down  
keys. Afterflow time provides shielding gas flow  
(and cooling water, if used) after the weld. Use  
short Afterflow times with low currents and small  
tungstens, long afterflow times at high output  
currents with large tungstens.  
10. Press and release the Arc Start Switch, and set  
the gas flow meter. The welder is now ready for  
welding.  
11. Position the tungsten electrode at the start of the  
weld at a 65 to 75 angle with the horizontal so  
that the electrode is approximately 1/8” (4mm)  
above the work piece. Press the Arc Start Switch.  
This opens the gas and water valves to  
automatically purge air from the hose and torch.  
After a 0.5 second preflow time, the high  
frequency becomes available to strike the arc.  
10. Press and release the Arc Start Switch, and set  
the gas flow meter. The welder is now ready for  
welding.  
11. Position the tungsten electrode at the start of the  
weld at a 65 to 75 angle with the horizontal so  
that the electrode is approximately 1/8” (4mm)  
above the work piece. Press the Arc Start Switch.  
This opens the gas and water valves to  
automatically purge air from the hose and torch.  
After a 0.5 second preflow time, the high  
frequency becomes available to strike the arc.  
12. Hold the Arc Start Switch or Amptrol down until an  
arc is established. If using an Amptrol, read the  
section on Hand and Foot Amptrol Operation.  
Release the Arc Start Switch or Amptrol to stop  
the arc and start the Afterflow timer. After the  
Afterflow time has expired, the gas and water  
valves will close. To make another weld, repeat  
steps 11 and 12.  
12. Hold the Arc Start Switch down until an arc is  
established. The arc will start at a low current  
value. Release the Arc Start Switch. At this point,  
the Square Wave TIG 255 will quickly ramp up to  
the welding current, and the weld will continue  
indefinitely. Press the Arc Start Switch a second  
time to initiate a 5-second downslope. The current  
will go down to a crater fill current that is equal to  
25% of the welding current. Release the Arc Start  
Switch to stop the arc and start the Afterflow timer.  
After the Afterflow time has expired, the gas and  
water valves will close. To make another weld,  
repeat steps 11 and 12.  
TIG WELDING SEQUENCE OF OPERATION  
(4-Step Mode)  
1. Connect an Arc Start Switch to the Remote  
Receptacle.  
2. Turn the welder, gas supply and water supply (if so  
equipped), on. The Control Panel Display and red  
LEDS will illuminate when the power is on.  
3. Select the TIG 4-Step Weld Mode.  
4. Select the Local current control. Set the output  
current using the Amps Up/Down keys. The output  
current setting will be displayed on the Ammeter. On later  
version machines, remote control is also available in TIG 4-  
Step mode on codes 10022 and higher utilizing ROM  
version S21228-4 and higher provided that the remote  
control used has separate Arc Start and Output Control  
mechanisms.  
ADVANCED TIG WELDING FEATURES  
AC Wave Balance and Auto Balance™  
AC Wave Balance is a feature unique to square wave  
TIG power sources. It is active only in AC TIG mode.  
It controls the amount of positive and negative current  
in the AC output.  
5. Select Continuous High Frequency if welding with  
AC polarity, or Start Only High Frequency if  
welding with DC- polarity. High Frequency Off can  
be used for scratch start welding.  
The Square Wave TIG 255 allows the operator to  
select Auto Balance™. This selection provides  
automatic adjustment of the AC Wave Balance; it is  
suitable for most welding conditions. Auto Balance  
gives the ideal amount of cleaning and penetration,  
based on the welding current output.  
6. Select AC or DC- electrode polarity. See Table 2.  
7. If welding with AC polarity, select Auto Balance™.  
This gives the optimum ratio between cleaning and  
penetration, automatically adjusted for the output  
current. If manual adjustment of the AC Wave  
Balance is desired, select Manual Balance, and  
adjust the wave balance with the Cleaning and  
Penetration keys. See the Advanced Features  
section for more information on setting and using  
the AC Wave Balance.  
Manual adjustment of the AC Wave Balance is also  
possible. Select the Manual Balance key, and the  
Balance setting will appear in the Momentary Display.  
Manual Balance settings vary from +5 (maximum  
cleaning) to -10 (maximum penetration). A setting of  
0 yields a balanced output (equal amounts of cleaning  
and penetration). Use the following as a guide when  
setting the Balance manually:  
8. Select TIG Pulser On or Off. If the TIG Pulser is on, adjust  
the pulse frequency with the Pulses Per Second Up/Down  
keys. See the Advanced Features section for more  
information on setting and using the TIG Pulser.  
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OPERATION  
5. Clamp the electrode in the electrode holder, start  
the weld by lightly touching the electrode to the  
work. Stop the weld by pulling the electrode away  
from the work piece. Note, in Stick Mode the  
output studs remain electrically “HOT”.  
BALANCED (0): The amounts of positive and  
negative are the same.  
CLEANING (+1 to +5): Provides more positive  
current than negative. Since the positive  
current produces the “cleaning” or oxide  
removal on aluminum, this setting is used for  
welding on heavily oxidized aluminum.  
AUXILIARY POWER  
PENETRATION (-1 to -10): Provides more negative  
current than positive. The arc plasma will be  
more concentrated and more easily directed  
to where the heat is needed. Higher  
penetration settings allow a given size of  
tungsten to carry more current.  
ALL MACHINES  
The Square Wave TIG 255 provides 10 amps of 115  
volt AC power at a standard NEMA 5-15R receptacle,  
located on the lower case back of the machine. This  
circuit is protected from shorts and overloading by a  
10 amp circuit breaker, located next to the receptacle.  
The auxiliary circuit is intended for running water  
coolers and small power tools, whose current draw is  
within the 10 amp rating. Note that some types of  
equipment, especially pumps and large motors, have  
starting currents which are significantly higher than  
their running current. These higher starting currents  
may cause the circuit breaker to open. If this situation  
occurs, the user should refrain from using the Square  
Wave TIG 255 auxiliary for that equipment.  
CAUTION: Use only the amount of cleaning required  
because the greater amount of positive current will  
heat the tungsten more and possibly cause it to melt  
or “spit”. Also, the arc is usually more flared and less  
stable with more cleaning current.  
In general, use just enough “cleaning” to remove  
oxides and to give good wetting to the puddle.  
TIG Pulser  
The Square Wave TIG 255 contains a unique TIG  
Pulser circuit. The TIG Pulser has On/Off selections,  
as well as adjustments for Pulses Per Second  
Up/Down. When the Pulser is turned On, or when the  
Pulses Per Second are adjusted, the pulse frequency is  
shown in the Momentary Display. It can be varied  
from 0.5 Hz to 10 Hz in 0.5 Hz increments. (One  
Hertz {Hz} is equivalent to one pulse per second.)  
The background current (the welding current at the  
low point of the pulse cycle) is automatically adjusted  
from 40% to 60% of the peak current by the Square  
Wave TIG 255. The duty cycle (the ratio between that  
time spent at the peak current vs, the time spent at  
the background current) is fixed at 50%.  
50/60Hz MACHINES - (Codes 10024 thru 10026 & 10134)  
Square Wave TIG 255 machines rated for 50/60Hz  
operation provide 2 amps of 220 volt AC power at a  
continental European (Schuko) type receptacle,  
located on the lower case back of the machine. This  
circuit is protected from shorts and overloading by a 2  
amp circuit breaker, located above the receptacle.  
The auxiliary circuit is intended for running water  
coolers whose current draw is within the 2 amp rating  
of the receptacle. Note that some types of equipment,  
especially pumps and motors, have starting currents  
which are significantly higher than their running  
currents. These higher starting currents may cause  
the circuit breaker to open. If this situation occurs, the  
user should refrain from using the Square Wave TIG  
255 auxiliary for that equipment.  
STICK WELDING  
1. Remove the amptrol or Arc Start Switch from the  
Remote Receptacle.  
OVERLOAD PROTECTION  
This welder has thermostatic protection from  
excessive duty cycles, overloads, loss of cooling, and  
high ambient temperatures. When the welder is  
subjected to an overload or loss of cooling, a  
thermostat will open. This condition will be indicated  
by the illumination of the yellow Thermostatic  
Protection Light on the case front (see Figure 2).  
Also, the Display will be blank, and all of the red  
Control Panel LEDS will be out. The fan will continue  
to run to cool the power source. No welding is  
possible until the machine is allowed to cool and the  
Thermostatic Protection Light goes out.  
2. Turn the welder on. The Control Panel Display  
and red LEDS will illuminate when the power is on.  
3. Select Stick Mode and Local Current Control. Set  
the output current using the Amps Up/Down keys.  
The output current setting will be displayed on the  
Ammeter. No other functions or adjustments  
operate in the Stick Mode.  
4. Select DC+, AC or DC- electrode polarity.  
– 23 –  
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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 used  
with a Lincoln K932-1 Undercarriage. Complete  
installation instructions are included with the K932-1  
undercarriage. When the undercarriage is properly  
installed, the Square Wave TIG 255 lift bail is non-  
functional. Do not attempt to lift the power source with  
the undercarriage attached. The undercarriage is  
designed for hand moving only; mechanized towing  
can lead to injury and/or damage to the Square Wave  
TIG 255.  
INSTALLATION OF FIELD INSTALLED OPTIONS  
Instructions for connecting the K932-1 Undercarriage  
and the K559-2 Magnum Cooler Horizontal TIG  
Mounting Bracket are included with those  
accessories.  
Installation of the K963 Hand Amptrol, the K814 Arc  
Start Switch and K870 Foot Amptrol are as follows:  
Lift the Output Cover Door (if so equipped) on the  
Square Wave TIG 255. Feed the cable up through the  
strain relief holes in the base, and connect the 6-pin  
MS-type (Amphenol) connector to the Remote  
Receptacle (See Figure 2). Secure with the threaded  
collar.  
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MAINTENANCE  
MAINTENANCE  
Safety Precautions  
WARNING  
ELECTRIC SHOCK can kill.  
• Only qualified personnel should  
perform this maintenance.  
• Turn the input power OFF at the  
disconnect switch or fuse box  
before working on this  
equipment.  
• Do not touch electrically hot  
parts.  
Routine and Periodic Maintenance  
WARNING  
To avoid receiving a high frequency shock, keep the  
TIG torch and cables in good condition.  
1. Disconnect power supply lines to machine before  
performing periodic maintenance.  
2. Periodically clean the inside of the machine with a  
low pressure air system. Be sure to clean the  
following components thoroughly. See Figure 6  
for location of those components.  
• Main Transformer  
• Output Studs  
• Polarity Switch  
• Rectifier Assembly  
• Control Box Assembly  
• Spark Gap Assembly  
• Protection PC Board -  
(Mounted to rear of control box assembly)  
3. Inspect welder output and control cables for  
fraying, cuts, and bare spots.  
4. Keep TIG torch and cables in good condition.  
5. The fan motor has sealed ball bearings which  
require no maintenance.  
6. Inspect spark gap spacing at regular intervals to  
maintain a 0.015 in (0.4mm) gap. (Smallest  
possible air gap consistent with good welding is  
desirable to minimize R.F.I. problems.) Dressing  
or any refinishing of the spark gap contacts is not  
recommended. If the contact surfaces become  
irregular or completely eroded, replacement of both  
electrodes is recommended.  
– 25 –  
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MAINTENANCE  
FIGURE 6 - GENERAL ASSEMBLY EXPLODED VIEW  
1
5
6
4
3
2
1. MAIN TRANSFORMER  
5. CONTROL BOX ASSEMBLY  
2. OUTPUT STUDS  
3. POLARITY SWITCH  
4. RECTIFIER ASSEMBLY  
6. SPARK GAP ASSEMBLY  
7. PROTECTION PC BOARD -  
(Mounted to rear of control box assembly)  
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TROUBLESHOOTING  
How To Use Troubleshooting Guide  
WARNING  
This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs  
performed on this equipment may result in danger to the technician and machine operator and will invalidate your  
factory warranty. For your safety, please observe all safety notes and precautions detailed in the Safety Section of  
this manual to avoid electrical shock or danger while troubleshooting this equipment.  
___________________________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and correct possible machine misadjustments.  
Simply follow the three-step procedure listed below.  
Step 3. CONSULT LOCAL AUTHORIZED FIELD  
SERVICE FACILITY  
If you have exhausted all of the recommended tests in  
step 2, consult your local Authorized Field Service  
Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM)  
Look under the column labeled “PROBLEM  
(SYMPTOMS)”. This column describes possible  
symptoms that your machine may exhibit. Find the  
listing that best describes the symptom that your  
machine is exhibiting.  
Step 2. PERFORM EXTERNAL RECOMMENDED  
TESTS  
The second column labeled “POSSIBLE AREAS OF  
MISADJUSTMENT(S)” lists the obvious external  
possibilities that may contribute to the machine  
symptom. Perform these tests/checks in the order  
listed. In general, these tests can be conducted  
without removing the case wrap-around cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
– 27 –  
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TROUBLESHOOTING  
Troubleshooting Guide  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major Physical or Electrical  
Damage is Evident.  
1. Contact The Lincoln Electric  
Service Dept. (216) 383-2531  
Machine is Dead -  
No Output - No Fan  
No Displays.  
1. Make certain that the input  
power switch is in the “ON”  
position.  
2. Check the input voltage at the  
machine. Input voltage must  
match the rating plate and  
reconnect the panel.  
3. Blown or missing fuses in  
input line.  
Fan runs - Display and control  
panel dark. No output from  
machine in either Stick or TIG  
modes.  
1. Check for proper input  
voltages. As per nameplate  
and reconnect panel.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
The voltmeter reads “00” in Stick  
Mode, and there is no output from  
the machine when in the TIG  
2-Step Mode.  
1. Inspect to assure that the arc  
start switch is in the on  
(closed) position when  
welding in the TIG Mode.  
Machine does not respond (no gas 1. Machine MUST be in one of  
flow, no high frequency and no  
open circuit voltage) when arc  
switch or amptrol is activated -  
displays and fan working.  
the TIG Modes.  
2. The arc start switch or amptrol  
may be defective. Check for  
continuity between pins “D”  
and “E” on cable connector  
when arc switch or amptrol is  
activated.  
115VAC Receptacle not working  
properly (voltage is below 108VAC).  
Machine has welding output - fan is  
running.  
1. Check for 115VAC at  
receptacle - if low (below  
108VAC), then check input  
voltage to machine.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
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TROUBLESHOOTING  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
Troubleshooting Guide  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Machine regularly over heats -  
thermostat opens, PL1 (yellow light  
on front panel) glows. The fan runs  
but machine has no output and no  
display.  
1. Welding application may  
exceed recommended duty  
cycle.  
2. Dirt and dust may have  
clogged the cooling channels  
inside the machine. Blow out  
unit with clean, dry  
compressed air.  
3. Air intake and exhaust louvers  
may be blocked due to  
inadequate clearance around  
machine.  
Machine makes a very loud  
buzzing noise in DC Stick Mode, or  
in DC TIG Mode when the arc start  
or amptrol is pressed.  
1. Inspect output stud insulators  
for cracks or signs of over-  
heating.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
There is no current draw from  
machine’s output studs.  
(The machine is not externally  
loaded).  
Authorized Field Service Facility.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
– 29 –  
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TROUBLESHOOTING  
Troubleshooting Guide  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The yellow light (PL1) on the front  
panel is not lit.  
1. Normal condition - this light  
will glow only if machine is in  
an overheated condition.  
(Thermal overload).  
One or more keypad lights (LEDS)  
are dark and cannot be lit when  
their respective keys are pressed -  
machine is operable.  
1. Be sure that the proper weld  
mode is selected. For  
example, the high frequency  
keys and keypad lights  
(LEDS) are not active in the  
stick mode.  
The Beeper (Piezoelectric Buzzer)  
cannot be heard - machine  
operating normally.  
1. Background noise may be too  
loud for user to hear beeper.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
Download from Www.Somanua–ls.c3o0m.–All Manuals Search And Download.  
TROUBLESHOOTING  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
Troubleshooting Guide  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
TIG MODE PROBLEMS  
Machine output is intermittently  
lost. Gas flow and high frequency  
are also interrupted.  
1. Problem may be caused by  
high frequency interference.  
Make sure that the machine is  
grounded properly according  
to the installation instructions.  
If there are other high  
frequency sources in the area,  
make certain that they are  
grounded properly.  
2. Check arc start switch or  
amptrol for proper operation  
and loose connections.  
Arc “Flutters” when TIG welding.  
1. Tungsten electrode may be  
too large in diameter.  
2. Tungsten not “Sharp” when  
welding in DC negative mode.  
3. If helium is used as a  
shielding gas, then reduce the  
percentage of helium.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
4. Adjust flow rate of shielding  
gas.  
5. Check hoses and connections  
for leaks.  
Lack of penetration in AC TIG  
welding.  
1. Manual balance control set  
improperly - set to negative  
10 (-10) for maximum  
penetration.  
Black areas along weld bead.  
1. Tungsten electrode may be  
contaminated. Replace or  
sharpen.  
2. Shielding gas flow may be  
insufficient.  
3. Contaminated gas or faulty  
gas line or torch.  
Black areas along weld bead at or  
near end of weld.  
1. Increase post flow time.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
– 31 –  
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TROUBLESHOOTING  
Troubleshooting Guide  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
TIG WELDING PROBLEMS  
Machine has low output when in  
TIG 4-Step Mode.  
1. Machine must be in “Local”  
Control Mode when 4-Step is  
used.  
Weak high frequency - machine  
has normal welding output.  
1. Spark gap may be misadjusted.  
Check and reset per  
maintenance instructions.  
2. Improper shielding gas flow.  
Adjust for a flow of 10 to 30  
CFH (4.7 to 14.1 l/min.) for  
most applications.  
3. Work and electrode cables in  
poor condition allowing high  
frequency to “Leak Off”. Use  
good quality cables with a high  
natural rubber content, such  
as Lincoln Stable Arc Cable.  
Cables should be as short as  
possible.  
The display shows zero amps, but  
indicates open circuit voltage  
(approximately 53V). The arc start  
switch or amptrol is not actuated.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
1. The arc start switch or amptrol  
may be defective. There should  
not be any continuity between  
pins “D” and “E” on the arc start  
cable connector, unless the  
unit is actuated.  
Authorized Field Service Facility.  
2. If an amptrol is not being used,  
the machine must be in the  
Local Control Mode.  
High frequency “Spark” is present  
at tungsten electrode, but operator  
is unable to establish a welding arc.  
Machine has normal open circuit  
voltage (approximately 53V).  
1. Torch may be faulty.  
2. If an amptrol is not being used,  
then the machine must be in  
the Local Control Mode.  
3. Tungsten electrode may be  
too large for the process.  
4. If helium shielding gas is being  
used, then reduce percentage  
of helium.  
5. If TIG welding in the DC  
negative mode, then a properly  
sharpened thoriated tungsten  
should be used.  
6. Check the welding cables and  
output stud connections.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
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TROUBLESHOOTING  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
Troubleshooting Guide  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
TIG WELDING PROBLEMS  
No high frequency. Machine is in  
the TIG Mode and has normal  
output.  
1. In order for the high frequency  
to operate, the machine must  
be either in the start only  
Mode or the continuous high  
frequency mode.  
2. The high frequency spark gap  
may be too large or shorted.  
Check gap as per  
maintenance instructions.  
No gas or water flow when arc start 1. Gas supply is empty or not  
switch or amptrol is activated in the  
TIG Mode. Machine has output -  
fan runs. When toggling between  
the Stick and TIG Modes a “Click”  
can be heard indicating that the  
solenoids are operating.  
turned on.  
2. Gas or water hose may be  
pinched.  
3. Gas or water solenoid may be  
blocked with dirt. Use filters  
to prevent reoccurrence.  
Consult your Local welder/gas  
distributor.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
Arc rectification when AC TIG  
welding.  
1. Tungsten electrode may be  
too small for process.  
2. Manual balance control may  
be misadjusted. Readjust to  
the negative direction.  
3. If helium gas is being used,  
reduce percentage of helium.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
– 33 –  
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TROUBLESHOOTING  
Troubleshooting Guide  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
STICK WELDING PROBLEMS  
Stick electrode “Blasts Off” when  
arc is struck.  
1. Weld current is set too high  
for recommended electrode  
size. Reduce preset current  
adjustment.  
Cannot adjust AC Wave Balance  
when welding in the Stick Mode.  
1. This is a normal condition.  
Wave balance keys are  
automatically disabled in the  
Stick Mode.  
Machine welds at a very low output 1. If welding in the Remote  
regardless of the preset current  
setting - arc is stable.  
Control Mode, the remote  
amptrol may be defective or  
not installed properly.  
2. If the output is low when the  
machine is in the Local  
Control Mode, the problem  
could be internal to the  
machine.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Variable or sluggish welding arc  
when welding in the Stick Mode.  
1. Check work and electrode  
cables for loose or poor  
connections.  
Authorized Field Service Facility.  
2. The weld cables may be too  
small or too long to permit the  
desired current to flow.  
3. The preset current adjustment  
may be set too low.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
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WIRING DIAGRAM  
2 3 5 A  
2 3 9 A  
– 35 –  
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WIRING DIAGRAM  
2 3 5 A  
2 3 9 A  
– 36 –  
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Now Available...12th Edition  
New Lessons in Arc Welding  
The Procedure Handbook of Arc Welding  
Lessons, simply written, cover manipulatory techniques;  
machine and electrode characteristics; related subjects,  
such as distortion; and supplemental information on arc  
welding applications, speeds and costs. Practice materials,  
exercises, questions and answers are suggested for each  
lesson.  
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.  
This printing will go fast so don’t delay. Place your  
order now using the coupon below.  
528 pages, well illustrated, 6” x 9” size, bound in simulated,  
gold embossed leather.  
The hardbound book contains over 750 pages of welding  
information, techniques and procedures. Much of this material  
has never been included in any other book.  
$5.00 postage paid U.S.A. Mainland  
A must for all welders, supervisors, engineers and  
designers. Many welding instructors will want to use the book  
as a reference for all students by taking advantage of the low  
quantity discount prices which include shipping by  
4th class parcel post.  
$15.00 postage paid U.S.A. Mainland  
Need Welding Training?  
The Lincoln Electric Company operates the oldest and  
most respected Arc Welding School in the United States at its  
corporate headquarters in Cleveland, Ohio. Over 100,000  
students have graduated. Tuition is low and the training is  
“hands on”  
How To Read Shop Drawings  
The book contains the latest information and application  
data on the American Welding Society Standard Welding  
Symbols. Detailed discussion tells how engineers and  
draftsmen use the “short-cut” language of symbols to pass  
on assembly and welding information to shop personnel.  
For details write:  
Lincoln Welding School  
22801 St. Clair Ave.  
Cleveland, Ohio 44117-1199.  
Practical exercises and examples develop the reader’s ability  
to visualize mechanically drawn objects as they will appear  
in their assembled form.  
and ask for bulletin ED-80 or call 216-383-2259 and ask for the  
Welding School Registrar.  
187 pages with more than 100 illustrations. Size 8-1/2” x 11”  
Durable, cloth-covered board binding.  
Lincoln Welding School  
BASIC COURSE  
5 weeks of fundamentals  
$700.00  
$4.50 postage paid U.S.A. Mainland  
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.  
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.  
Prices include shipment by 4thClass Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.  
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:  
$5.00  
For order value up to $49.99  
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For order value between $50.00 & $99.99  
For order value between $100.00 & $149.00  
For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.  
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.  
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)  
CHECK ONE:  
Name:  
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USE THIS FORM TO ORDER:  
BOOKS OR FREE INFORMATIVE CATALOGS  
Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199  
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.  
Lincoln Welding School  
Titles:  
Price  
$5.00  
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PH  
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New Lessons in Arc Welding  
Procedure Handbook “Twelfth Edition”  
How to Read Shop Drawings  
Incentive Management  
A New Approach to Industrial Economics $5.00  
The American Century of John C. Lincoln $5.00  
Seminar Information  
(ED-45)  
Educational Video Information  
(ED-93)  
NA  
AC  
James F. Lincoln Arc Welding  
Foundation Book Information  
Welding Preheat Calculator  
Pipe Welding Charts  
$3.00  
$4.50  
WC-8  
ED-89  
(JFLF-515)  
SUB TOTAL  
Additional Shipping Costs if any  
TOTAL COST  
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● Do not touch electrically live parts or  
electrode with skin or wet clothing.  
● Insulate yourself from work and  
ground.  
● Keep flammable materials away.  
● Wear eye, ear and body protection.  
WARNING  
Spanish  
● No toque las partes o los electrodos ● Mantenga el material combustible  
● Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa  
mojada.  
● Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
● Ne laissez ni la peau ni des  
● Gardez à l’écart de tout matériel  
● Protégez vos yeux, vos oreilles et  
vêtements mouillés entrer en contact  
avec des pièces sous tension.  
● Isolez-vous du travail et de la terre.  
inflammable.  
votre corps.  
ATTENTION  
German  
● Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
● Isolieren Sie sich von den  
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
● Não toque partes elétricas e  
electrodos com a pele ou roupa  
molhada.  
● Mantenha inflamáveis bem  
guardados.  
● Use proteção para a vista, ouvido e  
corpo.  
ATENÇÃO  
● Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE  
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES  
HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
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● Keep your head out of fumes.  
● Use ventilation or exhaust to  
remove fumes from breathing zone.  
● Turn power off before servicing.  
● Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
● Los humos fuera de la zona de  
respiración.  
● Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
● Desconectar el cable de  
alimentación de poder de la  
máquina antes de iniciar cualquier  
servicio.  
● No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
● N’opérez pas avec les panneaux  
ouverts ou avec les dispositifs de  
protection enlevés.  
● Gardez la tête à l’écart des fumées.  
● Utilisez un ventilateur ou un  
aspirateur pour ôter les fumées des  
zones de travail.  
● Débranchez le courant avant  
l’entretien.  
ATTENTION  
German  
● Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
● Vermeiden Sie das Einatmen von  
Schweibrauch!  
● Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
● Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig  
öffnen; Maschine anhalten!)  
WARNUNG  
Portuguese  
● Mantenha-se afastado das partes  
moventes.  
● Não opere com os paineis abertos  
ou guardas removidas.  
● Mantenha seu rosto da fumaça.  
● Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
● Não opere com as tampas removidas.  
● Desligue a corrente antes de fazer  
serviço.  
ATENÇÃO  
● Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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3
Y E A R  
IN CLUDIN G: P AR TS  
&
LABOR  
S22127-2  
LIMITED WARRANTY  
STATEMENT OF WARRANTY:  
TO OBTAIN WARRANTY COVERAGE:  
The Lincoln Electric Company (Lincoln) warrants to the  
original purchaser (end-user) of new equipment that it will  
be free of defects in workmanship and material.  
You are required y Lincoln Electric, your Lincoln  
Distributor, Lincenter or Field Service Shop of  
any defect weriod. Written notification is  
recomme
This warranty is void if Lincoln finds that the equipment  
has been subjected to improper care or abnormal  
operation.  
WA
n of the equipment confirms the  
ct covered by this warranty, the defect  
d by repair or replacement at Lincoln's  
WARRANTY PERIOD:  
All warranty periods date from the date of shipment
original purchaser and are as follows:  
Three Years:  
ANTY COSTS:  
Transformer Welders  
Motor-generator Welders  
Inverter Welders  
Automatic Wire Feeders  
Semiautomatic Wire Feeders  
Plasma-cutting Power Sou
Engine Driven Welders e  
accessories) with opera0 RPM  
ou must bear the cost of shipping the equipment to a  
Lincoln Service Center or Field Service Shop as well as  
return shipment to you from that location.  
SEE IMWS 1  
IMPORTANT WARRANTY LIMITATIONS:  
WARRANTY SUPERSEDED  
• Lincoln will not accept responsibility for repairs made  
without its authorization.  
Two Years:  
Engine Driven Welders (except e, engine  
accessories and Power-Arc 4000 generator/welders)  
with operating speed over 2,000 RPM  
• Lincoln shall not be liable for consequential damages  
(such as loss of business, etc.) caused by the defect or  
reasonable delay in correcting the defect.  
All engine and engine accessories are warranted by the  
engine or engine accessory manufacturer and are not  
covered by this warranty.  
• Lincoln's liability under this warranty shall not exceed  
the cost of correcting the defect.  
One Year:  
• This written warranty is the only express warranty  
provided by Lincoln with respect to its products.  
Warranties implied by law such as the Warranty of  
Merchantability are limited to the duration of this  
limited warranty for the equipment involved.  
Equipment not listed above such as gun and cable  
assemblies, water coolers, FAS TRAK or MIG-TRAK  
equipment, Power-Arc 4000 generator/welders, Wire Feed  
Module (Factory Installed) and field-installed optional  
equipment.  
March, ‘96  
World's Leader in Welding and Cutting Products  
Premier Manufacturer of Industrial Motors  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
22801 St. DColwanirloAadvfero.mCWlewvwe.lSaonmda,nuOahls.icoom44. A1ll1M7a-n1u1a9ls9SeUar.cSh.AAn.dTDeowl.n2lo1ad6.-481-8100  

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