Lincoln Electric SQUARE WAVE IM607, Operator'S Manual

Page 1: ...ATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 10457 Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding...

Page 2: ...AY 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 pur chase 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 E2...

Page 3: ...rical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders ...

Page 4: ...event 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 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 Weldin...

Page 5: ...iés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloi...

Page 6: ...he information must be followed to avoid minor personal injury or damage to this equipment CAUTION 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 receive...

Page 7: ...ION 5 CONNECTIONS FOR STICK SMAW WELDING 5 STICK ELECTRODE CABLE AND WORK CABLE CONNECTION 5 OPERATION SECTION 6 SAFETY PRECAUTIONS 6 GENERAL DESCRIPTION 6 INCLUDED EQUIPMENT 6 FOR GTAW TIG WELDING 6 FOR SMAW STICK WELDING 6 FOR INSTALLATION AND STARTUP 6 WELDING CAPABILITY 6 CONTROLS AND SETTINGS 7 OPERATING STEPS 8 WELDING IN TIG MODE 2 STEP 8 WELDING IN TIG MODE 4 STEP 8 REMOTE CONTROL OPERATIO...

Page 8: ... 175 Amps AC and DC INPUT SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES 1 Input Voltage phase Frequency 240 1 50 380 1 50 415 1 50 220 1 50 400 1 50 Input Ampere Rating on Nameplate 54 33 30 54 30 Type 75 C Copper Ground Wire in Conduit AWG IEC Sizes 10 5 2 mm2 14 2 1 mm2 14 2 1 mm2 10 5 2 mm2 14 2 1 mm2 Fuse Super Lag or Breaker Size 100 60 60 100 60 Type 75 C Copper...

Page 9: ...trically hazardous conditions such as welding in wet areas or on or in the workpiece MACHINE GROUNDING AND HIGH FRE QUENCY INTERFERENCE PROTECTION The welder must be grounded See your local and national electrical codes for proper grounding methods The high frequency generator being similar to a radio transmitter can be blamed for radio TV and electronic equipment interference problems These probl...

Page 10: ...out which is 33mm 1 3 in in diameter Strip away outer jacket of cord trim fillers and insert conductors through cord connector The jacketed por tion of the cord must go through the cord connector Slide the plastic compression nut up the cord to the connector and turn it until it tightens on the input cord Refer to the Technical Specifications page at the beginning of this section Fuse the input ci...

Page 11: ...the platform The cylinder s weight will push the platform downward against the floor forming a ramp At this point the cylinder may be rolled up the platform into its final position Secure the cylinder in place with the provided chain Unload by following these steps in reverse FIGURE A 1 Reconnect Leads CONNECTION INPUT SUPPLY H3 H4 H2 FOR 220 240V CONNECT COPPER LINK TO H2 SEE INPUT SUPPLYCONNECTI...

Page 12: ...NNECTIONS FOR STICK SMAW WELDING STICK ELECTRODE CABLE AND WORK CABLE CONNECTION Refer to Included Equipment in the Operation Section of this manual for STICK welding equipment which is included with the Square Wave TIG 175 An electrode holder with cable is supplied with the Square Wave TIG 175 Turn the Power Switch OFF Connect the Twistmate plug into the Electrode Gas Output Receptacle and turn i...

Page 13: ...7 volts at a lower duty cycle If the duty cycle is exceeded a thermal protec tor will shut off the output until the machine cools SQUARE WAVE TIG 175 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 Read and follow Electric Shock Warnings in the Safety section if welding must...

Page 14: ...igh ambient air temperature or exceeded duty cycle an internal thermostat will open disabling the welding output and this yellow light will illuminate The cooling fans will continue to run to cool the unit during this time The light will go out when the unit cools and the thermostat resets 6 POLARITY SWITCH Allows you to select between welding in AC DC or DC polar ity In DC polarity the electrode ...

Page 15: ...A 9 or LA 17 TIG torch simply connect the Twistmate plug to the receptacle located on the front of the machine See INPUT SUPPLY CONNECTIONS if another TIG torch is used 2 Set the MODE switch to 2 STEP TIG 3 Set the Polarity Switch to DC for weld ing steel or stainless steel or to AC for welding alu minum 4 Connect an Arc Start Switch or Amptrol to the Remote Control Connector 5 Turn on the cylinde...

Page 16: ...t Switch may be used to start and stop the welding if no remote control of the current is desired Refer to the Accessories section of this manual Both the Hand and Foot Amptrol work in a similar man ner For simplicity the following explanation will refer only to Amptrols meaning both Foot and Hand mod els The term minimum refers to a foot pedal in the up position as it would be with no foot pressu...

Page 17: ... Wave TIG 175 is rated from 10 175 Amps SMAW Process ELECTRODE POLARITY 3 32 1 8 5 32 Fleetweld 5P Fleetweld 5P DC 40 70 75 130 90 175 Fleetweld 180 DC 40 80 55 110 105 135 Fleetweld 37 DC 70 95 100 135 145 Max Fleetweld 47 DC 75 95 100 145 135 Max Jet LH MR DC 85 110 110 160 130 Max Blue Max Stainless DC 40 80 75 110 95 110 Red Baron Stainless DC 40 70 60 100 90 140 Mild steel procedures are base...

Page 18: ... with the Square Wave TIG 175 K859 1 LA 9 12 5 ft medium back cap K859 5 LA 9 25 ft medium back cap K860 1 LA 17 12 5 ft long back cap K860 5 LA 17 25 ft long back cap NOTE Each torch requires a Twistmate plug S22529 1 and strain relief boot M17255 be installed onto the cable Collets collet bodies and nozzles are not included and must be ordered separately Twistmate Plug S22529 1 and Strain Relief...

Page 19: ...ndition 5 Clean air louvers to ensure proper air flow and cooling 6 The fan motor has sealed ball bearings which require no maintenance 7 The arc starter spark gap spacing is factory set at 0 015 inch It typically will not require periodic maintenance Refinishing the contacts is not rec SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE WARNING WARNING ommended If the contacts are replaced reset ...

Page 20: ...S The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION If you have exhausted all of the items in step 2 Contact your Local Lincoln Authorize...

Page 21: ...age when arc start switch or Amptrol is activated fan is work ing 1 Make certain that the input power switch is in the ON position and machine is plugged in 2 Check the input voltage at the machine Input voltage must match the rating plate and voltage connection Refer to Reconnect Procedure in the Installation sec tion of this manual 3 Blown or missing fuses in input line 1 Check 5A fuse F1 locate...

Page 22: ...MS POSSIBLE AREAS OF MISADJUSTMENTS S RECOMMENDED COURSE OF ACTION Machine regularly over heats ther mostat opens Yellow light on front panel glows The fan runs but machine has no output 1 Welding application may exceed recommended duty cycle Reduce the duty cycle 2 Dirt and dust may have clogged the cooling channels inside the machine Blow out unit with clean dry low pressure air 3 Air intake and...

Page 23: ...re that the machine is ground ed properly according to the installation instructions If there are other high frequency sources in the area make cer tain that they are grounded properly 2 Check Amptrol for proper opera tion and loose connections 3 Check for proper input voltage and proper voltage reconnec tion 1 Tungsten electrode may be too large in diameter for the current setting 2 Tungsten not ...

Page 24: ...lean oxide layer with a stainless steel brush 2 Tungsten electrode may be cont aminated Replace or sharpen 3 Check for contaminated gas or leaks in the gas line torch or connections 4 Gas shielding may be insuffi cient Increase gas flow reduce tungsten stickout beyond gas cup 1 Check for poor connections in the welding circuit 2 Gas shielding may be insuffi cient Increase gas flow reduce tungsten ...

Page 25: ...tungsten electrode melts away 1 If the machine location is in a highly dirty environment with conductive contaminants check and clean the spark gap with a low pressure air stream per the maintenance instructions 1 Gas supply is empty or not turned on 2 Flow regulator may be set too low 3 Gas hose may be pinched 4 Gas flow may be blocked with dirt Check filter screen inside gas inlet fitting to sol...

Page 26: ... CAUTION STICK WELDING PROBLEMS PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTS S RECOMMENDED COURSE OF ACTION Stick electrode Blasts Off when arc is struck Stick electrode sticks in the weld puddle 1 Weld current may be set too high for electrode size Reduce current control setting or use a larger diameter electrode 1 The weld current may be set too low Increase the current control setting or ...

Page 27: ...RRENT OUTPUT 235 234 AMPTROL REMOTE 236 RECEPTACLE 238 REMOTE SV1 E C S ARC STARTER AS BLY L4 T3 115VAC S3 243 VOLTAGE RECONNECTION WIRING DIAGRAM SQUARE WAVE TIG 175 240 380 415 1 50 60 G1 G2 X1 F W X3 POS STABILIZER R4 217 G1 218 G2 G3 220 216 G4 277 B X8 D FRONT GANG SCR2 C SCR3 BYPASS PC BOARD MUST ALWAYS BE CONNECTED ACROSS POWER SWITCH L2 G4 218 J4 ELECTRICAL SYMBOLS PER E1537 F R 277A 216 H...

Page 28: ...21 DIMENSION PRINT 21 SQUARE WAVE TIG 175 4 00 13 76 1 40 10 00 19 53 344 2 HOLES 40 73 56 34 344 WELDER MOUNTING HOLES 8 21 2 54 11 50 CENTERED 27 93 9 72 25 19 36 10 23 28 19 22 40 73 L10087 7 12 96 ...

Page 29: ...NOTES SQUARE WAVE TIG 175 ...

Page 30: ...NOTES SQUARE WAVE TIG 175 ...

Page 31: ...and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals 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 inc...

Page 32: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 33: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 34: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...