Lincoln Electric SVM100-A service manual Installation, Technical Specifications Square Wave TIG

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INSTALLATION

TECHNICAL SPECIFICATIONS – SQUARE WAVE TIG 255

INPUT - SINGLE PHASE ONLY

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Standard

Voltage

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

Duty Cycle

40% Duty Cycle

NEMA Class II (40)

60% Duty Cycle

100% Duty Cycle

Welding Current Range

(Continuous)

5-315 Amps

AC and DC

Input Current at

Rated Output (1)

81/74/37

74/37/30

85/77/44

77/45/39

45/41/33

77/45/41

RATED OUTPUT

Amps

255

200

150

OUTPUT

Constant Open

Circuit Voltage

Stick OCV: 76

TIG OCV: 53

Code

Number

10022

10023

10024

10025

10026

10134

Volts at Rated Amperes

30

28

26

Auxiliary Power

115 Volts AC, 10 Amps

220Volts AC, 2 Amps

(50/60 Hz. machines only)

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RECOMMENDED INPUT WIRE AND FUSE SIZES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

For all Stick, DC TIG, and Balanced AC TIG

 

 

 

For Unbalanced AC TIG Welding Above 180

 

 

 

 

 

 

 

 

Welding at 255A/30V/40% Duty Cycle

 

 

 

Amps, 255A/16V/40% Duty Cycle, Auto

 

 

 

 

 

 

 

 

Based on the 1993 US. National

 

 

 

Balance Based on the 1993 U.S. National

 

 

 

 

 

 

 

 

 

 

Electrical Code

 

 

 

 

 

 

Electrical Code

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Type 75°C

 

 

 

 

 

 

 

 

 

 

Type 75°C

 

 

 

 

 

Fuse

 

 

Input

 

Type 75°C

 

Copper Ground

 

 

 

 

 

 

Type 75°C

 

 

 

Copper Ground

 

 

Input

 

 

(Super Lag)

 

 

Ampere

 

Copper Wire in

 

Wire in Conduit

 

 

 

 

 

 

Copper Wire in

 

 

 

Wire in Conduit

 

 

Voltage /

 

 

or Breaker

 

 

Rating on

 

Conduit AWG

 

AWG (IEC)

 

 

 

Input

 

 

Conduit AWG

 

 

 

AWG (IEC)

 

 

Frequency

 

 

Size

 

 

Nameplate

 

(IEC) Sizes

 

Sizes

 

 

 

Amperes

 

 

(IEC) Sizes

 

 

 

Sizes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

208/60

 

 

125

 

 

81

 

6 (16mm2)

 

6 (16mm2)

 

 

 

102

 

 

4 (25mm2)

 

 

 

6 (16mm2)

 

 

230/60

 

 

100

 

 

74

 

6 (16mm2)

 

8 (10mm2)

 

 

 

92

 

 

4 (25mm2)

 

 

 

6 (16mm2)

 

 

460/60

 

 

50

 

 

37

 

10 (6mm2)

 

10 (6mm2)

 

 

 

46

 

 

8 (10mm2)

 

 

 

10 (6mm2)

 

 

575/60

 

 

50

 

 

30

 

10 (6mm2)

 

10 (6mm2)

 

 

 

37

 

 

10 (6mm2)

 

 

 

10 (6mm2)

 

 

200/50/60

 

 

125

 

 

85

 

6 (16mm2)

 

6 (16mm2)

 

 

 

105

 

 

4 (25mm2)

 

 

 

6 (16mm2)

 

 

220/50/60

 

 

100

 

 

77

 

6 (16mm2)

 

8 (10mm2)

 

 

 

96

 

 

4 (25mm2)

 

 

 

8 (10mm2)

 

 

380/50/60

 

 

70

 

 

46

 

8 (10mm2)

 

8 (10mm2)

 

 

 

55

 

 

8 (10mm2)

 

 

 

8 (10mm2)

 

 

400/50/60

 

 

60

 

 

43

 

10 (6mm2)

 

10 (6mm2)

 

 

 

53

 

 

8 (10mm2)

 

 

 

10 (6mm2)

 

 

415/50/60

 

 

60

 

 

41

 

10 (6mm2)

 

10 (6mm2)

 

 

 

51

 

 

8 (10mm2)

 

 

 

10 (6mm2)

 

 

440/50/60

 

 

60

 

 

39

 

10 (6mm2)

 

10 (6mm2)

 

 

 

48

 

 

8 (10mm2)

 

 

 

10 (6mm2)

 

 

500/50/60

 

 

50

 

 

34

 

10 (6mm2)

 

10 (6mm2)

 

 

 

42

 

 

10 (6mm2)

 

 

 

10 (6mm2)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PHYSICAL DIMENSIONS

Height

Width

Depth

Weight

30.5 in.

19.0 in.

30.0 in.

 

 

(Lift bail, add 3.5 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.

SQUARE WAVE TIG 255

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Contents Square Wave TIG Safety Electric Shock can killARC Rays can burn Fumes and Gases can be dangerousCylinder may explode if damaged Welding Sparks can cause fire or explosionElectric and Magnetic Fields May be dangerousPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionInstallation Technical Specifications Square Wave TIGSafety Precautions High Frequency Interference ProtectionSelect Suitable Location StackingInput Supply Connections Input ConnectionsGround Connection TIG Torch Connection Reconnect ProcedureOutput Connections Table A.1 Stick Electrode Cable ConnectionOperation Section Operation Operating InstructionsGeneral Warnings Fumes and GasesSection TOC Polarity Do not Switch AC & DC Recti Fier Power Source While Weld ING TIG Gtaw Single PhaseWork Connec Coolant Tion OutputDesign Features Advantages Operational Features and ControlsGeneral Description Recommended Processes and EquipmentWelding Capability LimitationsControls and Settings Control Panel KeysCase Front Controls LoadAccessory Operation TIG Welding Table B.1 Recommended Polarity Settings for TIG WeldingHand and Foot Amptrol Welding Operation TIG Welding GuidelinesSquare Wave TIG 255 12/95 TIG Welding Sequence Operation 2-STEP ModeTable B.2 Typical Current Ranges 1 for Tungsten Electrodes TIG Welding Sequence Operation 4-STEP Mode Auxiliary Power Advanced TIG Welding FeaturesALL Machines AC Wave Balance and Auto BalanceOverload Protection Square Wave TIG Accessories Section Accessories Options / AccessoriesInstallation of Field Installed Options Undercarriage FunctionMaintenance Section Maintenance MaintenanceRoutine and Periodic Maintenance Safety PrecautionsFigure D.1 General Assembly Exploded View Square Wave TIG Power Supply Block Logic Diagram Theory of Operation SectionTheory of Operation Input Line Voltage and Main TransformerOutput Rectification and Feedback Control High Voltage / High Frequency Circuit DC Welding Output DC Welding CircuitAC Welding Output AC Welding CircuitSCR Operation SCR Operation Square Wave TIGThermal Protection Troubleshooting & Repair Section 1TROUBLESHOOTING & Repair HOW to USE Troubleshooting GuideTroubleshooting & Repair PC Board Troubleshooting ProceduresTroubleshooting Guide Output Problems12/95 Square Wave TIG Troubleshooting & Repair Recommended Course of Action Problems SymptomsPossible Areas of Misadjustments Function Problems Troubleshooting Guide Troubleshooting & Repair TIG Mode Problems Troubleshooting & Repair Troubleshooting Guide TIG Welding Problems Troubleshooting & Repair Stick Welding Problems PC Board Connector Locations Figure F.1 Control Board ConnectorsMaterials Needed Control Transformer T2 Voltage TestTest Description Test Procedure Control BOXControl Transformer T2 Voltage Test Figure F.4 Control Board and TransformerPROTECTION/SNUBBER Board Continuity Test PROTECTION/SNUBBER Board Continuity Test Figure F.6 PROTECTION/SNUBBER Board Test Points Table F.6 Square Wave TIGARC Start Trigger Circuit Test ARC Start Trigger Circuit Test Figure F.9 PROTECTION/SNUBBER Board Test Points Static SCR Test Static SCR Test Figure F.11 Protection Board Plug LocationsActive SCR Test Active SCR Test Figure F.13 PROTECTION/SNUBBER Board Plug LocationsBattery Test Silicon Controlled Rectifier TestNormal Open Circuit Voltage Waveform DC Stick Mode Scope SettingsNormal Open Circuit Voltage Waveform AC Stick Mode Normal Open Circuit Voltage Waveform DC TIG Mode Normal Open Circuit Voltage Waveform AC TIG Mode Typical Output Voltage Waveform Machine Loaded DC TIG Mode Machine Loaded to 200 Amps AT 50 VDCMachine Loaded to 200 Amps AT 46 VAC AC TIG Mode Auto Balance onMachine Loaded to 50 Amps AT 26VAC Volts 5ms Typical SCR Gate Voltage WaveformVolts 2ms Troubleshooting & Repair FAN Motor and Blade Removal Tools RequiredFAN Motor and Blade Removal SCR Heat Sink Assembly Removal Materials RequiredSCR Heat Sink Assembly Removal Recommended Meters for Machine Output Tests Retest After RepairInput Idle Amps Retest After Repair cont’d Figure F.16 Transformer Lead Test PointsElectrical Diagrams Electrical Diagrams Control Board G2150 PTC1,PTC2 THERMISTOR-PTC,56 OHMS,90MAControl Board G2150 cont’d Square Wave TIG PROTECTION/SNUBBER Board L9255 CAPACITOR-CEMO,4700P,50V,10% Square Wave TIG Wiring Diagram Square Wave TIG Machine Schematic Square Wave TIG 6 a 0 a 7 a 8 a 3 CG2150 A C C TControl Board Schematic Square Wave TIG 255 cont’d G2150 Y P a DPROTECTION/SNUBBER Board Schematic Square Wave TIG 255 L9255 Keypad LED Board Square Wave TIG 255 L9212