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Lincoln Electric TIG 275 User's Manual

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2. B 10 Setup Guidelines for TIG Welding with an Amptrol B 10 B11 Making TIG Weld with an B 12 ACCOSSOLIOS once mr ag eei a dde a tede nette aaa Section C Optional Equipment iii C 1 td ne editt iato teet Section D Safety ice dn n Hire eive se de E HE dO D 1 Routine and Periodic Maintenance D 1 Ov rlo d PrOL ClIOn I E D 1 Service Procedures Component Access Spark Gap Adjustment D 2 Under Cooler SEIE D 2 Troubleshooting reei Section E Safety Precautions iii E 1 How Use TroubleShooting Guide E 1 eben 2 10 7 Diagrams E Section F Wiring Diagrams l l l aep t ES nap t o An nas F 1 F 2 Dimension PriMS F 3 F 4 Parts IS it eu de P 543 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS PRECISION TIG 275 K1827 2 Export 50 60Hz RATED INPUT SINGLE PHASE ONLY Duty Cycle Applications Voltage 10 Max Amps With Out Max Amps With Power Factor Power Factor Capacitor 40 AC DC Stick Balance TIG 95 55 50 80 46 43 K1827 2 Unbalance 70 Penetration TIG 109 63 58 86 50 46 60 AC DC Stick Balance TIG 220 230 80 46 42 64 37 34 Unbalance 70 Penetration AC TIG 380 400 415 85 49 45
3. 4 Step Trigger Modes war DOWN SLOPE Normal sequence Hold the first trigger pull to maintain the starting current and delay up slope 4 STEP RESTART ENABLED With DIP Switch 3 Hold the second trigger pull for more than 1 second to activate the restart function When the trigger is released up slope will occur Actuate the trigger Or actuate and hold the trigger holding it less than 1 during down slope to immediately second to begin down slope to end down slope and maintain normal down slope crater current Hold the trigger for The following two more than 1 second to active the options are avialable restart function When the trigger during the normal is released up slope will occur down slope period 4 STEP RESTART DISABLED With DIP Switch 3 OFF As Shipped Hold the second trigger pull for more than 1 second to maintain crater current before stopping Actuate the trigger holding less Actuate the trigger a third Or actuate the trigger a third than 1 second to begin normal time during down slope to time during down slope to down slope The following two immediately end down slope immediately end down slope options are avialable during the 4 stop the third trigger pull to normal down slope period maintain crater current PRECISION TIG 275 LINCOLN B 10 TIG WELD CYCLE CHART 2 or4 STEP Trigger Closed SEE ITEM 12 4 STEP S
4. ID RALE HE ES OBRRRTMRRARS SERB x e 200 Yel AE z 2 cus UN UA Jada y e Aale veel Al dl WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ZS BIR Chinese LEIA E COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SBM BUOX HD OHBRBEE lt K HA 43 LTRHOR EMELT lt F ux APA PR gg yes s TE t B EH BB Ma p E 7 PS SRB AAAAMS pep HAY Sei BPs BC dl Lala J AAL Gant Gail Ca LINCOLN e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
5. Installation is Section A T chnical Sp cifications UU l aa REY YE mat ages 1 2 Safety 5 u uuu A 3 Select Suitable ive heen 3 M NP MC A 3 Sirene TS A 3 Undercarriage Lifting and Moving A 3 Mie A 3 Environmental Rating sise A 3 Machine Grounding and High FREQUENCY INTERFERENCE PROTECTION A 3 A 4 Input and Grounding Connections ss 4 Output Cable Connections and Limitations A 5 Work Cable Connection A 5 Stick Electrode Cable Connection A 5 TIG Torch Connection sisi A 6 Auxiliary Power Connections A 7 Remote Control If Used 7 Robotic Interface Connection nn A 7 8 DEER ACHEN uu u m Section B 1 Safety Precautions u B 1 Product D es erIpfi B 1 EE B 1 Duty ee B 1 Recommended Processes and Equipment B 2 Controls Settings srian a aaa B 3 THRU B 6 Internal Set Up Controls sis B 7 sick Welding Features peer cet ced decise ened B 7 TIG Welding Features B 7 2 Step Trigger Modes uii cedendo een LEE B 8 4 Step Trigger Modes B 9 TIG Welding Chart Gin
6. More for alum oxide Cleaning w o Spitting or wetting loss Balanced_for equal and current More for higher Penetration Local Remote Switch REMOTE Maximum Output Set to desired max Ampttol output level Minimum Output Press Display switch and Set to desired min to Min Amptrol Start Crater Amptrol output level f Postflow Set as low as required Higher for larger tungsten and current Advanced Panel Controls Trigger Switch 2 STEP Pulse Frequency 4 6 pps is a typical initial setting Set for bead shape and travel speed Higher for thinner plate and faster travel Lower for thicker plate and slower travel I Pulse Switch ON or OFF On Time 40 60 is a typical initial setting Set for total heat of Peak current Lower reduces distortion and burn thru Background Current 40 60 is a typical initial setting ZERO Set as low as will maintain a pulse arc Will not drop below Min Output setting Downslope For no arc out delay PRECISION TIG 275 LINCOLN B 12 MAKING A TIG WELD WITH AN AMPTR 1 Install welding equipment per Section A 5 2 Setup controls per Section B 10 OPERATION OL 8 Turn on the shielding gas supply and torch coolant input supply if used Note The Precision TIG Under Cooler or Water Solenoid connected
7. 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION TIG PROBLEMS Arc pulsates in AC polarity DC 1 Micro switch S2A on polarity switch polarity is o k does not open in AC polarity Black area along weld bead 1 Oily or organic contamination from work piece Tungsten electrode may be conta minated Leaks in gas line torch or con nections Output quits momentarily gas flow 1 May be caused by hi freq interfer and hi freq are also interrupted ence Check that machine is grounded properly Surrounding machines that generate hi freq also should be properly grounded Ground connection of Protection PC board may has become loose Ground connection H all recommended possible areas Bypass Stabilizer PC board may of misadjustment have been has become loose checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION Iffor any reason you understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PRECISION TIG 275 LINCOLN F 1 WIRING DIAGRAM epoo 1ueuudinbe eu BAIN jueujeoe dei eorues QIB ji s sjeued
8. See Item 8 This knob sets the Start output level When the arc lights using a new built in TIG start pulse this level upslopes quickly 0 5 sec w Advanced Panel zero w o and smoothly to the weld output level The set ting range for this Start control is the 2 amp mini mum range of the machine up to about 50 amps but no more than the level set by the Maximum Output control knob See Item 6 but otherwise is indepen dent of the Maximum setting This setting also serves as the Crater fill level but with a Precision TIG Advanced Panel it can be selected see Section B 7 to be either the Minimum Output control setting same as Start setting as shipped or the minimum rating of the machine 2 amps The Remote Amptrol range of control is between this Minimum setting and the Maximum Output con trol knob setting so these knobs can set the resolu tion of the Amptrol Also the Minimum setting serves as both the minimum Amptrol start level when the arc start switch is closed as well as the minimum Amptrol crater fill level before the arc start switch is opened to help prevent premature arc out and Hi Freq re initiation n STICK mode the Start control is not functional since Hot Start level is fixed or internal Advanced Panel adjustable see Section B 7 Pressing the Display momentary switch toggle left to Minimum Output position displays minimum amps rating of the machine PRECISION TIG 275 LINCOLN
9. 20 to 60 A 5 10 3 5 5 10 3 5 1 16 Up to 150 A 30 to 80 60 to 120 A 5 10 3 5 9 13 4 6 3 32 Up to 60 to 130 A 100 to 180 A 13 17 6 8 11 15 5 7 1 8 X 100 to 180 A 160 to 250 A 15 23 7 11 11 15 5 7 Tungsten electrodes are classified as follows by the American Welding Society AWS 1 5 Lanthana 0 15 to 0 40 Zirconia EB cz orange D ss black Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications Balanced Wave Unbalanced Wave requires derating of the electrode LINCOLN PRECISION TIG 275 C 1 ACCESSORIES C1 OPTIONAL EQUIPMENT FACTORY INSTALLED OPTIONS The basic Precision TIG 275 machine is factory equipped with A 3 8 Adapter 520403 4 for air cooled torch con nection of a PTA 9 or PTA 17 FIELD INSTALLED OPTIONS The following Options Accessories are available for the Precision TIG 275 and are installed per instructions in this manual and or provided in the package e K1829 1 Precision TIG Advanced Control Panel Provides 2 4 step trigger with adjustable Pulser con trols and Down slope timer for TIG welding Also includes adjustable Hot Start and Arc Force internal panel controls for Stick welding and other user selectable features e 1828 1 Under Cooler Cart Includes a cooler in a drawer with hoses and a lockable storage drawer on a dual bottle undercar riage see below K1869
10. NO er gt HALINOLNALOS TOHLNOD 055 3019834 001 02 voten 52 05 80151538 001 002 1 51888 LAHS OL ui313WOUN310d 1nd1nO XOL i313WOLIN31Od 1508 HALZNOLN2LOd 1051409 3ONv IVa H3L3WOLIN3LOd 1OMINOO ANALNO S3HOHO GIOHOL 4 Sez SV Hee Kok Rot pu S wend IVNOILdO ddd NOILdO 91 SHOLONON HOIH HOLONGN eme 30010 3344 WOO AN div Dez 5 34078 IL NO HOLIOVAVILAHS 3SVHd 219100 39VL1OA 3 1 y00 SSVd AB K 40 TENVd IOHLNOD NOLLISOd OV NMOHS MBIA Suel anwawaivm ZE PRECISION TIG 275 8 z 23 HOLIMS OSOIN onvouva 20 035010 935070 a 3 0 HOIIMS HOLIMS ALINYI0d ax ke zwei 600 lt 909 n FI I
11. as well as the TIG Torch connection panel Recommended Cable Sizes for Combined Lengths of Copper Work and Electrode Cables using 759 C Wire Machine Rating 100 Ft 101 to 200 Ft 275A 40 1 0 53 5 mm 2 0 67 4 mm WORK CABLE CONNECTION 15 2 0 weld cable with clamp is available 2150 1 or included with the Precision TIG Welding Package model Otherwise it is user provided With power source off connect a separate work cable to the 1 2 13 threaded WORK stud of the welder and secure a tight connection with the flange nut provided The work cable should be routed through the cable strain relief hole provided in the base directly below the welding output terminal Note If the Precision TIG is equipped with an Under Cooler or Under Storage unit the coiled work cable and clamp or excess work cable length may be con veniently stored in the drawer while remaining con nected STICK ELECTRODE CABLE CONNECTION If manual stick welding is desired with power source off connect a stick electrode cable to the 1 2 13 threaded STICK Electrode stud of the welder and secure a tight connection with the flange nut provided The electrode cable should be routed through the cable strain relief hole provided in the base directly below the welding output terminal WARNING DISCONNECT STICK ELECTRODE WELDING CABLE WHEN TIG WELDING EVEN THOUGH HI FREQ IS NOT APPLIED TO THE PRECISION TIG STICK TERM
12. une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage o
13. 1 2 stud Connector for PTA Torch two piece K2166 3 3 8 TIG Torch Connector for PTA 9 17 one piece Included as S20403 4 with Precision TIG models e 3100211 Harris Argon Flow Regulator Includes 10 hose K2150 1 Work Lead Assembly 15ft 2 0 cable with 1 2 stud lug and work clamp PRECISION TIG 275 LINCOLN 0 1 MAINTENANCE D 1 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 WARNING To avoid receiving a high frequency shock keep the TIG torch and cables in good condition ROUTINE AND PERIODIC MAINTENANCE Very little routine maintenance is necessary to keep your Precision TIG 275 running in top condition No specific schedule can be set for performing the follow ing items factors such as hours of usage and machine environment should be considered when establishing a maintenance schedule Periodically blow out dust and dirt which may accu mulate within the welder using an air stream Inspect welder output and control cables for fraying cuts and bare spots e Inspect the spark gap at regular intervals to maintain the recommended spacing See the Service Procedures See Service Procedures in this Section for complete information on spark gap set tings The
14. 5 8 DIGITAL METER AND DISPLAY SWITCH 3 digit LED meter is used to monitor the preset and actual welding procedure based on the Display momentary switch position Before welding with Display switch in center nor mal position the digital meter displays the preset welding amps set by Maximum Output control knob See Item 6 If in Stick mode using REMOTE See 5 the digital meter displays the preset weld ing amps set by the Remote control See Item 11 While welding with Display switch in center normal position the digital meter displays the actual weld ing amps with one amp resolution XXX and accu within 4 2A of reading e Any time in TIG mode and while pressing the Display switch to left the digital meter displays the amps preset by the Minimum Output control knob See 7 e Any time Stick mode while pressing the Display switch to left the digital meter displays the minimum amps rating of the machine See Item 7 e Any time in either mode while pressing the Display switch right to Volts position the digital meter dis plays actual output volts Volts is displayed with 0 1 volt resolution and accuracy within 3 1V of reading 9 POSTFLOW TIME This knob is used to set the TIG mode shielding gas postflow time over the range of about 2 to 60 seconds after the arc is shut off The postflow on time status is indicated by the Green panel light e Gas pr
15. Postflow Time Extension See Item 9 ON Doubles the time ranges OFF Standard time ranges as shipped Switch 42 2 Step Trigger Restart Feature See Figure B 3 ON Restart Enabled as shipped OFF Restart Disabled Switch 43 4 Step Trigger Restart Feature See Figure B 4 ON Restart Enabled OFF Restart Disabled as shipped Switch 4 NOT CURRENTLY FUNCTIONAL Switch 5 Crater Fill Level See Item 7 ON Level is minimum rating of the machine 2A OFF Level as shipped is Minimum Output setting same as Start level The Preflow Postflow Time doubling feature can also be selected on Precision TIG 275 models without the Advanced Panel by accessing the Control board in the control box per above instruc tions then disconnecting the jumper terminals attached to the jumper plug connected to receptacle J3 of the Control board Refer to Machine Wiring Diagram PRECISION TIG 275 LINCOLN B 8 FIGURE B 3 2 Step Trigger Modes gt C rene Cus A UP SLOPE DOWN SLOPE 2 STEP RESTART DISABLED With DIP Switch 2 OFF Actuate the trigger a second time during down slope to immediately end down slope Hold the trigger to maintain crater current 2 STEP RESTART ENABLED With DIP Switch 2 As Shipped up slope and restart PRECISION TIG 275 LINCOLN B 9 FIGURE B 4 gt mSTARTICRATER CURRENT
16. e Keep cylinder away from areas where it could be damaged Never allow the torch to touch the cylinder e Keep cylinder away from live electrical cir cuits e Maximum inlet pressure 150 psi The Precision TIG machines do not have Hi Freq available at the Stick electrode stud therefore stud connection adapters such as LECO S19257 series cannot be used for torch connection Single piece cable air cooled torches with a 3 8 24 RH connector fitting such as the Magnum PTA 9 17 or LA 9 17 require the provided S20403 4 Torch Connector while those with a 7 8 14 RH connector fitting such as the Magnum PTA 26 or LA 26 require the available K2166 1 Torch Connector See Figure A 3 Two piece cable air cooled torches such as PTA or LA torches can be used with the available 1 2 Stud Connector S20403 3 with with a 7 8 14 LH male fitting Magnum PTW 18 20 or LW water cooled Torches require no adapter for Precision TIG connection PRECISION TIG 275 LINCOLN A 7 INSTALLATION FIGURE front Panel Air Cooled Torch Torch Adapter Two Cable K2166 2 Opt 8 17 26 9 78 14 LH ons cnt K2166 1 Opt o am 520403 4 Been BEZ AUXILIARY POWER CONNECTIONS The Precision TIG machines provide a standard NEMA 5 15R duplex receptacle located on the upper case back on the torch side of the machine e The bottom outlet of this duplex receptacl
17. fan motor has sealed ball bearings which require no maintenance Overload Protection OVERLOAD PROTECTION FAN AS NEEDED F A N The Precision TIG 275 has the F A N circuit feature which means the cooling fan will operate only while welding then for about 8 minutes after welding has stopped to assure proper machine cooling This helps reduce the amount of dust and dirt drawn into the machine with the cooling air The cooling fan will oper ate briefly when the machine power is initially turned on and continuously while the yellow Thermal Shutdown Light is lit see Thermostatic Protection THERMOSTATIC PROTECTION This welder has thermostatic protection from excessive duty cycles overloads loss of cooling and excessive ambient temperatures When the welder is subjected to an overload or inadequate cooling the primary coil thermostat and or secondary coil thermostat will open This condition will be indicated by the illumination of the yellow Thermal Shutdown Light on the front panel see Item 10 in Section B The fan will continue to run to cool the power source Postflow occurs when TIG welding is shut down but no welding is possible until the machine is allowed to cool and the yellow Thermal Shutdown Light goes out NO ARC PROTECTION The machine outputs Background OCV gas and HF will be shutdown if the trigger is closed without weld ing for 15 seconds to protect the Background resistor from overheating with F A N
18. hand moving only mechanized movement can lead to personal injury and or damage to the Precision TIG 275 TILTING Each machine must be placed on a secure level sur face either directly or on a recommended undercar riage The machine may topple over if this precaution is not followed ENVIRONMENTAL RATING Precision TIG 275 power sources carry an IP21S Environmental rating They are rated for use in damp dirty rain sheltered environments MACHINE GROUNDING AND HIGH FRE QUENCY INTERFERENCE PROTECTION The frame of the welder must be grounded A ground screw marked with the symbol GD is located on the input connection panel Figure A 1 for this purpose See your local and nation al electrical codes for proper grounding methods The spark gap oscillator in the high frequency genera tor being similar to a radio transmitter can be blamed for many radio TV and electronic equipment interfer ence problems These problems may be the result of radiated interference Proper grounding methods can reduce or eliminate radiated interference The Precision TIG 275 has been field tested under rec ommended installation conditions and has been found to comply with F C C allowable radiation limits This welder has also been found to comply with NEMA stan dards for high frequency stabilized power sources Radiated interference can develop in the following four ways Direct interference radiated from the welder Direct interfer
19. machine is set to AC polarity and TIG mode 5 LOCAL REMOTE CURRENT CONTROL SWITCH 2 position switch selects how the welding output is controlled for both Stick and TIG Modes e LOCAL Top position selects output control only by the machine panel Output Control See Item 6 REMOTE Bottom position selects output control to also be by an Amptrol See Item 6 or other remote 10K pot control connected to the Remote recepta cle See Item 11 This switch selection is indicted by the Green panel light turning on In either position the arc start switch functions when connected to the Remote receptacle See Item 11 6 MAXIMUM OUTPUT CONTROL The large knob is used to set the output welding current over the rated output range of the machine With the Current Control switch to LOCAL position this knob sets the welding output level With the Current Control switch to REMOTE posi tion this knob sets the maximum welding level that the Peak output can be set with the remote Amptrol The new Technology minimum current circuit provides for low end welding down to 2 amps previously unobtainable on an SCR platform TIG machine 7 MINIMUM OUTPUT CONTROL AND DISPLAY SWITCH A smaller knob is used to preset the minimum cur rent level only for TIG mode Pressing the Display momentary switch toggle left to Minimum Set posi tion displays the Minimum control level setting on the Digital meter
20. mended duty cycle Bad thermostat or its connections Meter doesn t light up Losing AC supply to Control PC board Loosing input to machine Faulty Control PC board If all recommended possible areas of misadjustment have been Faulty trigger or hand foot Amptrol checked and the problem persists or connections Contact your local Lincoln Authorized Field Service Facility in Tig mode Faulty Protection PC board or bad connection to Control PG board Losing trigger supply to Control PC board No output in both Stick and Tig 1 Bad connection at P4 of Control PC board 2 Faulty Control PC board CAUTION Iffor any reason you understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PRECISION TIG 275 LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION METER PROBLEMS Meter does not light up Bad meter or its connection Bad connection at P8 of Control PC board If all recommended possible areas Faulty Control PC board of misadjustment have been checked and the problem persists Contact your local Lincoln Meter does not display V Volt or Bad Display switch or its connec Authorized Field Service Facility Min Minimum curren
21. off per above 2 Remove the access panel on the right case side See Component Access 3 Check the spark gap spacing with a feeler gauge If adjustment is required 1 Adjust the gap by loosening the Allen head screw on one of the aluminum blocks reset the gap and tighten the screw in the new position If spark gap is correct 1 Reinstall the access panel on the right case side UNDER COOLER SERVICE The required maintenance and service instructions for the Under Cooler are provided in the operator s manu al IM723 provided with the Under Cooler Cart PRECISION TIG 275 LINCOLN E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE CU A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel 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 and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2
22. sistent TIG starting Nor does it provide a way for con sistent crater fill control to feel at what decreasing con trol pedal position the arc start switch will re open causing arc out PRECISION TIG 275 LINCOLN B 11 OPERATION B 11 The new foot pedal provides such independent action distinction of precisely where the arc start switch actu ates without over riding minimum control pedal posi tion and precisely where the control pedal has been returned to minimum position without inadvertently de actuating the arc start switch The result is repeatable consistency in TIG weld starting and crater fill for man ual process control Using this new foot pedal with the Precision TIG s new presettable Minimum Output level in addition to the presettable Maximum Output level further enhances the starting and crater level consistency as well as the control resolution of the manually controlled foot pedal Setup for TIG Amptrol Welding FIGURE B 6 FIGURE B 5 Foot T Rock P oe Control Pressure Switch Adjustable or Removable Heel Stop Maximum Output Machine Setting Fully Pressed Control Pedal At Rest ll LE Minimum Output Control Pedal Machine Setting Tima Pressed At Rest Switch Pedal Switch Pedal Standard Controls Power Switch ON I Mode Switch TIG Balance Polarity Switch AUTO AC or DC or Set
23. the governor or idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your body between the electrode work cables If the electrode cable is on your right side the work cable should also be on your right side D Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN B SAFETY ELECTRIC SHOCK can 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 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 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 high risk of unavoidable or accidental contact with the workpiece or groun
24. to the Cooler receptacle runs the Fan As Needed machine cooling fan with See Maintenance Section D so the cooler fan and water pump will also not run continuously in idle but will while welding 4 With the torch held safely away from everything run N close the Arc Start Switch of the Amptrol and set the gas flow meter Then open the switch The welder is now ready for welding Position the tungsten electrode at the start of the weld at a 65 to 75 angle with the horizontal in the direction of pushing travel so that the electrode is approximately 1 8 4 mm above the work piece B 12 Close the arc start switch This opens the gas valve to automatically purge air from the hose and torch then shields the arc strike area After the 0 5 sec ond preflow time the high frequency becomes available to strike the arc When the arc strikes the torch coolant if used starts to flow Also if welding DC TIG the high frequency shuts off just after the arc strikes Hold the arc start switch closed at minimum Amptrol Start level See Section B 10 until an arc is estab lished then increase the output to the desired weld ing level and push the torch in the direction of trav el At the end of the weld decrease the Amptrol output to the crater fill level before releasing the arc start switch to start the Postflow time Hold the torch gas shielding over the solidifying weld crater while post flow tim
25. work or ground Accidental contact can cause overheating and create a fire hazard 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 4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 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 6 h Also see item 1 c LINCOLN CYLINDER may explode gt if damaged 7 a
26. z B Pr eis Ad d s Jo Aal AIX Wear eye and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo R HAUSHERMRELTTF EU OMAR RSR ez 119 Sal die ule Lilly lan alg Sawa 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 HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour te
27. 0 enen zez e vx f ova Ze 3009 149119378 REI AOV SH 4 092 WNOLLVN es ra GNNOYS OL fe os 198 4 sx E Dog 3909 9319313 1004 y Avidsia anno BAWA 1439034 OVE WNOLLVN SRL Lt THNVd 3N svo OVASEL OL asvo 7031409 703105 Lo SSVdAR 4 c 2 T V Ve ge ang ao T ems Lan aas Enya 15 003 G3M3IA z ba 7 EEEREN 94 P 4 QUE 3ALLO31ONd d HOLIMS N3MOd 24 OL ds LO3NNOO 2 3 o INOLLO3NNOO 110A 0 Z 0zz 96 i ain deem OL dVH1S LO3NNOO LIOA 009 086 NMOHS SV FH H IH OL 4 8 LO3NNOO away T3NYd TOHINOO NOLLONNO9 10A SL 02211 3002 SNIHIM 922 911 NOISIO3Sd DIMENSION PRINT F 2 F 2 099111 S310H ONILNNOW 3SV8 9820 JO 2 YALSTOH 97 LFZ PRECISION TIG 275 LINCOLN
28. 1 Undercarriage Includes a dual bottle rack with chain and an under carriage with 5 front casters 10 rear wheels and a handle K1830 1 Water Solenoid Kit Provides for stopping flow of external water supply Connects to coolant inlet and cooler receptacle of Precision TIG Can not be used with a water cooler K870 Foot Amptrol Single pedal foot activation of arc start switch and output control with 25 plug cable K870 1 Start Pedal Foot Amptrol Independent start pedal on control pedal provides two stage foot action to easily feel start switch clo sure at minimum output level for enhanced arc start and crater fill control Provided with adjustable or removable heel stop and 25 plug cable Refer to Figure B 5 e 963 3 Hand Amptrol Fastens to torch for convenient thumb activation of arc start switch and output control with 25 plug cable K814 Arc Start Switch Needed for TIG welding without an Amptrol Includes 25 plug cable and attaches to torch for convenient finger control K1831 1 Power Factor Capacitor Kit Used when welding at higher output currents to reduce input current and help keep electricity costs to a minimum e Magnum and PTW Series Torches All Air Cooled or Water Cooled Magnum TIG Torches may be used with the PRECISION TIG 275 Connection adapters are only required for Air Cooled Torches Refer to Diagrams on A 7 K2166 1 7 8 Torch Connector for PTA 26 one piece K2166 2
29. 67 39 36 EN 100 AC DC Stick Balance TIG 70 41 37 52 30 28 Unbalance 70 Penetration TIG 65 38 35 46 27 25 Idle Amps 10 6 5 23 13 12 Idle Power 400W 500W RATED POWER FACTOR STICK 1827 2 em IEC 60974 1 Shown on Front of this IM manual with Advanced Control Panel Refer to Optional Equipment Exceeds NEMA Unbalanced Load Specification comparable for Auto Balance PRECISION TIG 275 LINCOLN 2 INSTALLATION A 2 RATED OUTPUT 60974 1 K1827 2 Duty Cycle Applications Volts at Rated Amperes ps 40 AC DC Stick Balance TIG 31 0 275 Unbalance 70 Penetration TIG 20 2 255 60 AC DC Stick Balance TIG 29 0 225 Unbalance 70 Penetration AC TIG 18 0 200 10096 AC DC Stick Balance TIG 200 Unbalance 70 Penetration AC TIG 150 ADDITIONAL OUTPUT CAPACITY Output Current Maximum Open Type of Output Auxiliary Power Range Circuit Voltage 15Amp Circuit Breaker and NEMA 5 15R Duplex 2Amps DC Receptacle for up to to STICK AND TIG CC Constant Current 115VAC 8Amp Auxiliary Power Receptacle 115VAC weld Switched Cooler Receptacle load 340Amps AC DC AC DC 79 68 AC DC GTAW E Stick SMAW 5 Amp Circuit Breaker and grounded 220VAC Euro Schuko receptacle RECOMMENDED INPUT WIRE AND FUSE SIZES For all Stick DC TIG and Balanced AC TIG Welding For Unbalanced AC TIG Welding Above 275 Amps at 275A 40 Duty Cycle with out Standard Po
30. E NOTES PRECISION TIG 275 LINCOLN NOTES PRECISION TIG 275 LINCOLN WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel moja a Aislese del trabajo de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Beriihren Sie keine stromfiihrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas elec trodos com a pele ou roupa molha da Isole se da e terra o REPOR ELE Chiku c 6 MLMPT APSSAPRBS NTWSHIELT FSU e E UL TERRAE RR E SPR 9e f KE C EUNT PETER eru SUSS Xe e AXE deal Zei AN A h l ail ei Q5 ie pa Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos U DOMTORRIER THEW 9
31. EE ITEM 12 or When Downslope Drops Below OPERATION With PULSE ON No Pulsing During Upslope Time B 10 4 STEP Trigger 4 STEP Trigger Re closed or Re opened 2 STEP Trigger after Opened Downslope Time SEE ITEM 12 SEE ITEM 12 Background Setting MAXIMUM OUTPUT SETTING Adjustable 2 Max A SEE ITEM 6 Amptrol or Remote PEAK Range SEE ITEM 6 amp 7 PULSE FREQ Adjustable 0 1 20 pps SEE ITEM 14 MINIMUM OUTPUT Start SETTING Adjustable 2 50A SEE ITEM 7 CRATER FILL LEVEL Advanced Panel Select Mach Min or MIN Setting as w o Panel ON TIME Adjustable 5 95 SEE ITEM 7 SEE ITEM 15 BACKGROUND Adjustable MIN Setting 100 Peak SEE ITEM 16 PREFLOW UPSLOPE Fixed 0 5 sec Fixed 0 5 sec orx2 w o Amptrol SEE ITEM 9 SEE ITEM 7 START TIME Manual in 4 Step SEE ITEM 12 SETUP GUIDELINES FOR TIG WELDING WITH AN AMPTROL Both the Hand and Foot Amptrols work in a similar manner They are meant to be used for remote current control for TIG welding using the machine s 2 Step trigger mode See Item 12 The Amptrol is capable of controlling the output of the Precision TIG over the range between the level preset by the Minimum Output control when the Amptrol is at its inactivated state and the level preset by the Maximum Output control when the Amptrol is at fully activated state It is important to note that even with the Precision TIG s new MicroStart Technology some tungste
32. INAL IT WILL BE ELECTRICALLY HOT TO WORK WHEN TIG WELDING PRECISION TIG 275 LINCOLN A 6 INSTALLATION A 6 FIGURE A 2 Colle QO CONTROL RECEPTACLE TIG TORCH CONNECTION PANEL STICK ELECTRODE STUD TIG TORCH CONNECTION The Precision TIG torch connection box located on the right side of the machine provides all the input and output connections for the installation of both air cooled and water cooled TIG torches with fittings con forming to Compressed Gas Association CGA stan dards Note The Precision TIG provides an insulated Torch Reel and Holster for handy and safe storage of con nected torch when not welding and excess torch cable length while welding WARNING Combination connectors Power Water and Power Gas are electrically hot while welding in STICK or TIG modes If using an Air Cooled Torch be sure coolant is shut off and or Cooler is unplugged from the Precision TIG Water Cooler Receptacle on the torch side of the upper case back Observe the safety precautions necessary for han dling and using compressed gas containers Contact your supplier for specifics Shown without hinged stud cover CABLE STRAIN RELIEF HOLES CYLINDER could explode if damaged ws Keep cylinder upright and chained to support
33. ING e ELECTRIC SHOCK can kill Only qualified personnel should perform this installation 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 Precision TIG 275 grounding screw behind the reconnect panel cover located near the back of the left case side to a good electrical earth ground Always connect the Precision TIG 275 to a power supply grounded in accordance with the National Electrical Code and all local codes SELECT SUITABLE LOCATION Place the welder where clean cooling air can freely cir culate in through the top rear vents and out through the bottom rear vents 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 nui sance trips GRINDING Do not direct grinding particles towards the welder An abundance of conductive material can cause mainte nance problems STACKING The Precision TIG 275 s cannot be stacked UNDERCARRIAGE LIFTING AND MOVING When the Precision TIG 275 is purchased as a weld ing package or used with any of the available Undercarriage optional accessories proper installation makes the Precision TIG 275 lift bale nonfunctional Do not attempt to lift the power source with an under carriage attached The undercarriage is designed for
34. ITCH 8 DIGITAL METER AND DISPLAY SWITCH 9 POSTFLOW TIME 10 THERMAL SHUTDOWN LIGHT 11 REMOTE RECEPTACLE 12 TRIGGER SWITCH 13 PULSE MODE SWITCH 14 PULSE FREQUENCY CONTROL 15 PULSE ON TIME CONTROL 16 PULSE BACKGROUND CURRENT CONTROL 17 DOWNSLOPE TIME Ode i Shown without hinged stud cover 1 POWER SWITCH Input line switch turns input e The CC Stick mode may be used for general power ON or OFF as indicated by the on or off sta pose stick welding SMAW within the capacity of tus of the front panel displays the machine The capacity is too limited for arc air carbon AAC gouging 2 POLARITY SWITCH The 3 position rotary power switch has detente positions for DC AC and DC e In this mode the output terminals are activated selections for the Electrode output welding polarity electrically HOT gas flow is not activated and HOT START and ARC FORCE levels are fixed or 3 MODE SWITCH The mode switch allows vertical Advanced Panel selectable See Section B 7 with ly positioned selection of the two machine welding no front panel adjustment modes The selected mode is indicated by a lit col ored panel light which permits viewing the machine 3 b TIG mode Bottom position No panel light setting from a distance When the Polarity Switch is set to AC the TIG Sae ner Top position med paner ghi mode provides continuous high frequency to
35. POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility DO NOT use volt ohm meter to measure output voltages TIG mode The High Frequency Arc Starter voltage can damage the meter ____ Iffor reason you do not understand the test procedures or unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PRECISION TIG 275 LINCOLN 5 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION OUTPUT PROBLEMS 1 Thermal shut down Dirt and dust may have clogged the cooling channels inside machine air intake and exhaust louvers may be blocked welding application may exceed recommended duty cycle Wait until machine cool down and thermal light goes out Blow out machine with clean dry low pressure air check air intake and louvers stay within recom
36. RETURN MAIN MENU ses IM908 PRELISIDN TIG 275 uid For use with machines having Code Numbers 11370 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 Precision TIG 275 shown with optional Advanced Control Panel and Under Cooler Cart PTS OPERATOR S MANUAL LINCOLN Copyright 2006 Lincoln Global Inc e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries Distributors Worldwide Cleveland Ohio 44117 1199 U S A 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com ISO 9001 ANSI RAB fl Se aa Las ali Designed and Manufactured Under a rogram Certified by l SAFETY WARNING N CALIFORNIA PROPOSITION 65 WARNINGS gt For Diesel Engines Diesel engine exhaust For Gasoline Engines The engine exhaust from some of its constituents are known to the State this product contains chemicals known to the of California to cause cancer birth defects and State of California to cause cancer birth defects other re
37. Use only compressed gas cylinders containing the correct shielding gas for the 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s re
38. andard items such as TIG torches hoses and water coolers PROCESS LIMITATIONS Precision TIG machines are not recommended for arc gouging due to it s limited output capacity and are also not recommended for pipe thawing EQUIPMENT LIMITATIONS The Precision TIG machines are protected from over loads beyond the electrical ratings and duty cycles per the Specifications Section A 1 A 2 with Thermostat protection of the primary and secondary transformer coils The Precision TIG machines do not have Hi Freq available at the Stick electrode stud therefore stud connection adapters such as LECO S19257 series cannot be used for torch connection RECOMMENDED EQUIPMENT INTERFACE Machine Input Cable Clamp Gas Reg Hose Magnum Torch Magnum Parts Work Clamp Lead Foot Amptrol air cooled PT275 K1827 2 User provided LE Harris 3100211 PTA9 or PTA17 KP507 or KP508 K2150 1 Work Lead Assembly K870 or K870 1 PRECISION TIG 275 LINCOLN B 3 OPERATION B 3 CONTROLS AND SETTINGS The Front Control Panel contains the knobs and switches necessary for adjusting the operation of the Precision TIG 275 with function indicator lights and an electronic display for volts and amps The components are described below FIGURE B 1 CONTROL PANEL POWER SWITCH POLARITY SWITCH MODE SWITCH AC BALANCE CONTROL LOCAL REMOTE CURRENT CONTROL SWITCH MAXIMUM OUTPUT CONTROL MINIMUM OUTPUT CONTROL AND DISPLAY SW
39. commendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 iv SAFETY iv PR CAUTIONS DE 5 Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des
40. con nect panel to an earth ground 2 Connect the input leads to terminals marked 11 0 and L2 V on the reconnect panel Use a single phase line or one phase of two or three phase line 3 On multiple input voltage welders be sure the reconnect panel is connected for the voltage being supplied to the welder CAUTION Failure to follow these instructions can cause immediate failure of components within the welder Welders are shipped connected for the highest input voltage as listed on the rating plate To change this connection designations on the reconnect panel LOW MID and HIGH correspond to the name plated input voltages of a triple voltage welder Dual voltage welders use only LOW and HIGH EXAMPLE On a 208 230 460 volt welder LOW is 208V MID is 230V and HIGH is 460V Note Export model has a voltage range for LOW and MID connections LOW is 220 230V MID is 380 400V and High is 415V the jumper strap to the terminal stud corre sponding to the input voltage level used Make sure all connections are tight OUTPUT CABLES CONNECTIONS AND LIMITATIONS WARNING To avoid being startled by a high frequency shock keep the TIG torch and cables in good condition Turn the power switch of the power source OFF before installing adapters on cable or when con necting or disconnecting adapter plugs to power source Refer to Figure A 2 for the location of the WORK and STICK terminals
41. cooling off as well as to conserve on gas waste AUXILIARY POWER CIRCUIT BREAKER The 115vac auxiliary circuits and rear receptacle see Section A Auxiliary Power Connections are protected from overloads by a 15 amp circuit breaker located above the receptacle If the breaker trips its button pops out exposing a red ring When the circuit breaker cools the button can be reset by pressing it back in Note When the breaker trips not only will the recepta cle s auxiliary and cooler power be interrupted but so will the power to the shielding gas solenoid and machine cooling fan The Export models also include a 5 amp circuit break er located on the opposite side of the upper case back for protection of the 220vac Schuko type cooler recep tacle PRECISION TIG 275 LINCOLN D 2 MAINTENANCE D 2 SERVICE PROCEDURES Operation of the Precision TIG should be trouble free for the life of the machine Should a malfunction occur however the following procedures will be useful to trained service personnel with experience in repairing arc welding equipment COMPONENT ACCESS The following components are accessible for routine set up and periodic service without requiring removal of the case sides or roof Input Reconnect Panel refer Section A is located behind a removable panel on the rear of the left case side Remove the two screws with a screwdriver or a 3 8 9 5mm hex driver on the bottom corners of this panel to rem
42. d use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN L RAYS can burn 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 standards 4 b Use suitable clothing made from durable flame resistant SE AUG 06 material t
43. del or Under Cooler Cart e 5 5 k 5 e H c z z Es z The Precision TIG Export models also provide a grounded 220vac Euro type Schuko receptacle and a 5 amp circuit breaker located on the upper case back on the reconnect side of the machine intended for use with a 220vac water cooler REMOTE CONTROL If Used The Foot Amptrol included with the Precision TIG Welding Package or other Remote accessory is installed by routing the plug of its control cable up through the left cable strain relief hole provided in the base see Figure A 2 then connecting the 6 pin plug to the mating Remote receptacle behind the stud panel cover See Operation Section B 2 for mating plug wiring Note If the Precision TIG is equipped with an Under Cooler or Under Storage unit the Foot Pedal or other remote control accessory and coiled control cable or excess cable length may be conveniently stored in the drawer while remaining connected PRECISION TIG 275 LINCOLN A 8 INSTALLATION ROBOTIC INTERFACE CONNECTION Robotic interface can be made at the Remote Receptacle See Operation Section B 2 The machine is shipped with the remote receptacle circuit internally connected to receptacle J5 of the Control board for standard Amptrol operation In order to enable the remote receptacle for robotic interface its connection plug must be moved from J5 to J5A on the Co
44. deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince
45. e expires and the gas valve reopens The torch coolant if used continues to flow for up to 8 minutes after the arc goes out with the Fan As Needed feature to assure torch cooling e Repeat steps 5 through 7 to make another weld RECOMMENDED ELECTRODE AMPERAGE RANGES PRECISION TIG 275 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 95 100 135 145 180 Fleetweld 47 DC 75 95 100 145 135 200 Jet LH MR DC 85 110 110 160 130 220 Blue Stainless DC 40 80 75 110 95 110 Red Baron Stainless DC 40 70 60 100 90 140 Mild steel procedures are based on recommended procedures listed in C2 10 8 94 and the maximum rating of the PRECISION TIG 275 Excaliber 7018 procedures are based on Jet LH 78 MR Blue Max procedures are based on C6 1 6 95 Red Baron Procedure are based on ES 503 10 93 GTAW Process Electrode Polarity DC Approximate Argon Electrode Tip Preparation Sharpened Balled Gas Flow Rate EWZr C F H Electrode EwTh 1 EWCe 2 EWTh 1 EWTh 2 EWTh 2 EWLa 1 EWP EWCe 2 EWLa 1 Stainless Electrode Size in EWG EWG Aluminum Steel 010 Up to 15 A Up to 15 A Up to 15 A 3 8 2 4 3 8 2 4 020 Up to 15 A 10 to 15A 5 to 20 A 5 10 3 5 5 10 3 5 040 Up to 80 A 20 to 30 A
46. e provides switched 115VAC power for the Under Cooler or Water Solenoid accessory This Cooler receptacle turns on when the arc starts and remains on for about 8 minutes after the arc goes out with the Fan As Needed machine cooling fan see Maintenance Section so the Cooler s fan and water pump will not run continuously in idle but will run while welding The top outlet of this duplex receptacle provides at least 8 amps at 115VAC whenever the Precision TIG Power switch is ON This auxiliary circuit is intended for running 115VAC accessories or small power tools Note 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 See next paragraph Both the receptacle circuits are protected from shorts and overloads by a 15 amp circuit breaker located above the receptacle if the breaker trips its button pops out exposing a red ring When the circuit break er cools the button can be reset by pressing it back in Note When the breaker trips not only will the auxil iary and cooler power be interrupted but so will the power to the shielding gas solenoid and machine cooling fan COOLANT IN INPUT hack Panel For Gas Supply hose with 5 8 18RH male Provided with Weld Package model For Coolant Supply Hoses with 5 8 18LH male Provided with Weld Package mo
47. een the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Farthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position c g ships hull or building steclwork a conncction bonding the workpiccc to carth may reduce emissions in some but not all instances Care should be taken to preven
48. eflow time for TIG mode is fixed at 0 5 sec ond with no panel control Both time ranges are x2 extendable if needed by internal control box selection See Section B 7 10 THERMAL SHUTDOWN LIGHT This yellow LED panel light turns on if the machine output is shut down because internal overheating has occurred and turns off when the thermostat resets 11 REMOTE RECEPTACLE A 6 socket receptacle is provided for the connection of an Amptrol or other remote control See Figure B 2 When the Current Control Switch See Item 5 is in the REMOTE position the Amptrol or other remote 10K pot connected to the Remote recep tacle controls the TIG or Stick mode output within the range preset by the Maximum and Minimum Output controls See Item 6 and Item 7 also 8 for meter display OPERATION B 5 e When the Current Control Switch is in either LOCAL or REMOTE positions the arc start switch functions when connected to the Remote receptacle FIGURE B 2 REMOTE RECEPTACLE Front View ARC START REMOTE OUTPUT SWITCH CONTROL For 18 12P Plug LECO S12020 27 ADVANCED PANEL CONTROLS The following controls are included only if the Precision TIG 275 has the Advanced Control Panel K1829 1 option installed Refer to Section B 10 Tig Weld Cycle Chart for graphic illustration of these TIG welding func tions 12 TRIGGER SWITCH This 2 position switch selects how the arc start switch connected to the above R
49. emote receptacle functions in 2 Step or 4 Step mode CAUTION DO NOT USE 4 STEP IF USING AN AMPTROL REMOTE Neither the arc start switch nor the output con trol in the amptrol will function normally to shut off or control the out put ONLY USE 2 STEP n 2 Step position the arc start switch functions the same as without the Advanced Panel 1 Closing switch starts preflow then a fixed 0 5 sec ramp time from Minimum Start setting level See Item 7 to Weld setting 2 Opening switch initiates Downslope ramp time setting See Item 17 from Weld set ting to Crater fill level See Item 7 which then stops the arc and initiates Postflow time See Item 9 Note See Section B 7 for 2 Step operation during Downslope with Restart feature selected to be dis abled instead of enabled as shipped PRECISION TIG 275 LINCOLN B 6 OPERATION B 6 n 4 Step position allows welding without continu ously holding the start switch trigger The arc start switch functions in the following manner 1 Closing switch starts preflow then arc starts at Minimum Start setting level See Item 7 If the trigger is maintained closed after preflow time the output remains at the Start level until it is released 2 Opening switch initiates fixed 0 5 sec ramp time from Start setting level to Weld setting 3 Reclosing switch initiates Downslope ramp time setting See item 17 from Weld setting down to the Crater
50. ence radiated from the welding leads Direct interference radiated from feedback into the power lines e Interference from re radiation of pickup by ungrounded metallic objects Keeping these contributing factors in mind installing the equipment per the following instructions should minimize problems 1 Keep the welder power supply lines as short as possible Input leads within 50 feet 15 2 m of the welder should be enclosed in rigid metallic conduit or equivalent shielding There must be good electri cal contact between this conduit and the welder Both ends of the conduit must be connected to a driven ground and the entire length must be contin uous 2 Keep the work and electrode leads as short as pos sible and as close together as possible Lengths should not exceed 25 feet 7 6 m Tape the leads together when practical PRECISION TIG 275 LINCOLN A 4 3 Be sure the torch and work cable rubber coverings are free of cuts and cracks that allow high frequen cy leakage Cables with high natural rubber content such as Lincoln Stable Arc better resist high fre quency leakage than neoprene and other synthetic rubber insulated cables 4 Keep the torch in good repair all connections tight to reduce high frequency leakage 5 The work terminal must be connected to a ground within ten feet of the welder using one of the fol lowing methods e metal underground water pipe in direct contact with t
51. ference may result and cxtra precautions may be required when a welding power source is used in a domestic establisnment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may bo as simple as carthing grounding the welding circuit sec Note In other casos it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the carth circuits of other equipmont Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and ad
52. fill level See Item 7 of the machine 4 Reopening switch after Downslope time holds Crater fill level until switch opens then stops the arc and initiates the Postflow Time See Item 9 Or reopening switch during Downslope time immediately stops the arc and initiates the Postflow Note See Section B 7 for 4 Step operation during Downslope with Restart feature selected to be enabled instead of disabled as shipped 13 PULSE MODE SWITCH Turns on the Pulse Mode as indicated by the Green panel light turning on Pulsing provides a Peak current level set by REMOTE and or LOCAL control of the output cur rent See 5 for a time determined by the Pulse Frequency Control setting See Item 14 and the 96 ON Time See Item 15 The balance of the cycle time is at the Background Current level See Item 16 Pulsing begins after upslope when the output cur rent rises above the Background Current level and ends when the output current drops below this level 14 PULSE FREQUENCY CONTROL This knob is used to set the Pulse Frequency over the peak pulse range of about 0 1 pps to 20 pps One pulse cycle time 1 pps 10 to 05 sec range 15 PULSE ON TIME CONTROL This knob con trols the duration of the peak current as a percentage 5 to 95 of one pulse cycle The balance of the cycle time will be at the Background Current setting See Item 16 16 PULSE BACKGROUND CURRENT CONTROL This knob controls the leve
53. he earth for ten feet or more A 3 4 19 mm galvanized pipe or 5 8 16 mm solid galvanized iron steel or copper rod driven at least eight feet into the ground The ground should be securely made and the ground ing 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 This is not rec ommended 6 Keep all access panels and covers securely in place 7 All electrical conductors within 50 feet 15 2 m of the welder should be enclosed in grounded rigid metallic conduit or equivalent shielding Flexible helically wrapped metallic conduit is generally not suitable 8 When the welder is enclosed in a metal building several good earth driven electrical grounds as in 5 above around the periphery of the building are rec ommended Failure to observe these recommended installation procedures can cause radio or TV interference prob lems and result in unsatisfactory welding performance resulting from lost high frequency power INSTALLATION A 4 INPUT and GROUNDING CONNECTIONS WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Be sure the voltage phase and frequency of the input power is as specified on the rating plate loca
54. jacent to the welding equipmont b radio and television transmitters and receivers C computer and other contro equipment d safety critica equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h the time of day that welding or other activities are to be carried out 110093 LINCOLN SAFETY ELECTROMAGNETIC COMPATIBILITY EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained betw
55. l If all recommended possible areas PC board only Hot Start level of misadjustment have been Stick electrode sticks in the weld puddle Poor starting in DC polarity Arc flutters in DC polarity ok in AC polarity Arc flutters in both DC amp AC polari ties too high 1 Current may be set too low for electrode size 2 Machine with Advanced Control PC board only Arc Force level set too low TIG WELDING PROBLEMS Input line may be too low Bad connection at P11 of Control PC board Bad Background rectifier back ground resistor R7 or background diode D2 1 Tungsten not sharp 2 Bad free wheeling diode D1 or its connection 1 Tungsten electrode may be too large in diameter for the current setting 2 Gas shielding may be insufficient 3 Contaminated gas or leaks in the gas line torch or connections 4 Helium blend is used as a shield ing gas CAUTION checked the problem persists Contact your local Lincoln Authorized Field Service Facility If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PRECISION TIG 275 LINCOLN
56. l of the Background Current as a percentage MIN 100 of the Peak REMOTE and or LOCAL output level See Item 6 down to the Minimum Output setting See Item 7 17 DOWNSLOPE TIME This knob is used to set the time over the range of zero to about 10 seconds to ramp down from weld setting to Crater fill level See Item 7 f the arc goes out after the Downslope time is initi ated the Downslope time is interrupted and the Postflow time is initiated This prevents Hi Freq re initiation during ramp down crater fill When using an Amptrol remote control where the downslope is controlled by the operator down to the crater fill level the Downslope time should be set to zero so as not to have the Downslope time delay when the arc start switch is opened PRECISION TIG 275 LINCOLN 7 B 7 INTERNAL SET UP CONTROLS Precision TIG 275 models which have an Advanced Panel K1829 1 option installed have the following additional control features which are set up using the DIP Switch 51 provided on the internal panel of this option Access to this internal panel is obtained by removing the two screws securing the top corners of the Precision TIG front control panel and swinging the con trol panel down to reveal the panel mounted on the sur face of the Precision TIG Control board CAUTION THE CONTROL BOARDS CONTAIN STATIC SEN SITIVE COMPONENTS To avoid possible damage to these compo
57. live parts or electrode with skin or wet cloth ing Insulate yourself from work and ground Always wear dry insulating gloves e Read and follow Electric Shock Warnings in the Safety section if weld ing must be performed under electrical ly hazardous conditions such as weld ing in wet areas or on or in the work piece FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Es WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS 4 can burn Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual PRODUCT DESCRIPTION The Precision TIG 275 is part of a new family of indus trial arc welding power sources providing constant cur rent single range square wave AC DC TIG GTAW with new patented pending Micro Start Technology Presettable Min and Max Output controls and built in high frequency stabilization for continuous AC TIG and DC TIG starting It also has AC DC Stick SMAW capability with adjustable Arc Force availability A TIG Pulse Panel Power Factor Capacitors and a Water Solenoid are available as field installed optional kits Also a new Undercarriage with double gas bottle rack is available for field installation as well as a new Under Co
58. nd igniting Do spill fuel when filling tank fuel spilled 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 EMF fields may interfere with some pacemakers welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in posi tion 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety ido minimize exposure to EMF fields from the welding circuit 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 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 1 f Do not put your hands near the engine fan Do not attempt to override
59. nents be sure to ground yourself by touching the machine s sheet metal while handling or making settings on the internal control box components PRECISION TIG ADVANCED PANEL Internal Panel O _ gt E DIP SWITCH S1 OFF SWITCH POSITIONS FACTORY SETTINGS STICK WELDING FEATURES The following DIP switch feature selections function only when the Precision TIG is set to Stick mode See Item 3 Switch 6 Hot Start Level Provides an extra out put boost pulse at the arc strike to enhance arc starting This is factory set for a level about 50 extra which is usually good for most stick welding applications ON Hot Start level is used as shipped OFF No Hot Start Switch 7 Arc Force Level Prevents stubbing of the electrode by providing extra output current if the arc voltage drops below the level required to sustain the welding arc High 46596 and Low 41296 factory set levels are selectable which are good for most stick welding applications ON Higher for a crisper arc often desired for 6010 type electrodes OFF Lower Arc Force as shipped for a softer arc with 7018 or general type electrodes Switch 8 NOT CURRENTLY FUNCTIONAL TIG WELDING FEATURES The following DIP switch feature selections function only when the Precision TIG is set to TIG mode See Item 3 e Switch 1 Preflow
60. ns may be difficult to start at the low 2 amps minimum rating of the machine Rather than guessing where to depress the Amptrol to start the arc reliably the Minimum Output control allows presetting the exact level so reliable starts as well as minimum crater fill levels can be consistently obtained at the minimum Amptrol inac tivated state FIGURE B 6 shows Precision TIG setup for TIG welding with an Amptrol DOWNSLOPE POSTFLOW Adjust 0 10 sec Adjust 2 60 sec w Advan Panel orx2 Fixed 0 sec w o SEE ITEM 9 SEE ITEM 17 CRATER FILL TIME Manual in 2 4 Step w Restart Disabled SEE ITEM 12 amp TIG Welding Features USING THE START PEDAL FOOT AMPTROL K870 1 To further enhance reliability of consistently obtaining this minimum level just after the Amptrol s start switch is closed or just before it opens for crater fill the new K870 1 Start Pedal Foot Amptrol is available Its independent start pedal on control pedal provides two stage foot action to easily feel start switch closure at minimum output level for precise arc start and crater control Also an adjustable heel stop helps assure comfortable foot location See Figure B 5 Currently available TIG foot pedal controls combine the arc start switch actuation in the same pedal action with the output control variable resistance This technique provides no independent tactile feel of where the arc start switch actuates and at what control level for con
61. ntrol board Refer to the machine Wiring Diagram The robotic interface functions with the Precision TIG set to either TIG or STICK mode but must be in REMOTE switch position for the Preset Control inter face to function When in the REMOTE position with robotic interface neither the MAXIMUM OUTPUT nor the MINIMUM OUTPUT panel controls limit the inter face control setting over the rated output range of the machine The diagram in Figure A 4 below shows the remote receptacle plug connections and signals for robotic interface REMOTE RECEPTACLE Front View FIGURE A 4 For 18 12P Plug s I LECO 4 CONTROL lt INPUT FROM ROBOT t 0 10 Rated Output Range d E E Li Note The Interface connection ARC START cable may pick up noise interference Additional bypass filtering circuits may be needed for the external circuits INPUT FROM ROBOT 18Vac 10ma switch ARC ESTABLISHED OUTPUT TO ROBOT High Not Welding Robotic Low Welding Precision TIG Control Common Common PRECISION TIG 275 LINCOLN B 1 OPERATION B 1 SAFETY PRECAUTIONS Read and understand this entire section before operat ing the machine WARNING e ELECTRIC 5 can kill Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse box Do not touch electrically
62. o protect your skin and that of your helpers from the arc rays 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 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough 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 The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker expo sure level should be checked upon installation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH limits Do not weld in location
63. oler Cart which is also included in an avail able efficiently integrated entire TIG Welding Package with convenient built in storage provisions for welding equipment and components The Precision TIG 275 includes advanced features such as a Digital Meter Presettable control Auto BalancelM Fan As Needed F A N fixed Preflow vari able Postflow shielding gas and Timers In addition 2 Step 4 Step and Pulse TIG operation with adjustable Downslope Time control are included with an available field installed kit It also features a Stick stud panel and a universal TIG torch connection box for simultaneous but separated electrode outputs PIPE THAWING The Precision TIG 275 is not recommended for pipe thawing Duty Cycle The duty cycle is based upon a 10 minute time period i e for 4096 duty cycle it is 4 minutes welding and 6 minutes idling If the rated duty cycle is significantly exceeded the thermostatic protection will shut off the output until the machine cools to a normal operating temperature Refer to Specification Section A 1 PRECISION TIG 275 LINCOLN B 2 OPERATION B 2 RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Precision TIG 275 is recommended for the TIG GTAW and Stick SMAW welding processes within its output capacity range of 2 amps DC or 5 amps AC to 340 amps AC DC It is compatible with most Magnum TIG accessories refer Equipment Limitations as well as many industry st
64. oth DC amp AC polarities regardless of preset 1 Bad connection at P6 of Control PC board Bad shunt connection Faulty Control PC board Faulty SCR bridge High output current in DC polarity regardless of preset o k in AC polar ity 1 Shorted free wheeling diode D1 In 2 step Tig output stays on for more than downslope time after trig ger open machine with Advanced Control panel only 1 Bad 2 4 step switch or its connec tion Bad connection at P1 of Advanced Control PC board Output stays on after releasing hand foot Amptrol machine with Advanced Control panel only 1 Downslope is not set at min Bad Downslope potentiometer R12 or its connection CAUTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PRECISION TIG 275 LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION STICK WELDING PROBLEMS 1 Current may be set too high for electrode size Stick electrode blast off when arc is struck 2 Machine with Advanced Contro
65. ove it Control Box components and PC Boards refer Section B 6 are located behind the front control panel Remove the two screws with a screwdriver or a 3 8 9 5mm hex driver on the top corners of this panel to swing it down e Spark Gap assembly refer Spark Gap Adjustment is located behind a removable panel on the rear of the right case side under the torch box Remove the screw with a screwdriver or a 3 8 9 5mm hex driver on the bottom center of this panel to remove it SPARK GAP ADJUSTMENT The spark gap is set at the factory to a gap of 0 015 inches 0 4 mm See Figure This setting is ade quate for most applications Where less high frequen is desired the setting can be reduced to 0 008 inch es 0 2 mm WARNING Use extreme caution when working with circuit the high frequency The high voltages developed can be lethal Turn the input power off using the disconnect switch or fuse box before working inside the machine This is particularly important when working on the secondary circuit of the high voltage transformer T3 because the output volt age is dangerously high FIGURE C 1 SPARK GAP Note In highly dirty environments where there is an abundance of conductive contaminants use a low pressure air stream or a firm piece of paper to clean out the spark gap Do not disturb the factory gap set ting To check the spark gap 1 Turn the input power
66. productive harm or other reproductive harm 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 amp Cutting ANSI Standard Z49 1 from the American Welding Society 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 FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running QA 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 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 weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts a
67. r les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaga Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP55UtRc5cuc Ss C F eu CARE EUR Fa fE ie sk HE 24758 else e S XACEREE SHAE AAS Ash FANH H 718 Assis oe lue Gall bacs ga d uu Mall Ge Quad sas Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas e X7TTL2A 9 UAVCRU D gt DFM C F uv e SAUTER Aie Shy pha NM ale Do not operate with panel open or guards off No con panel abierto guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas
68. s 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 prod ucts 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 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 Also see item 1 b SAFETY WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent 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 Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the
69. stabi WARNING lize the arc for AC TIG welding ELECTRIC SHOCK can kill Hi Freq turns on after preflow time with the arc When the Power Source is ON in start switch closure and turns off when the arc STICK mode the Electrode circuits of goes out after the arc start switch opens both the Stick and TIG torch cables are electrically HOT to Work Arc voltage and current are sensed to determine if ce ERROR the arc is established or out PRECISION TIG 275 LINCOLN B 4 OPERATION B 4 When the Polarity Switch is set to DC or the TIG mode provides high frequency only for starting Hi Freq turns on after pre flow time with the arc start switch closure and turns off when the arc is established Also functions for DC polarity to permit balling of tungsten for AC TIG welding 4 AC BALANCE CONTROL The potentiometer control permits AC wave balance adjustment from Penetration 85 negative wave with the control full CW position to Max Cleaning 65 positive wave with the control set near min imum CCW position e Full minimum CCW position is the Auto Balance position which is indicated by the Green panel light turning on This feature automatically provides the proper amount of cleaning and penetration for nor mal AC TIG welding The mid position is the Balanced position 50 positive and negative waves The Balance control is only functional if the
70. t tion Bad connection at P9 of Control PC board GAS PROBLEMS Circuit breaker CB1 open Press CB1 in to reset Bad connection at P12 of Control PC board Faulty gas solenoid valve SV1 or its connection Faulty Control PC board No control on post flow time Faulty potentiometer R3 or its connection Bad connection at P9 of Control all recommended possible areas PC board of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Pre flow amp Post flow time too long Advanced Control PC board was installed check setting of DIP switch on that board Missing plug P3 on Control board or bad connection at P3 when an Advanced Control PC board is not present CAUTION Iffor any reason you understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PRECISION TIG 275 LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION No hi freq Hi freq intensity too weak Hi freq on continuously in DC Tig Hi freq shuts off after starting in Tig HI FREQ PROBLEMS Circuit breaker CB1 open Bad connection at P12 of Control PC board Spark gaps shorted Faul
71. t the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Soloctivo screening and shiclding of other cables and cquipment in the surrounding arca may alleviate problems of interference Screening of the entire welding installation may be considered for special applications 1 Portions of the preceding text are contained in EN50199 Electromagnetic Compatibility EMC product standard for arc welding cquipmont 3 1 96H L10093 LINCOLN for selecting QUALITY product by Lincoln Electric We want you ank You io take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to 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 yo
72. ted on the rear of the machine Fuse the input circuit with the recommended super lag fuses or delay type1 circuit breakers Choose an input and grounding wire size according to local or national codes or use Section A 2 Using fuses or circuit break ers smaller than recommended may result in nui sance tripping from welder inrush currents even if not welding at high currents Unbalanced AC TIG welding draws higher input cur rents 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 185 amps is planned the higher input currents require larger input wire sizes and fuses per Section A 2 Remove the reconnect panel cover located near the back of the left case side to reveal the reconnect panel Welder supply line entry provision is in the case rear panel Entry is through a 1 75 inch 44 mm diameter hole in the case back Appropriate supply line strain relief clamp is provided by installer See Figure A 1 FIGURE A 1 CONNECT INPUT POWER LEADS CONNECT INPUT e GROUND LEAD been CONNECT INPUT VOLTAGE LEVEL All connections should be made in accordance with all local codes and national electrical codes Installation by a qualified electrician is recom mended PRECISION TIG 275 LINCOLN 5 INSTALLATION A 5 1 Connect the terminal marked below the re
73. ty Control PC board Dirty spark gap or improper gap setting Faulty Arc Starter assembly Bad connection at P11 of Control PC board Micro switch S2A is not engaged amp disengaged properly when switch ing between DC amp AC polarity S2A locates on the Polarity switch Faulty Control PC board Micro switch S2A is not engaged amp disengaged properly when switch ing between DC amp AC polarity S2A locates on the Polarity CAUTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PRECISION TIG 275 LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PRESET amp OUTPUT CONTROL PROBLEMS Meter does not display preset 1 Faulty potentiometer R1 or its con nection 2 Bad connection at P9 of Control PC board Faulty Advanced Control PC board if present or its connection to the main Control PC board Missing plug P3 on Control board or bad connection at P3 when an Advanced Control PC board is not present High output current in b
74. u la piece souder doit tre branch une bonne mise la terre 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place LINCOLN SAFETY ELECTROMAQNETIC COMPATIBILITY EMC Conformance Products displaying the CE mark are conformity with European Community Council Directive of May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility 89 336 It was manufactured in conformity with a national standard that implements harmonized standard EN 50 199 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for usc with other Lincoln Electric cquipmont It is designed for industrial and professional usc Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Bc aware that inter
75. ur machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet e For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it e For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment n TABLE OF CONTENTS Wu Page
76. wer 255A 40 Duty Cycle Auto Balance Penetration with Factor Correction Capacitors out Standard Power Factor Correction Capacitors Based on the 1999 U S National Electrical Code Based on the 1999 U S National Electrical Code Input Type 75 C Type 75 C Type 75 C Type 75 C Input Fuse Ampere Copper Wire in Copper Fuse Input Copper Wire in Copper e Conduit AWG na Conduit AWG 505 Voltage Super Lag Rating IEC Sizes Ground Wire in Super Lag Ampere IEC Sizes Ground Wire in phase or Breaker Rating on 104 F Conduit AWG or Breaker Rating 40 C 104 F Conduit AWG Frequency Size Nameplate Ambient IEC Sizes Size Ambient IEC Sizes 2202300506 125 95 4 21 2 mm2 6 13 3 mm2 4 21 2 6 13 3 mm2 380400 506 80 55 8 84mm2 8 8 4 2 90 63 6 13 3 8 8 4 mm PHYSICAL DIMENSIONS Weight Approx 397 Ibs 180 kgs TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 20 C to 40 C 04 to 104 F 40 C to 85 C 40 to 185 F TRANSFORMER INSULATION CLASS 180 C H 1 ALSO CALLED INVERSE TIME THERMAL MAGNETIC CIRCUIT BREAKERS CIRCUIT BREAKERS WHICH HAVE A DELAY IN TRIPPING ACTION THAT DECREASES AS THE MAGNITUDE OF CURRENT INCREASES 50 60Hz IEC Max range exceeds 310A PRECISION TIG 275 LINCOLN A 3 INSTALLATION A 3 SAFETY PRECAUTIONS Read entire installation section before starting installation WARN

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