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Lincoln Electric SVM162-B User's Manual

Contents

1. FEL c o TOROID TOROID aa Ke 5V H Ces Y 301 F3 SCR1 GATE G1 216 oi 302 TUE PT IN SCR2 GATE G2 G4 ING 303 ia SCR3 GATE G3 L o 2 306 al lt 1 lt 301 304 304 COM SCRA GATE G4 G1 SCR1 02 303 gt 2 gt Qcr SCC ING SCR1 SCR2 CATHODE 218 li G2 olo IN 433 gt METER lt 3 304B SCR3 CATHODE 247 M 220 REH 4 205mV BETVVEEN 4 4 lt 302 SCR4 CATHODE 216 jk RECTIFIER c IN amp INC
2. Fir i Sio PRECISION TIG 275 WIRING DIAGRAM 575 V elo 2 A SE CONNECT STRAP TO HIGH H4 AS SHOWN lk EE SCHEMA DE CABLAGE DIAGRAMAS DE CABLEADO Gu o w CONNECTER LA BRIDE SUR HAUT i o lt PANNEAU DE COMMANDE VIEWED FROM REAR CONNECTION IS PIN TO PIN BETWEEN J23 AND J5 SUJETADOR DE CONEXI N A ALTO C ENLEVER LA FICHE CAVALIER EN 3 QUAND ON NSTALLE LE C SEH a no SAE 4 TIG OPTION PC BOARD 0 EN B el ud CONNECT ST
3. 516 28 O CONTROL PANEL VIEWED FROM REAR D 19 PRECISION TIG 275 WIRING DIAGRAM anc di i 460 VOLT CONNECTION cc T CONNECT STRAP TO x 306 iz 1 301 ER ee ECH HIGH H4 AS SHOWN 5 3 303 gt 2 gt 2 D pr METER Ze 304B POWER SWITCH ao oS 230 VOLT CONNECTION E IS 441 302 CONNECT STRAP TO m anne sd 4 d MID H3 G P E VIEWED FROM REAR L1 U CO C1 208 VOLT CONNECTION MID C CONNECT STRAP TO bh HIGH LOW T OLU 251 L5 CONTROL PC BOARD O d C2 H1 MINIMUM NE DO SH L2 V COM N OUTPUT DISPLAY m POVVER FACTOR 301
4. CIRCUITRY MAY BE DIFFERENT ENGINEER burkhart FROM AN ACTUAL MACHINE EN 170 SOLID EDGE UNITS MATERIAL APPROVAL PROJECT REFERENCE none e NA ME r ao RS mue 5 E OT Ou 16990 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED FROMX A02 MANUFACTURER No menu options jumper IN TOROID TOROID o Fj R1 GATE O o Push amp hold no menu options jumper out C 7 Gl 216 2 o at power up defaults 343 GND SOR3 GATE G2 2 Dat G3 M Gl o S3 c 344 344 Bata SCRAGATE GA SORT x MENU METER 77 2 347 7 Menu Switch SCRLSCR2 CATHODE 218 M G2 ga O 9 SWITCH Ze 205 347 5 SCR3CATHODE 217 M 220 RECTIFIER 25 316D O preset amp actual lt A 343 sun 2n 1 cic 2 ES 220 50HZ MACHINE ONLY E um aliberation see new control bd instructions ert 5 S 3
5. o o 1 29 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED FROMXA 02 ITEM QTY PART NUMBER DESCRIPTION 215 R19 R47 R48 R49 MANUFACTURER 1 1 1G4763 A PC BOARD BLANK R50 R51 R52 R53 R54 12 1S19400 10R0 RESISTOR MF 1 4W 10 0 1 D UFACTU No 2 RIL TRI2 X5 XOF 4 CF000003 6 32 X 375 ROUND HEAD MACHINE SCREW R308 R311 O 3 TRI2 5 X9 4 1 1064 13 6 LOCK WASHER R17 R20 R21 R22 R29 a 4 TRIL TRI2 X5 X9 AS REQ E 1868 THERMO J OINT COMPOUND R40 R41 R44 R55 R56 o 5 TRI2 X6 X9 4 15181043 HEAT SINK ALUMINUM E XTRUDED FOR 1 TO 220 R58 R75 R76 R136 dp 6 2 S 19300 7 SUPPORT PCB SNAP SN 063 WHT R176 R210 R213 R214 7 5 0 OZ E2861 SEALANT R241 R275 R282 R287 o o 8 1 2001 Sene sor T RRE R288 R291 R319 R323 43 S19400 4751 RESISTOR MF 1 4W 4 75K 1 S R325 R329 R330 R331 R359 R366 R375 R378 c c REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW R379 R383 R404 R406 R407 R408 R409 R412 5 REFERENCES QTY PART NUMBER DESCRIPTION R418 CI C7 C178 C179 4 5166688 CAPACITOR CEMO 330pF 100V 596 R24 R39 R46 R84 R97 S C2 C5 C17 C21 C25 R109 R
6. 424 SW a i i th de re tt Ht he Se tm at vu d a MP n gy AM R DA RO Pl Pi bk ree Bi ei e H m e r n m ray rm rar mi ee rh Bra RP qax iy hi Raa aka mil 15V 851 1A Va m x x m G 13 dBd a 224 AUTOBALANCE LED x vr tt dr reg dt md i 1 15V 10Vref 1 1 d 1 1 1 768K lt E b i bg TRIM FOR 105 Vpk DCV b i2 ma i BALANCE POTI cw E CLN 159 ME AUTO 0 I por i p t 1 D Ve i 33074 Fr la d GND 10K SHT 3 BALANCE SHT 2 i 1 1 1 il 29 1 i e PEAK LIM EN i APPROX L VOLTS 7 E is R419 TI 41 475K i 1 1 1 022 d i O54 R240 40V DV 10K ARCEST 1 i 400V ME ki i 1 l 224K i i d i i i IBALANCE 1 p d vi maa ian aa La 1 1 15V i 1 1 i DEL Ela i sov 1 CONTROL VOLTAGE I CLAMP
7. Fir olo S o CONTROL PANEL VIEWED FROM REAR a PRECISION TIG 275 WIRING DIAGRAM olo L1 ms H1 w e 575 VOLT CONNECTION cic CONNECT STRAP TO E 5 306 ai 14 01 SLV S1 n HIGH H4 AS SHOVVN o z 303 gt 2 2 D D Io METER e 7 POVVER SVVITCH Q 460 VOLT CONNECTION cc t Cea el m CONNECT STRAP TO C Ke 6c HA LOW 2 VIEWED FROM REAR L1 U 6 O I C1 MID HIGH Ke TT 15 CONTROL PC BOARD C4 O XM m zd H1 MINIMUM NE OUTPUT DISPLAY 24 12 m7 COM ot O N s 301 Late _ GROUND RECONNECT PANEL de 2 305 T 1 i OPTIONAL D 304 44 J8 X5 267 x LO 304A lt 5 N 63 5VAC WTV Sols 256 H2 460V x 2 je gt 1 W 221 eee TO GROUND PER 2207 ET e 321 R222 NATIONAL H4 575V S X9 291 o O O L S 7 2 R 57 7 1 LA ELECTRICAL CODE x9 S 415VAC 231A 2 O O 1 3138 313 232 papa c 18VAC F x4 232 8 I 314 1 lt 4 F STICK BALANCE o LOCAL e MMM 315 5 lt Sg o E o Q OUTPUT POST FLOW L346 NM L12 s X1 z5 eo 317 746 ex 318 lt 84 1 G1 w209 S 78VAC Hie 319 9 ER oro 20VAC o 320 406 e x8 P
8. l A KA un X16 x13 330744 33076 le rm rr rm L V iie vi daa ben z m dam dm dam m lara yun mx x x ma x xx x m x m x um mum xu mu gums m ovu er iyu rli re ER VU LE at E DEI EE na apa x xo max u E EE u 15 ON IN AC TIG BEFORE DUTPUT ENABLED 2 15K nS FT START SHT 2 y ERROR AMPLIFIER M I I I I I I I 1 1 I 1 I 1 I 1 1 0 022uF 1 Sov 1 GND I I I I I 1 1 L 1 I I a a a ear inscri 1 pi m m tr Pr ru vm 5 PHASE DETECTOR Ww y x a en BV I I 1 1 I I 1 I I 1 1 I I 30K R126 1 CONTROL VOLTAGE DIVIDER LIMITS HIGHEST VOLTAGE 768k iS LOWEST OUTPUT Ex GNDX 7 i 1 1 1 I I I sO wD I m 1 I I 1 1 I I 1 1 fem V sno PHASE_FIRE SHT 2 A A EN SV 1 1 1 L i I 8 332 R d 1 1 i UNE SYNC C27 i 0 004 TuF 1 SOV 1 1 1 1 1 1 1 1 1 1 1 14 22uF S V GND er ere eh ah db AG YA ARR YI EA EE SE SE ETE RS SYNS YR ERT SN TT EN ETE PY
9. n n mz nn ma m n n vu m Er er hr ae PROPRIETARY amp CONFIDENTIAL SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE ABILITY OF A COMPLETE BOARD THIS D i 24 SW 1 b I I F 2119 200uH 200uH d 18 1 T2 1 p17 2 A 1A FR 1 15V ADEM 1 1 1 BACKGROUND CIRCUIT Te eles fel file i un un b 475 x z m m E i I s 03 b 05A 011 i c Pod CLN ER dd i erf SC 7 x p de SS e 11 FIRE SCR 12 d t i gt 132 K 35 NE Mz c2 ya 20 OHMS 100 W pog 4 75K 1000f E 475 d 1 100 Ns 11 i 1 I 1 1 1 I 1 uer T Po 9 24V SW 8 aa xi D 1 57 191 1132 50 OHM HOLDING i I CURRENT RESISTOR 1 E 200uH 1 1 NEG EE OUTPUT 016 Fog 1A ER 15V LOOV 1 d 1 m 11 2 za 495K e m i s 06 AE as gt an Par Rad S 1 d 6 E 00 475K S 10087 d Es ajos Hi d I 100 i Li 1 390uH ELECTRODE d 7 E 225mA 2133 1 1 GND 0905 74F 1 Cat 1400V i L 45 1 i 1 n 1 m POWER L2 390uH WORK i 225mA 1 15 16V UNREG 1 5 16V UNREG SCH SHT 1 i 24V SW 5V i I 5 1 b b DRAWN 4 DIAGRAM MAY NOT SHOW THE EXACT ENG NEER Y TN APPROVED COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER NOTE This diagram is for reference only I
10. o o D p e 1 Remove input power to the Precision TIG 7 Activate the torch trigger and check for sc ka 275 machine approximately 115 VAC at the solenoid leads SI 231A and 235 If the correct voltage is 9 2 2 Remove the left case side present the solenoid should activate and 3 Perform the High Frequency Circuit gas should flow 8 If voltage is present at leads 231A and 4 Locate the gas solenoid in the torch connec 235 and the solenoid does not activate the tion box solenoid may be defective The solenoid l can be further checked by removing leads 5 Put the mode switch S3 in the 2 Step TIG 231A and 235 from the solenoid and position applying the external isolated 115 VAC sup ply to the solenoid terminals If the solenoid activates with the external supply but not A WARNING when powered by the control board the problem may be in the control board If you 0 ELECTRIC SHOCK CAN hear solenoid activation but there is still no KILL gas flow check for restrictions in the line With input power ON there when the test is complete replace leads are high voltages inside the 231A and 235 Return to Section TOC Return to Master TOC machine Do not reach into the machine or touch any 10 Reassemble the two leads previous internal part removed in the High Frequency Circuit Disable Procedure 11 Reassemble the left case side 12 If a water so
11. 000 Ch Eo 02000000 8 GL Ae e r le o o REMOTE S CONTROL E O RECEPTACLE P e e STICK O TIG TORCH CONNECTION PANEL 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 A 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 CABLE STRAIN RELIEF HOLES CYLINDER could explode if damaged Keep cylinder upright and chained to a support Keep cylinder away from areas where it could be damaged Never allow the torch to touch the cylinder Keep cylind
12. o s RE 15 olo cc 22 Return to Section TOC Return to Master TOC el ELECTRICAL DIAGRAMS SCHEMATIC BYPASS STABILIZER P C BOARD S22530 1 CODE 10806 amp 10807 ARC STABILIZER CAPACITOR ARC STABILIZER Cg 19 10 250V CONNECTION MADE THROUGH HOLE WITH SOLDER PAD C1 C2 C3 C4 TP Tpo 05 05 05 05 200 224 600V 600V 600V 600V m 160J 160J Graphic GND GND CONNECTION MADE THROUGH SOLDER PAD AND SCREW TO STEEL STANDOFF ON MACHINE NOTES GENERAL INFORMATION NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED TO ELECTRICAL SYMBOLS PER E1537 CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD CAPACITORS MED 022 50V UNLESS OTHERWISE SPECIFIED THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER DIODES 14 400V UNLESS OTHERWISE SPECIFIED NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual gris RESISTOR C5 600V LABELS A SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION C6 600V G 21 CONNECTION MADE THROUGH HOLE WITH SOLDER PAD C7 C8 alls 09 600V 600V Graphic S22530 1B0 Rev A TT l FRAME CONNECTION EARTH GROUND CONNECTION PRECISION TIG 275 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC
13. G 5 ELECTRICAL DIAGRAMS 5 WIRING DIAGRAM ENTIRE MACHINE CODE 11158 G5692 Fir PRECISION TIG 275 WIRING DIAGRAM 460 V SES 2 1 CONNECT STRAP TO HIGH H4 AS SHOWN o 2 CONTROL PANEL VIEVVED FROM REAR SCHEMA DE CABLAGE DIAGRAMAS DE CABLEADO L1
14. O Io Ir CHS ope o Of a lz ole 1 2 lz ol o r l 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a o lx ole cre 515 ol o cic Return to Section TOC Return to Master TOC F 17 F 17 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF TROUBLESHOOTING GUIDE RECOMMENDED SYMPTOMS The meter does not display V volt Or minimum current NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced Process panel or harness is defective MISADJUSTMENT S FUNCTION PROBLEMS 1 Toggle the display switch It may be dirty COURSE OF ACTION 1 Check the leads between the display switch and the control board See the Wiring Diagram 2 The display switch may be faulty 3 The control board may be faulty The meter does not light up Other machine functions are
15. 1 Perform the SCR Bridge Test 2 The control board may be faulty 1 Check the polarity switch for excessive wear or faulty connec tions 2 Check the interior heavy current carrying leads and connections CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir C olo o Ola lz ole cre Sla ol o cic Return to Section TOC Return to Master TOC F 15 F 15 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS The meter does not display V volt 1 Check that either the advanced 1 Check H1 potentiometer and or minimum current control board or jumper plug is in associated leads between the J3 on the control board control board and plug J9 See the Wiring Diagram 2 The control board may be faulty NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced Proce
16. 4 TP7 TP9 TP10 6 T13640 18 MOV 320VRMS 150 20MM R6 1 516296 5 TRIMMER MT 1 2W 10K 10 LINEAR TP11 TP12 o NOTES R8 R16 R120 R122 TPS I T13640 11IK MOV 150VRMS 45 14MM NA CAUTION THIS DEMCE IS SUBJ ECT TO DAVAGE BY STATIC ELECTRICITY SEE E2454 R172 R317 R356 R369 11 519400 1000 RESISTOR MF UA 100 196 TRI2 TRI4 4 S15161 27 TRIAC TO220 8A 800V li BEFORE HANDLING R376 R380 R402 NA XI I 51790024 IC CMOS GATE NAND 2 INPUT QUAD SCHM SS c R9 R91 R116 R117 5 1619400 3322 RESISTOR MF 1 4W 33 2K 19 NA X 1 5179008 IC CMOS INVERTER SCHMITT HEXHC14A SS c N B KEEP THIS AREA FREE OF ENCAPSULATION MATERIAL 2 50 MIN BOTH SIDES OF R350 m NA X4 X14 2 5150186 IC CMOS SWITCH ANALOG QUAD 4066 55 Sh 5 BOARD R13 1 1146484 RESISTOR WW 5W 40 5 SQ Xo I S151286 IC VOLT REG FIXED 3 1 4 1A 15V 10220 R14 R18 R141 R142 S z N C SQUEEZE COMPONENTS TOGETHER BEFORE APPLYINGITEM 7 AND OR R143 R144 R145 R146 NA X16 1 Seene UOLT ee PERF 33074 ADJ 3 T 4 3A 350 10220 o ENCAPSULATION MATER AL R147 R148 R149 R150 lu NA XIT I 15150184 IC CMOS INVERTER SCHMITT HEX 458455 C N D APPLY ITEM 7 ON COMPONENT SIDE ONLY AS SHOWN 7 Ge 7 75 5 519400 4785 RESISTOR MF 1 4W 47 5 1 X7 I M151024 IC ARRAY DRIVER PERIPHERAL NPN DARL APPLY ITEM 7 ON BOTH SIDES OF BOARD AS SHOWN EXCEPT TOP SURFACE OF R413 R40 RAST Ra NA X1
17. x1 GROUND C_ RECONNECT PANEL CAPACITORS Q m So WE o 1 OPTIONAL 4 mu o L 304 46 8 S x5 e 267 UT N O 5 Ea 5 lt 2 208V 63 5VAC d Sm 306 lt 6 H3 230V ap 268 v d 8 jg DD W 221 TO GROUND PER 32 R222 NATIONAL Ha 460v X8 231 I olo 8 7 pos T T ELECTRICAL CODE eX9 3 115VAC Z 312 2 F O O L 3138 5 313 ELE 204 18VAC 20007 Fir 314 lt 4 5 MAXIMUM IN 315 5 o xq cls STICK BALANCE o LOCAL OUTPUT POST FLOW 316 8 L12 S 31776 XX 318 8 91 G4 W209 78VAC O Se 319 92 Ssl 6 500 s o 320 40 ECON dx E yo n 2 vy VU 0 313 321 11 45 G4 1 TIG REMOTE 32212 14 DD 02 D T1 o 9 MODE o E gt 6 gt 217 4 POLARITY SWITCH MICRO SWITCH N Se e lt g sos 97 220 1 AC D E B F OPEN cic Low SE B5 y DC B D C E A F G H CLOSED x o 227 5 9 218 DC B D A E C F G H CLOSED 232 5 CU QA NG AD 216 115VAC t o REAR GANG MICRO SWITCH CB 2 D2 S2A no CB1 C9 ZN 15A 1 331 Ag NC 233 T STICK AUTO BAL REMOTE P FLOW THERMAL B lt 6 lt e 4 IE 3 231 HR x 7 18 ke 332 y A e ae z Q A Y Y 7 G 5 75 E Ta 0 8 4 y N Ww lt 4 Ms co 3 5 5 334 B 1 9 4 7 24 9 05 Nue Er DIK
18. F 58 TROUBLESHOOTING amp REPAIR F 58 POLARITY SWITCH REMOVAL AND REPLACEMENT continued Figure F 15 Switch Location REMOVAL PROCEDURE 1 Remove the input to the PRECISION TIG 275 machine Using the 3 8 nut driver remove the case sides and top 3 Locate the polarity switch See Figure F 15 4 Using a 1 2 vvrench label and disconnect leads B C 252 Pos Neg D2 diode assem bly S 253 choke lead X2 and all leads from the main transformer Be sure to label leads for reassembly Disconnect leads 265 and 266A using quick disconnects Using a phillips head screw driver remove the screw from the polarity switch handle See Figure F 15 With the 2 slot head screw drivers carefully pry the polarity switch handle Carefully peel back the lower nameplate on the case front located around the polarity switch to gain access to the polarity switch mounting nuts NOTE Do not remove the sticker completely 9 Using a 7 16 nut driver remove the two polarity switch mounting nuts located behind the previously removed nameplate 10 The polarity switch is ready for removal REPLACEMENT PROCEDURE ls 2 Replace the polarity switch Secure the polarity switch in its original posi tion with the 7 16 mounting nuts Firmly press the lower nameplate back into its original position on the case front Press the polarity switch
19. GAS OUTPUT 58 18 RH WARNING Us PLUG inkTER COO LER WHEN en AIR COO LED TO RO NES 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 The Precision TIG Export models also provide a grounded 220 VAC 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 220 VAC 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 9 INSTALLATION ROBOTIC INTERFACE CONNECTION Robotic interface can be made at the Remote Receptacle 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
20. NE 42 UTADO INFERIOR A TIERRA CONFORME EL C DIGO o 6 CU Sol 7 EL CTRICO NACIONAL p X9 115VAG 231A R5 PHASE SHIFT RESISTOR 200 100 Q mo 6 amp 201 F 1 R6 HOLDING RESISTOR 50 225 amp amp e pans F 5 X10 R7C R7D RESISTOR 5 50 e O BALANCE quali unu ii x R8A R8B EQUILIBRE STICK 313B 313 x1 2 1 INPUT POWER SWITCH O LECTRODE MAX OUTPUT POST FLOW 314 XS t zevac 52 POLARITY SWITCH VARILLA o LOCAL i RENDEMENT ECOULEMENT DE POTEA I 315 5 9 Bao 20VAC S2A MICROSWITCH ON POLARITY SWITCH E 5 SALIDA FLUJO DEL POSTE 316 1 lt X6 amp jg xs cr xo Se MENU SWITCH 5 E 317 1 lt 7 SCR1 2 3 4 MAIN POWER SCR S NG cio p 318 8 T1 sv GAS SOLENOID VALVE 115VAC 319 9 N SV2 WATER SOLENOID VALVE 115VAC OPTIONAL 9 VUS 2 ys 321 112 E ee ken a 322 1 49 1 m T2 HIGH VOLTAGE TRANSFORMER 912 A DISTANCE 52 S2A 4 REMOTO lt 2 A C D E OPEN OUVERT ABIERTO 522 0 58 O ele zB EL GER DC B D C E A F GH CLOSED FERM CERRADO CC CONDENSATEURS FACTEUR DE PUISSANCE 50 460 515 SR QN NT J t B D A E C F G H CLOSED FERM CERRADO CAPACITORES DE FACTOR DE POTENCIA 50 460 512 C4 05 CONDENSATEURS DERIVATION 0047 oio B CAPACITORES DE DERIVACION 0047 cc t k BALANCE 0 77 E 1217 bu S2A ANO C6 CONDENSATEUR HAUTE TENSION 0015 12kV EQUILIBRE 381 7 X
21. Q xi SH 215 os 00 Fir Se m m 224 yee i E 1 Wa amp JSK VG LINE SYNC PHASE A CLN SIGNAL ve 100pF cix AUN AA TRASE A C 100 Nae i la olg Soy ei 1 o E gt 512 028 E E PEN LN 1 ix 7 1A FR Ba oV L2 gt o 400V bajk PHASE B PHASE A 00 S fio 22V SW E V olo E 7 See b 9 SCRZ GATE du 1 Rze 7 a xi p z OR T da 540938 gt gt 5 d 2 Ger 11 PHASE B PEN SIGNAL par i 1A FR We 0 004 7uF F R SER2 4 o o 4004 En SOV M o SHT 23 ve SHT 2 her 15V Vom os 45V M 16Y UNREG 014 025 015 IM 1A J 4 S 24V SW 4004 av 400V 16V_UNREG SCR amp GATE SHT 2 24V_SW 518395 8 15 18395 3 15 X5 xs es z 2815 io 7805 200V C73 C40 131 s 1804 HA 2 S ux 090 m Tm Ver T GENERAL INFORMATION uu gee on 7 7 ELECTRICAL SYMBOLS PER E1537 A O O CAPACITORS MFO 072 50V UNLESS OTHERWISE SPECIFIED p p Peo mti 15V V ano RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 2 S E O O DIODES 14 400V UNLESS OTHERWISE SPECIFIEO A arm VOL TARE MET et S C POWER SUPPLY SOURCE POINT pum COMMON CONNECTION V o o L C106 ha d n IFF FRAME CONNECTION ges o l r uF G FT o 50V 50V EARTH GROUND CONNECTION x13 x16 19 s x2 428 xi i x T gt 9 du THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED o 226N 224N D 1014 33
22. R12 OR ve 2 4 12V DC RELAY COIL c m 201 s 262 FREE WHEELING DIODE Luet L gt 15 204 270 263 BACKGROUND DIODE Dlt Neo io V Vv Vy NN s gt W209 201 4 OUTPUT INDUCTOR CHOKE Q c Nam 1 o So o Ra 12345878310 16 R210 m 204 i HIGH FREQ INDUCTORS o 599 00 55 Ge TT 2208 W209 RF TOROID CHOKES o yy 357 n Y 220A Rag OUTPUT CONTROL POTENTIOMETER 10K MEN o LU d bo Em TTT BALANCE CONTROL POTENTIOMETER 10K OI N k E L10 400 pe em POST FLOW POTENTIOMETER 10K Ms 403 3 E ges E MIN OUTPUT POTENTIOMETER 10K 4 STEP ON PULSE ON M 404 242 2 PHASE SHIFT RESISTOR 200 100 e M 405 x5e Z gt HOLDING RESISTOR 50 225 ER 2551 AS B 406 lt 6 214 o RESISTOR 20 100 gt 2 LR ae C 407 7 P RESISTOR 5 50 C 57 Sung d 408 lt 8 lt n FAN S FREQ CONTROL POTENTIOMETER 10K d 41 EN 409 92 O Ger ON TIME CONTROL POTENTIOMETER 10K 2 STEP orr TI 410 10 y 2139 07 BACKGROUND POTENTIOMETER 10K TRIGGER PULSE Hr ATI salle E 5 TRANSFORMER DOWN SLOPE POTENTIOMETER 10K TT W ta S PRIMARY INPUT POWER SWITCH o E BYPASSI THERMOSTAT TRANSFORMER POLARITY SWITCH 260 N STABILIZER THERMOSTAT MICROSWITCH ON POLARITY SWITCH EC E k PC BOARD MAIN POWER SCR S 1 12345678910 GAS SOLENOID
23. Y Y YT BEIEN 32111 S45 G4 es TG 322 42 54 G2 e EEE T1 olo MODE o J4 e w 2 p gt 6 gt 217 POLARITY SWITCH MICRO SWITCH N c lt SE gt T 220 AC A C D E B F OPEN Sic m li DC B D C E AF G H CLOSED 515 pe S 218 DC B D A E C F G H CLOSED 232 4 ER ER Do REAR GANG MICRO SWITCH D i C8 TAG clic SZA NO 15A SH w lt 1 lt ii S SC STICK AUTO BAL REMOTE P FLOW THERMAL 331 g lt 6 NE 233 YOY A e A e Ae M ENX 380 We 9 E C E R B R w B 16 w B W B 18 W 4 DCH Ji 5 mam NS p lt ODO gt Ey 333 a 1 ge 8 lt ZS 2 wae LO I 334 m CR4 2 6 bel B 9c 5 D Q O gt 1 252 i S S 4 V S 253 PP d om 263 234 L7 e s SV2 2 4 382m 2 quam TET venen SHOW Eu 12 3 N z N IN AC POSITION ae ae N D gt 3 gt 271 s Hn gt 11 gt 220B SCH 2 NC B J7 ADVANCED CONTROL PANEL be x gt 6 gt SE POWER FACTOR CAPACITORS 50 460 OPTIONAL OPTIONAL zT J3 208 2 BY PASS CAPACITORS 0047 a 6 Fa gt 5 262 V of R7 L o 2714 BACKGROUND HIGH VOLTAGE CAPACITOR 0015 12kV o O FREQ B ON TIME BACKGROUND DOWN SLOPE 12345678910 13 263 1 A RECTIFIER PHASE SHIFT CAPACITOR 15uF 250VAC pes ET TT a 4 213 269 O R8 O 267 HIGH FREQ PROTECTION CAPACITORS 22 400 gt d 214 D y 271 268 CIRCUIT BREAKER 15 AMP R10 R11
24. olo O o KI 5 0 5 ois g z e 2 ei kd olo cc Cc Return to Section TOC Return to Master TOC G 22 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY BYPASS STABILIZER L10121 1 CODE 10806 amp 10807 NOTE L10121 1 BYPASS STABILIZER ITEM REQ D PART NO IDENTIFICATION C1 C2 C3 C4 C5 C6 C7 C8B 8 T11577 46 05 600V 513490 155 15 250v RI 714648 25 10 DN T 13640 18 320V 160J G 22 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine PRECISION TIG 275 G 23 ELECTRICAL DIAGRAMS G 23 SCHEMATIC BYPASS AND CE P C BOARD S24206 CODE 10893 90 7 LINE 1 U LINE 2 V N Return to Section TOC Return to Master TOC D B2 O 2 2 dud en 2f5V 0047 A 0047 440V 440V o O 2 Ce o o U o fed Sh T o a Return to Master TOC olo eg FRAME GROUND PF ban o 1 ois o g clc FILE NAME 824206 1AA sis o o c
25. A DISTANCE 5 T d 7 7 AC AC D E BF OPEN OUVERT ABIERTO GAS SOLENOID VALVE 115VAC c lt ai REMOTO b TLA S s L 217A DC B D C E A F G H CLOSED FERM CERRADO WATER SOLENOID VALVE 115VAC OPTIONAL 5 2 59 co mo gt 9 gt 218 C Lou B D A E C F G H CLOSED FERM CERRADO T2 HIGH VOLTAGE TRANSFORMER VA VU KS J 1o 216 T2 HIGHVOLTAGETRANSFORMER u olo E B S2A No 1 77 REMOTE POST FLOW THERMAL w lad Os ta 19A 0162 CONDENSATEURS FACTEUR DE PUISSANCE 50 460 STICK QUILIBRE DISTANCE ECOULEMENT DE POTEA THERMIQUE 331 lt SCR3 NC ged RS CAPACITORES DE FACTOR DE POTENCIA 50 460 ELECTRODE BALANCEADO REMOTO FLUJO DEL POSTE TERMAL B X6 VARILLA 3 es T im W 24 C4 C5 CONDENSATEURS DERIVATION 0047 HRS HE HG HG H EI 3 CAPACITORES DE DERIVACI N 0047 t 755 7 vo bi B 333 lt 7 J10 lt 4 8 0 1 Y ce CONDENSATEUR HAUTE TENSION 0015 12kV Se Me HP S v SCRA l 8 D CAPACITOR DE ALTO VOLTAJE 0015 12kV 5 Q o i 73994 e Line m A O Q C7 CONDENSATEUR DEPHASAGE 15M7250VCA 8 8 8 2 8 w Leone gt 1 252 A CAPACITOR DE CAMBIO DE FASE 15uf 250VCA L L L L a og o g cs C amp C9 CONDENSATEURS DE PROTECTION HF 22 400 e s 25 Land DE CAPACITORES DE PROTECCI N CONTRA ALTA 405 270 A T FRECUENCIA 22 400 ADVANCED CONTROL PANEL OPTIONAL E no e A PANNEAU DE COMMANDE AVAN
26. Actuate the trigger a second time during down slope to activate up slope and restart 2 Step eps 12 17 07 JRH PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC B 11 OPERATION B 11 FIGURE B 4 3 8 FIRE SL 8 5 Sls n 012 eee START CRATER CURRENT ci 5 4 Step Trigger Modes n UP SLOPE Belg DOVVN SLOPE o o po Torch Button 1 a NW SG E Je NS Output Current Pre Flow Post Flow Pre Flow Post Flow Gas E m E O Normal Sequence Hold the first trigger pull to maintain c m the starting current and delay slope 2 Sls o o 4 Step Restart Enabled du T clc With DIP Switch 43 ON 313 T 16151 JU pr am Button J EN N N d 277 N i LE E Output Current Pre Flow y m Hold the second trigger Actuate the trigger Actuate the trigger Or actuate and hold the trigger pull for more than 1 holding it less than 1 again during during dovvn slope to immediately O O second to activate the second to begin down slope to end down slope and maintain O O restart function When the normal down slope immediately end crater current Hold the trigger for E trigger is released The following two down slope and stop more than 1 second to activate the up slope will occur options are available restart function When the trigger 5 D during the normal is released up
27. CAPACITORS MED 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS hms 1 4W UNLESS OTHERWISE SPECIFIED DIODES 14 400Y UNLESS OTHERWISE SFECIFIED A SUPPLY VOLTAGE NET 0 POWER SUPPLY SOURCE POINT Y COMMON CONNECTION F T FRAME CONNECTION EARTH GROUND CONNECTION THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL te OTHER PARTIES R USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INFORMATION REFERENCE EQUIPMENT TYPE PRECISION TIG 275 375 PAGE 05 OF 05 WITHOUT AFFECTING THE INTERCHANGE DRAWN BYe2IMK Sr mama ABILITY OF amp COMPLETE BOARD THIS T A SUBJECT SCHEMATIC CONTROL PCB Wes SOME DIAGRAM MAY NOT SHOW THE EXACT ENGINEER TN SCALE THIS N VUTT UT G 4762 A COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER APPROVED DRAWING oiseasttion NA DATE 7 27 2007 nungen 8261 amp 162 1A NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual PRECISION TIG 275 G 18 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY CONTROL ABOVE CODE 11000 G4763 1 NG PROGRAM X20 WTH ITEM 8 ANDLABEL X20 WITH PART NO OF ITEM 8
28. ITEM HEQ D PART NO IDENTIFICATION C 1 C2 S23020 3 CAPACI TOR PM 0047 440V AC C3 C4 S23020 2 CAPACI T R PEMF 2 2 275VAC Return to Section TOC Return to Master TOC olo O o zm 5 0 5 ois g z e 2 ei kd olo cc Cc L 10882 4 3 20 98 BOTTOM VIEW Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the id machine ELECTRIC PRECISION TIG 275 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O o fed o o U o fed T o cc Return to Section TOC Return to Master TOC O O o o o SL G 25 ELECTRICAL DIAGRAMS SCHEMATIC TIG OPTION P C BOARD BELOW CODE 11000 G4039 PAGE 1 zarar Yare 1 2 Ven R47 oiw blur 1 Sov 01W Vo 07 Wik Soy HK Ven jiw 028 iK gl R29 e Div ae a D A 45 R30 GND 8 y G
29. PRECISION TIG 2 5 es For use with machines having Code Numbers 10806 10807 10893 11158 11159 Return to Master TOC View Safety Info 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 Return to Master TOC View Safety Info 3 e 2 a 0 Gio 2 el JE 315 oc uu SERVICE MANUAL ax xuu LI MCOLN 3 Copyright O Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC View Safety Info SAFETY A WARNING AN CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above Fo
30. b S v un im 50668 13 V V ano A Bc PEN y au SS 400V 7 CONTROL VOLTAGE C45 Ca 10V 2 METER ACTUAL LOK CLAMP LIMITS MAX ME 3 1022uF 10 V LTS 600 AMPS R278 R126 SCR FIRING ANGLE amp ook ev r soy Raz e EMITS BIGGEST VOLTAGE AUTD HIGH e 1 A O G k LOWEST OUTPUT amp 10K O m R302 M ang GND O O SHE m e 211 ES x C33 FE E FI EL Su Vy olur n Sov c ON IN AC TIG BEFORE le GM 7 o olo OUTPUT ENABLED sg LsK 10Y m mmm 079 DND o 15V 121 WOULD MAKE SHT 2 e 9 8 Y no O 8 S GAINS 33 4 SOFT START 475K L 7 Che SEA d RS ED nd 40668 6 5 Ru Hs SHT 2 062 1 yi BALANCE m en 1 i OI BODA 0007 n n wp ys E d 2244 HIGH STICK MODE OR OC ec d Va S 33 CA 42 SCH 101 L V E x d ES n GND 22 B SV M n TUF I 10K 8 S y SV gt 221K Z 029 23 2 TRIM OFFSET FOR 18 AMPS A D Zou T MODE NO BACKGROUND 2 m X E Ve Ven 475K c R355 R96 TK ZAV USW H 2 E TGR 07 50V 63V 10V 1A FR EH 400V H15V C29 2 200uH 022 gs 0 904 7uF V ano sv ALA Sov LW 4 00Vj p 017 06 app SCR3 CATHODE J 6 gt J 4 Y 0 LODY LOOV AEN PULL LOW TO OISABLE QUTPUT 7 en 3ov uu EN 2 iid 093Bg 820pF vi l 10 Ce M sno 5 RAG 5 in gi Er m a e xi SCRL GATE Ven 03 i N e KL D 13 332k Z E p 3 1 10938 3
31. 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 reconnected panel Welder supply line entry provision is in the case rear panel Entry is through a 1 75 inch 44mm diameter hole in the case back Appropriate supply line strain relief clamp is provided by installer See Figure A 1 All connections should be made in accordance FIGURE A 1 Orit E a 4 vi CONNECT INPUT ka POWER LEADS Ki D E El KE CONNECT INPUT CONNECT INPUT GROUND LEAD B VOLTAGE LEVEL eS 1 1 with all local codes and national electrical codes Installation by a qualified electrician is recom mended PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a o lx ole cre 312 ol o cic Return to Section TOC Return to Master TOC A 6 1 Connect the terminal marked below the recon nect panel to an earth ground 2 Connect the input leads to terminals marked L1 U and L2 V on the reconnect panel Use a single phase line or one phase of a 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 co
32. 7 16 Open End Wrench Allen Head Type Wrenches PRECISION TIG 275 LINCOLN F 59 F 60 TROUBLESHOOTING amp REPAIR F 60 olo o SCR REMOVAL AND REPLACEMENT continued 2 2 Figure F 16 SCR DETAILS oic p 2 2 Gate E z Anode Glo Cathode olo Outer Metal O O Ring ope m 3 SPECIAL INSTRUCTIONS 5 Clean the area on the heat sink around the e S o SCR mounting surface using a putty knife E NOTE Before disassembling the existing recti or similar tool DO NOT SCRATCH THE fier note toward which heat sink the outer SCR MOUNTING SURFACE metal ring of the power SCR is mounted Also c a note the positioning of the gate lead of the 6 Polish each heat sink s mounting surface SCR Failure to reinstall the new SCR in the using NO 000 fine steal wool Wipe surface same orientation as the original may result in clean with a lint free cloth or paper towel subsequent damage to the new SCR and 7 Inspect the mounting surfaces of each new other components of the welder See Figure SCR F 16 a Remove all burrs and wipe clean Do A CAUTION not use steel vvool or any abrasive cleanser on the SCR mounting sur The unclamping and clamping procedure out faces lined below is critical for the prevention of internal SCR damage Failure to follow this 8 Apply a thin 0 001 to 0 003 layer of procedure may result in subsequent damage PENETROX A 13 Lincoln Electric
33. DISTANCE C7 5 PIECE EJEMPLO ESTE ES EL PIN 1 DEL Wl y OF CONNECTOR ON PC BOARD NEGRO ROJO BLANCO APT RECEPTACULO REMOTO e d J REAR ELECTRODE AVANT papa io CONECTOR J5 DEM VUE DES CONNECTEURS SUR CI G GREEN BBLUE Y YELLOW olo CSTARTERASBLY Ener og ELECTRODO FRONTAL VISTA DEL CONECTOR EN LA VERT BLEU JAUNE w 2 L N C O L N 5 29368 ENSEMBLE DEMARREUR DARC ELECTRICAL SYMBOLS PER E1537 TARJETA ELECTRONICA VERDE AZUL AMARILLO cic e ENSAMBLE DE ARRANCADOR DE ELECTRODE ARRIERE SYMBOLES LECTRIQUES SELON E1537 O ORANGE A ARCO ELECTRODO POSTERIOR SIMBOLOS ELECTRICOS CONFORME A E1537 NARANJA 2 z ELECTRIC CLEVELAND OHIO cr ele I cc NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN ELECTRIC PRECISION TIG 275 5 ELECTRICAL DIAGRAMS Ge SCHEMATIC ENTIRE MACHINE BELOW CODE 11000 G4075
34. E o o Cw ai i E 90 50V 10V 310 m 012 JM E 1 I i 1 i n 1 1 i OPEN 1 2 WHEN 2X i HE We m m ES Vivo Vos d E t nGAS_TIME2X Vw POSTFLOW I 10K z eat 51 1 bnr re us ma 11 x 40V OC MAX J2 RESERVED FOR ai E i 0 Um q 51 55 2 2 FUTURE USE STICK SW O sv amp 19 09 l f A 0228 gx EI Sp ONE 3 a 7 sele i 50 iW zl og RELAY COIL MUST HAVE n E NOT INSTALLER B SHT 1 475K i i i s FREE WHEELING DIODE 5V MOS 5 4 gt roi orun Vprein om Vann Von S 2 235 gt TK LIFT Ti 56 II m b Y u d t m nLIFT TIG 1 m 432 E GNO i OOo 0 004 7uF Y GNO M ARCEST 5 56 COM av Byg oe s i 1400V 15 e i 1 Y Y Xy nonc Tm ECK eS ADVANCED 723 V ano i DISPLAY SELELT 0 41 m 345 ES CONTROL iv C 2 as V ono i QV 2 huri amp I GENERAL INFORMATION Er 1 DON E y 2 i A9 ELECTRICAL SYMBOLS PER E1537 iud 10 10 i S STICK RED 20mA capacrtORS MFO 022 50V UNLESS OTHERWISE SPECIFIED 7 i O O 4 GND C154 F RESISTORS Ohms 174W UNLESS OTHERWISE SPECIFIED LABELS O E A 0220 Sch 10066 14 400Y UNLESS OTHERWISE SPECIFIED EY uu 1 3V El A P T 1 N A L M lw C POWER SUPPLY SOURCE POINT c S 0 SI LO i COMMON CONNECTION E E O o 2 BA ARCEST i POWER i V TIG STICK IF FROME
35. ELECTRODE BALANCEADO REMOTO FLUJO DEL POSTE TERMAL 981 gs NC es DE OR EATE OAE TET VARILLA vev 7 7 S sp Oc ONDENSATEUR D PHASAGE 15M 250VCA HRS HGK HGH HEX 7 r332 ER o o Qs CF CAPACITOR DE CAMBIO DE FASE 15uf250VCA LC s d A v f ASA y 888 TGS Jo z lt C8 09 CONDENSATEURS DE PROTECTION HF 22 400 alege lt 6 0 1 CAPACITORES DE PROTECCION CONTRA ALTA Ka Ke D1 O N S m p 7334 57 y SCR4 1 M E FRECUENCIA 22 400 8 c 8 8 m b Q CBI DISJONCTEUR 15 AMP N L N MM eh ape Loa 263 e INTERRUPTOR AUTOM TICO 15 AMPS L7 8 CR4 BOBINE RELAI DE 12V CC gt 2 269 4 NN d BOBINA DE RELEVADOR DE 12V DE DC E 2107270 N D D DIODE ROUE LIBRE ADVANCED CONTROL PANEL OPTIONAL e ND gt 3 gt 271 4 E DIODO DE RUEDA LIBRE PANNEAU DE COMMANDE AVANCE OPTION 115 71229A 4 PANEL DE CONTROL AVANZADO OPCIONAL uo Van NC E H INDUTEBISDE SORTIE STARTER T gt 6 gt lt 217A INDUCTOR DE SALIDA ESTABILIZADOR ON TIME BACKGROUND DOWN SLOPE 2 R da m e Z J 8 Lala INDUGTANGES HE O MG ARRI RE PLAN VERS LE BAS PENTE Valdas 292 i NEN 4 R7A mo H7C 218A z INDUCTORES DE ALTA FRECUENCIA O FREQ FONDO ABAJO CUESTA 12345678910 139 263 o SI Lee 5 GE s o R7D 271A L4 L13 STARTERS TOROIDE FR QUENCE RADIO O O YYYYYYYYYY 94 213 R7B m 269 o ESTABILIZADORES TOROIDAL RF Fle RO R10 R11 R12 OR KE g R5 R SISTANCE DEPHASAGE 200
36. U O H1 CONNECTER LA BRIDE SUR HAUT H4 g N A CONNECTION IS PIN TO PIN BETWEEN J23 AND J5 201107 o 2 HANE b Eno a B CONNEXION CONTACT CONTACT ENTRE J23 ET J5 TE PANEL DE CONTROL VISTO DESDE ATR S N B ROBOTIC INTERFACE CONNECTION PN L2 V O z COMO SE MUESTRA olo N C REMOVE JUMPER PLUG IN J3 WHEN INSTALLING By CONNEXION INTEREAGE ROBOTIQUE S1 230 V ba l m ENLEVER LA FICHE CAVALIER EN J3 QUAND ON INSTALLE LE C EN 115VAC laz c TIG OPTION PC BOARD b C8 e CONNECT STRAP TO MID H3 E OPTION TIG CONNECTER LA BRIDE SUR MOYEN H3 515 METER 51 344 bg DECONNECTER LE CABLE DU CAVALIER ENTRE LES CONTACTS 1 E 7 d SE 313 COMPTEUR 2 347 PIN 2 IN J3 TO DOUBLE PREFLOW 8 FOSTFLOW T MES 1777 2 DANS J3 POUR DOUBLER TEMPS DE PREGAZ ET POSTGAZ Ha Hs H AX 208 V ER o MEDIDOR a l 345 N E DISPLAY TOGGLE SHOWN IN M N AMP POSITION L1 U l 233B 3 Lo 231 CONNECT STRAP TO LOW H2 J7 SE BRANCHE LA PRISE A INTERRUPTEUR INF RIEURE ls MID ot H1 5 SUJETADOR DE CONEXION A BAJO H2 S3 HIGH LOW N boss 0001107 A LA CONEXI N ES DE PIN A PIN ENTRE J23 Y J5 Ee C4 G crs id TARJETA ELECTRONICA C REMUEVA EL CONECTOR DE PUENTE EN J3 CUANDO INSTALE LA E COM S xs e 346 N L5 DE CONTROL TARJETA DE PC TIG OPCIONAL SERRE BANIIERD DE RECONNEXION L H2 208V 63 5VAC ol 616 POWER FACTOR CAPACITORS 50 460 N D DESCONECTE EL CABLE DEL PUENTE
37. lead to G and reverse the A and C leads on cathode and G lead to the gate the SCR Close switch SW 1 The voltmeter should read zero If the voltage is higher 7 Close switch SW 1 Switch SW 2 should be than zero the SCR is shorted open The voltmeter should read zero If the voltmeter reads higher than zero the 10 Replace any SCRs that do not pass the SCR is shorted test Seel SCR Bridge Assembl 8 With switch SW 1 closed close switch SW 2 5 for two seconds and release The voltmeter 11 Replace plug J4 on the control board should read 3 to 6 volts before and after switch SW 2 is released If the voltmeter does not read or reads only while SW 2 is depressed the SCR or battery is defective Repeat Battery Test Procedure described in Step 5 12 Replace the case sides and top OO O Io Ir CHS ope o Of a o lx ole cre Sla ol o cic PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC F 39 TROUBLESHOOTING amp REPAIR F 39 TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED TO 2 AMPS DC TIG MODE HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC AC BALANCE CONTROL IN AUTO OUTPUT CONTROL AT MINIMUM This is the typical AC output voltage wavefo
38. remote receptacle for robotic interface its connection plug must be moved from J5 to J5A on the Control board Refer to the machine Wiring Diagram Return to Section TOC Return to Master TOC 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 O O face control setting over the rated output range of the EIE machine opg i D E The diagram in Figure A 4 below shows the remote e O receptacle plug connections and signals for robotic cle interface 5 gt ol o amp m FIGURE A 4 REMOTE RECEPTACLE Front View For 18 12P Plug porre es I ES PRESET CONTROL a INPUT FROM ROBOT 0 10Vdc Rated Output Range Note The Interface connection ARC START cable may pick up noise INPUT FROM ROBOT interference Additional 18Vac 10ma switch bypass filtering circuits may be needed for the external circuits ARC ESTABLISHED OUTPUT TO ROBOT High Not Welding Low Welding OO O Io P Cl ope bo Ola lz ole ci lz ol o cic VJ Robotic Precision TIG Control Common Common PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC A 10 NOTES PRECISION TIG 275 LINCOLN E A 10 OOL Je1sey 01 U
39. 1 1S19400 3012 RESISTOR MF 1 4W 30 1K 1 0 1112 2 122189 CHOKE RF 390UH 596 225MA CONFORMAL R322 I 5194003570 RESISTOR MF 1 4W 357 1 O OCI OCH OCI5 OCIS 4 S15000 16 OPTOCOUPLER TRIAC DRIVER ZVC 3083 R335 R342 R344 R345 OCI3 OCH 2 S15000 31 OPTOCOUPLER TRIAC DRV RANDOM 800V R347 R365 R381 7 5194002000 RESISTOR MF 1 4W 200 1 O O OCI6 OCH 2 1515000 10 1OP TOCOUPLER PHOTO Q OV CNY 1733 R348 R349 R362 R363 4 S19400 20RO RESISTOR MF 1 4VV 20 0 196 01 04 018 3 2704 69 TRANSISTOR PNP 10226 0 5A 40V 2N4403 R357 I 15194001502 RESISTOR MF IAW 15K 195 Q2 Q3 O5 Q6 Q7 Q12 R361 R367 R368 3 s194002231 RESISTOR MF 1 AW 2 21K 196 Q13 Q16 Q17 Q19 R382 I 51940031500 RESISTOR MF 1 4W 150 196 a Q20 Q21 Q22 Q23 19 112 0468 TRANSISTOR NEN 10226 0 34 90V 204401 R301 I 5194005622 RESISTOR MF 1 4W 56 2K 1 o o Q24 Q26 Q27 Q28 Q29 R401 1 T10812 79 TRIMMER ST 1 2W 100 10 LINEAR D D NA 010 011 7130054 TRANSISTOR NMF T0220 15A 60V 85 R414 I 5183805 THERMISTOR P TC 0 5 1 17 OHMS 0 5A NK NL NA 025 1 2704 73 TRANSISTOR MME 4 PIN 1A 100V IRFD110 SS TL T2 2 112737 2 TRANSFORMER PULSE 3 WINDING 1 1 1 a R2 1 0812 41 TRIMMER ST 1 2W 10K 1026 LINEAR TPL TP5 TP6 4 113640 25 MOV 130VRMS 90 20MM o gt R3 R5 2 516296 3 TRIMMER MT 1 2W 500 10 LINEAR TP2 1 1113640 16 MOV 150VRMS 80J 20MM D R4 R7 2 0812 73 TRIMMER ST 1 2W 2K 10 LINE AR
40. 2 STEP Trigger after Opened 4 STEP Trigger Re opened Downslope Time CRATER FILL LEVEL Advanced Panel DIP sw Select Mach Min or MIN Setting as w o Panel DOWNSLOPE POSTFLOW Adjust 0 10 sec Adjust 2 60 sec w Advan Panel or x2 Fixed 0 sec w o CRATER FILL TIME Manual in 2 4 Step w Restart Disabled Return to Section TOC Return to Section TOC OO O Io Ir CHS ope 1 Ola lz ole cre 512 ol o cic Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Setup for TIG Amptrol Welding Standard Controls Power Switch ON Mode Switch TIG AC Balance Polarity Switch AC or DC More for alum ide 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 Amptrol output level Minimum Output Press Display switch Fas meme RUD UA and Set to desired min Min to Max 2 Max to Min Amptrol Start Crater Amptrol Amptrol output level Ki y NS Postflow NEM on Set as low as required Higher for larger o a o tungsten and current Advanced Panel If used Trigger Switch 2 STEP Pulse Frequency 4 6 pps is a typical initial setting 25 75 Set for bead shape and travel speed or Higher for thinner plate and faster travel Lower for thicker plate and slower travel On Time 40 60 is a typical initial
41. 275 machine should be approximately 0 5 or 0 10 volts 2 Locate and remove plug J4 from the control 5 Battery Test Check the battery by shorting board See Figure F 7 leads A and C and then close switch SW 3 Perform the following test for all four SCRs 1 Replace the battery if voltage is less than Sed Figure F 8 4 5 volts O lo O o Ir CHS ope Ola o c ope cre 515 ol o cic PRECISION TIG 275 LINCOLN E geri Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS olo 1 Of a lz ole cre Sla ol o cic Return to Section TOC Return to Master TOC F 37 TROUBLESHOOTING amp REPAIR F 37 ACTIVE SCR TEST continued Figure F 8 Active SCR Test Set Up SW1 R2 d el Ev R1 sw2 6 volt lantern Z battery G SCR under test R1 4 ohms 10 watts R2 3 ohms 10 watts Resistor values are 10 PRECISION TIG 275 LINCOLN amp F 38 TROUBLESHOOTING amp REPAIR F 38 ACTIVE SCR TEST continued Figure F 9 SCR Gate Locations LIFT BAIL STABILIZER Return to Section TOC Return to Master TOC SCR4 CATHODE SCR3 CATHODE SCR1 SCR2 CATHODE SCR3 SCR4 ANODE SCR2 ANODE Return to Section TOC Return to Master TOC 6 Connect SCR into the test circuit as shown 9 Open switch SW 1 disconnect the gate lead ini Figure F 8 I A Lead to anode C
42. 3 WOU ISS MOUS Cu NE ac dio aia F 4 2 Test Procedures Meter Calibration Adjustments 8338833888 3 3333333 nnns F 19 High Frequency Circuit Disable Procedure 2 2 F 23 Protection 2102 1 F 25 T1 Main Transformer Test ab ind UU tie F 27 Gas Water Solenoid Test F 31 006 EE RR o F 33 Active SCR A F 35 O Typical Output Voltage Waveform Tig Model F 39 O Typical Output Voltage Waveform AC Tig Mode F 40 5 Typical AC Voltage Waveform 50 AMPS AC Tig F 41 Y Typical AC Voltage Waveform 2 AMPS AC ToMode F 42 Typical Output Voltage Waveform 200 AMPS DC Tig Mode F 43 O E 5 Replacement Procedures High Voltage Transformer Removal amp 1 F 45 Control Board Removal and 1 F 49 SCR Bridge Assembly Removal and Replacement F 53 Polarity Switch Removal and 4 F 57 SCR Removal and 4 F 59 Retest after Repair 61 O O E 9 i B o an PRECISION TIG 275 LINCOLN Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master
43. 4 STEP Trigger Re closed or 2 STEP Trigger Opened ON TIME Adjustable 5 95 B 12 4 STEP Trigger Re opened after Downslope Time CRATER FILL LEVEL Advanced Panel Select Mach Min or MIN Setting as w o Panel 0 1 20 pps Start SETTING i Adjustable 2 50A BACKGROUND Adjustable MIN Setting 100 Peak PREFLOVV UPSLOPE Fixed 0 5 sec Fixed lt 0 5 sec or x2 w o Amptrol START TIME Manual in 4 Step DOWNSLOPE POSTFLOW Adjust 0 10 sec Adjust 2 60 sec w Advan Panel or x2 Fixed 0 sec w o CRATER FILL TIME Manual in 2 4 Step w Restart Disabled CODES ABOVE 11000 K2621 1 With PULSE ON No Pulsing During Upslope Time or When Downslope Drops Below Background Setting 2 or 4 STEP Trigger 4 STEP Trigger Closed 1 Open HOT START Default 0 Menu Set MAXIMUM OUTPUT SETTING Adjustable 2 Max A Amptrol or Remote PEAK Range PULSE FREQ Adjustable 0 1 20 pps ON TIME Adjustable MINIMUM OUTPUT 5 95 Start SETTING Adjustable 2 50A SPOT TIME Adjustable 0 5 5 0 sec nn m m m m UPSLOPE to output setting Default 0 5 sec Menu Set PREFLOW Default 0 5 sec Menu Set BACKGROUND Adjustable MIN Setting 100 Peak START TIME Manual in 4 Step PRECISION TIG 275 LINCOLN 4 STEP Trigger Re closed or
44. 4E2529 of the SCR Handle all SCRs with care or PENTROX A heat sink compound to each heat sink s SCR mounting surface a Care must be used to prevent foreign PROCEDURE material contamination of the SCR to heat sink junction OO O Io Ir CHS ope o Of a o lx ole cre 515 ol o cic 1 Remove the main input supply power to the machine 9 Place the new SCR between the heat 2 Perform the SCR Diode Rectifier sinks Be sure that the outer metal ring of z the SCR is facing toward the same heat Assem emoval procedure sink as the old SCR s metal ring Be sure 3 Using a 7 16 open end wrench alternately that the roll pin of the heat sink engages loosen nuts 1 2 turn each until heat sinks the hole in the SCR The SCR contact are loose Remove nuts and leaf spring IT surfaces must sit flat against both heat sink IS RECOMMENDED THAT NEW HARD surfaces WARE LEAF SPRING AND H ING BE SSES 10 Perform the SCR Diode Rectifier USED FOR ASSEMBLY Assembly Replacement Procedure 4 Remove the old SCR 11 Replace the case sides and top PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O c o 02 E D Return to Section TOC Return to Master TOC O O ES i o as F 61 TROUBLESHOOTING amp REPAIR F 61 RETEST AFT
45. 5 125 0 5 22 25 PRECISION TIG 375 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Io Ir CHS ope bo Ola lz ole cre Sla ol o cic Return to Section TOC Return to Master TOC F 57 TROUBLESHOOTING amp REPAIR POLARITY SWITCH REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the polarity switch MATERIALS NEEDED 3 8 Nut Driver 1 2 Wrench 7 16 Wrench Phillips Head Screw Driver Slot Head Screw Driver 2 Required PRECISION TIG 275 LINCOLN F 57 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a o lx ole cre Sla ol o r l Return to Section TOC Return to Master TOC
46. 8 Kee B 406 ES mM D E 8 8 2E E 2812 d umm Jk EA ae L16 Cea N z A IN AC POSITION B 3c N D N m SC gt 11 gt 220B DE y N C E 5 gt 6 265 POWER FACTOR CAPACITORS 50 460 OPTIONAL ADVANCED CONTROL PANEL evo M OPTIONAL mn 43 941 3 12 266 7 BY PASS CAPACITORS 0047 Do 3 5 262 V ot R7 271447 BACKGROUND HIGH VOLTAGE CAPACITOR 0015 12kV O 4 Eer 263 ee B RECTIFIER PHASE SHIFT CAPACITOR 15uF 250VAC O FREQ ON TIME BACKGROUND DOWN SLOPE 12345678910 o bd de O 7 A 54 213 ER 269 R8 HIGH FREQ PROTECTION CAPACITORS 22 400 Ec 244 CIRCUIT BREAKER 15 AMP Lir R40 R11 R12 OR wc 12V DC RELAY COIL cls P gt T 201 oN FREE WHEELING DIODE o 2 UTG C d V EELER b zi T 270 BACKGROUND DIODE L 401C db el W209 OUTPUT INDUCTOR CHOKE o E co 2 12345678910 16 9 R210 00 HIGH FREQ INDUCTORS 5 Oa Ago 2320 sa YYYY 220B RF TOROID CHOKES d 2 Q i i s m m C 220A OUTPUT CONTROL POTENTIOMETER 10K ld d Fd od dd BALANCE CONTROL POTENTIOMETER 10K olo pr 184 quli M POST FLOW POTENTIOMETER 10K 110 li de Eos 3 MIN OUTPUT POTENTIOMETER 10K els deren eh eege 1 404 H PHASE SHIFT RESISTOR 200 100 S 1 m deg JZ 256 2 lt HOLDING RESISTOR 50 225 15 o IA 8 Ae cac O 6 RESISTOR 20 100 5 ER NE D d EH V 407 7 E E SSC N RESISTOR 5 50 mo 1 89 L 408 lt 8 FAN O
47. CONNECTION SHT ME q GN L EARTH GROUND CONNECTION o U ASS eg 416V UNREG 15V ge EE ER ER NE EE 1 16Y 1 ARCEST F 1 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATEB ml I SHT1 SHT 1 SHT 1 PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC 2 7 086 HIGH ARC ESTABLISHED dini N p v i 00 i SINCE COMPONENTS OR CIRCUITRY Ieren INFORMATIDN reference EQUIPMENT TYPE PRECISION TIG 275 375 PAGE 02 OF 05 ROBOTIC COMMON 00874 45V z l 10Vref 10V o o 1424 50V SV 10Vre 10 i WITHOUT AFFECTING THE 1557177 DRAWN BA IMK T SCHEMATIC CONTROL PCR DEUMENT DOCUMEN PE GND 557 DO s DO k p DIAGRAM MAY NOT SHOW THE EXACT ENGINEER OM TN QNT SUBJECT TUS er Di 7 1 ep UMEN LE COMPONENTS DR CIRCUITRY OF CONTROLS MATERIAL A 97 2 HAVING A COMMON CODE NUMBER PAPPROVED DRAWING Al NA NA part 7 27 2007 homeen CRM38261 10 312 i D r ic NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E ELECTRIC PRECISION TIG 275 Return to Section TOC Return to Master TOC Return to Section TOC olo O o FIRE oiz RE 15 olo cc Cc Return to Section TOC Return to Master TOC Return to Master TOC G
48. EE EE a E EEE EE EE St c olg a ox mm am PART NUMBER DESCRIPTION d 2 REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW REFERENCES QTY PARTNUMBER DESCRIPTON O O U U O 9 Cl C2 C4 C5 C7 C9 C10 C14 C15 C16 C17 C18 E C19 C21 C22 C23 C24 C26 C27 C28 C29 C30 C31 5 c c C32 C33 C34 C38 C39 C40 C41 C42 C43 C44 C45 HE CAPACITOR SMD CE RAMIC 0 1MF 50V 1096 X7R S 0805 C47 C49 C50 C51 C52 C53 C54 C55 C56 C57 312 ceco 2 12502055 CAPACITOR SMD CERAMIC 2700pF 50V 5 X R 50805 CIL C12 C13 C35 C36 C37 C46 C8 8 S25020245MT SMD CERAMIC LOMF 25V 10 X7R 51206 104 05 06 07 REVISION CONTROL D mm mm 8 250061 ZENER DIODE SMD OSW S IV SSSODIH o G4040 2F0 N D 5 N D PART NO IDENTIFCATION CODE TEST PER E3937 AC 25050 1SMT R1 R13 R26 R66 R87 R93 R105 R126 R163 R164 COAT WITH E1844 AND E3668 1 CONT EACH 71 SCHEMATIC REFERENCE G4039 2F0 R2 R3 R4 R5 R8 R12 R43 R47 R68 R88 R90 R108 19 525000 10015 BUY DETAIL MAKE DETAIL R109 R112 R122 R145 R146 R147 R160 TUT R6 R10 R14 R16 R17 R18 R21 R28 R29 R32 R33 BUY PER E3867 MANUFACTURE PER E1911 ROHS R48 R52 R53 R56 R61 R63 R64 R65 R89 R92 R101 BUY BLANK COMPL
49. Je1Se A 01 Ulm ki NOL 491SEVN 01 Ulm ki NOL Je1Se A 0 Winey NOL uonoeg oi OOL uonoeg oj NOL uonoeg oi OOL uonoeg oj Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Cl ope ao Of a lz ole ci lz ol o cic Return to Section TOC Return to Master TOC F 31 TROUBLESHOOTING amp REPAIR GAS WATER SOLENOID TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will help the technician to determine if the solenoid is receiving the correct voltage also if the solenoid is functional MATERIALS NEEDED 3 8 Nut Driver Voltmeter Ohmmeter Multimeter Isolated 115 VAC Power Supply PRECISION TIG 275 LINCOLN amp F 31 F 32 TROUBLESHOOTING amp REPAIR F 32 O lo fo GAS WATER SOLENOID TEST continued
50. METAL FILM 1 10W 1 00K 196 S 0805 5 NZ NJ APPLY ITEM 3 TO CONNECTORS PLASTIC MOUNTING PINS R145 R146 R147 R174 O A R179 5 EC NE NF o EN d olo RESISTOR SMD METAL FILM 1 10W 1 82K 1 50805 19 cic el RESISTOR SMD METAL FILM 1 10W 31 6K 1 50805 513 ER o R96 1 15250842SMT THERM ISTOR SMD PTC 0 35 1 40HMS 2 04 00 60801 108 1722 2 RESISTOR SMD ME TAL FILM 1 10W 9 09K 196 5 0805 REVISION CONTROL RESISTOR SMD METAL FILM 1 10W 2000HMS 1 50805 A G4761 1A0 SS ad i RESISTOR SMD METAL FILM 1 10W 16 5K 1 S0805 PART NO IDENTIFICATION BT 1 15198698 SWICHDIP SPST 8 CIRCUITS SET SWITCH POSITIONS CODE 2 SI512811S5MT ICSMDCOMPARATORQUAD290D po r Saos COAT WTH E1844 AND E3668 NA wf 7 S1512845MT 5 GEN PURPOSE 24D 07 00 SCHEMATIC REFERENCE G4760 1A0 e 2S 15018 6SMT__ IC SMD CMOS SWITCH ANALOG QUAD 4066BD SS i np XOMA 1 MAKE DETAIL 1 25073 125 IC SMD CMOS PSOC 8BIT CY8C27643 TFN495S MANUFACTURE PER E1911 6 2 1525065 35 IC SMD CMOS INVERTER SCHMITT HEXVHCIA SS 6BOARDS PER PANEL UNLESS OTHERWISE SPECIFIED Se Kan CAPACITANCE MFD VOLTS ALAYER BOARD BLANK PANEL INDUCTANCE HENRIES RESISTANCE OHMS ALL COMPONENTS AND MATERIALS USED IN THS ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 SEE ELECTRONC FILE FOR ADDITIONAL INFORMATION THIS DO
51. MOV 150VRMS 80J 20MM qa T r q z 6 T 3640 18 MOV 320VRMS 1504 20MM old ya g n a uxuulnl U LUL Umm m EE k ER SS o AT B3 B5 318180963 TRIMMER MT 1204500 10 C LINEAR TRH TRI 2 S18395 27 TRIAG T220 8A 800V WITH S18104 3HS Ra PA ME MD TRIB 2 81516127 TRIAC T2208480V 00 R2 1 Tl0812 41 TRIMMER ST 1 2W 10K 10 LINEAR 1220 8A 0 ITEM REGD PART NO DESCRIPTON HORT 5 mo812 73 TRIMMER ST IPW K JE ENERA N AD 1 81501815 IC CMOS GATE NAND 2 INPUT QUAD SCHM SS R6 1 516296 5 TRIMMER MT 1 2W 10K 10 LINEAR N A X2 X11 2 9150184 IC CMOS INVERTER SCHMITT HEX 4584 SS 1 1 SEEBLANKINFO PC BOARD BLANKREF Re Rie Ria R gt leigo 2805007 X3 1 ST5128 10 VOLTAGE REF ADJ PRECISION 4311 nm 2 592 E2981 7 SEALANT R172 R317 R356 940071000 MAIS X10 Xi4 3 S15018 6 IC CMOS SWITCH ANALOG QUAD 4066 85 3 300 PCB SUPPORT R9 R91 R116 R117 i X5 1 51839538 REGULATOR HEAT SINKASBLY S15128 6 S18104 3 c R350 Tome PR X6 X8 2 15183953 REGULATOR HEAT SINKASBLY S15128 5 818104 3 R10 R98 4177 R278 5 st94o0 4750 RESISTOR MF 1 4W 475 1 7 X12 X13 X16 4 S15128 4 OP AMP QUAD GEN PURPOSE 224N 5 R336 X8 1 51512818 OP AMP QUAD HIGH PERF 33074 fed 11 R17 R21 R22 N A X15 1 8254312 ROM ASSEMBLY SS ER o NOTES R24 R29 R31 R32 X17 1 15102 4 IC ARRAY DRIVER PERIPHERAL NPN DARL 5 7 E 7 N A x18 1 M15102 3 IC CMOS UNDERVOL
52. Process panel or harness is defective The machine does not respond no gas flow no high frequency and no open circuit voltage when the arc start switch or Amptrol is activated The thermal light is not lit NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced Process panel or harness is defective POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 The welding application may have exceeded the recommend ed duty cycle Allow the fan to cool the until the thermal light is off 2 The air louvers may be blocked Remove the air obstruction and allow the unit to cool 1 Make sure the machine is in the TIG mode The Amptrol or arc start switch may be defective Check for continuity zero ohms between pins and E on the cable connector when the Amptrol or arc start is pressed Check the Local Remote switch for proper operation F 6 TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION One of the thermostats may be faulty Check or replace See the Wiring Diagram Check for loose or faulty wires on the thermostats and associat ed circuitry See the Wiring Diagram 3 The fan motor may be faulty or mechanically obstructed The fan should run when welding or when a thermostat is open 4 The control board may be faulty 1 Perform thel Protection Boa
53. TOC OO O Io Ir CHS OTL o Of a o lx ole cre 512 ol o r l Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE Ai WARNING Service and repair should be performed by only 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 malfunc tions Simply follow the three step procedure list ed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into four main categories Output Problems Function Problems Cutting Problems and LED Function Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted without removing the case wrap around cover Step 3 RECOMMENDED COURSE OF A
54. Vas m 3 SC SE 10Vref 2218 e M GNA d 1122 m on 1 s ad 07 m ATSR i SOTA 59 020 HH ig I 1 V P axi mp eee gt lor END bulur dv gt GAS p ICONTROL BOARD 12 1 4 q 1 nl 50V R372 i SPLCLK 1 ai Vprein SV SDL ES D O 332 GND pm Pro 56 2K nINTERL CK gt 4373 E 9sPLSS g UK ISK 30744 100 E MO most i OD 247 gm 2288 ale j POT y ise v D i gt MISO 2 cH Vi BAD eg a E n bi l v r aa O4uF I l 4 50V 332018 332 ISP inin 5V 2 16V UNREG I O O GND nTRIGGER E d COOLER RECEPTACLE RELAY p i Au SUK i i JUL 12 Y BE COM D224 Q 3 1 34 R amp 21 1201 CLK Fg 3 A 18 3 4 ag wi L 1 i I 1 uz 0201 091 S 3755 1100 1 ol b 087 iw GNO 1 He DATAL act ATA 2 2 Ka bon 1 14 C LOCAL 100K SH m LAM d 15Y x FOR PSOC DATA H 43 13 o H E I PROGRAMMING N 1 CH DATAL m Laz 1 aa 2202 JUMPER WHEN I H E GND 1 na 502 7 Iv 100V 1 0261 METER BOARD 1 S 20 415 O o V i lt 4 POST_FLOW por CONNECTED a z i POST_FLOW gt 1 50y j POST FLOW o Xi4 i A3 Ho 2 SOV VEND 2 b i 02 REMOTE T mmm bara xasan anlam I 1 I 0217 1 i GND 1 51V cisi xP olo aos US b YA o 1 S 20 1 E d q P LB 100 d T gt 2 2 i T 7 Sy R402 MELK 43 Ao i i 2 E ane p 5 imi 18V 13 if l f 1A Sum F 3 5 i 50V 4
55. Voltage 10 Max Amps With Out Max Amps With Number Power Factor Capacitor Power Factor Capacitor 40 AC DC Stick Balance TIG Unbalance 70 Penetration AC TIG 60 104 94 47 80 72 36 124 112 56 95 86 43 AC DC Stick Balance TIG 86 78 39 64 58 29 Unbalance 70 Penetration AC TIG 208 230 460 95 86 43 62 56 28 100 AC DC Stick Balance TIG Unbalance 70 Penetration AC TIG Idle Amps 4096 AC DC Stick Balance TIG Unbalance 7096 Penetration AC TIG 6096 AC DC Stick Balance TIG Unbalance 7096 Penetration AC TIG 100 460 575 AC DC Stick Balance TIG Unbalance 70 Penetration AC TIG 77 70 35 55 50 25 73 66 33 40 36 18 6 5 3 36 32 16 Idle Amps ddePower 300W 500W 40 AC DC Stick Balance TIG 95 55 50 80 46 43 Unbalance 70 Penetration AC TIG 109 63 58 86 50 46 6096 AC DC Stick Balance TIG 80 46 42 64 37 34 K1827 1 Unbalance 7096 Penetration AC TIG 220 230 85 49 45 67 39 36 10096 380 400 415 AC DC Stick Balance TIG 70 41 37 52 30 28 Unbalance 70 Penetration AC TIG 65 38 35 46 27 25 IEC 60974 1 Idle Amps 10 6 5 23 13 12 Idle Power 400W 5OOW RATED POWER FACTOR STICK K1825 1 K1826 1 amp K1826 2 K1827 1 RATED OUTPUT NEMA EW1 Class l 40 K1825 1 K1826 1 2 K2619 1 2 Duty Cycle Applications Volts at Rated Amperes Amps 40 AC DC Stick Balance TIG Unbalance 70 Penetration A
56. 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 A WARNING DISCONNECT STICK ELECTRODE WELDING CABLE WHEN TIG WELDING EVEN THOUGH HI FREQ IS NOT APPLIED TO THE PRECISION TIG STICK TERMINAL IT WILL BE ELECTRICALLY HOT TO WORK WHEN TIG WELDING PRECISION TIG 275 LINCOLN E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a o lx ole cre 312 ol o cic Return to Section TOC Return to Master TOC A 7 INSTALLATION A 7 FIGURE A 2
57. aaa NEU EEN Section G Wiring Diagram Entire Machine Code 10806 G4031 sese G 2 Wiring Diagram Entire Machine Code 10807 DAT G 3 Wiring Diagram Entire Machine Code 10893 G4031 2 G 4 Wiring Diagram Entire Machine Code 11158 DG G 5 Wiring Diagram Entire Machine Code 11159 DI G 6 Schematic Entire Machine Codes below 11000 G4075 G 7 schematic Entire Machine Codes above 11000 ben G 8 Control P C Board Schematic Codes below 11000 G3908 Page 1 G 9 Control P C Board Schematic Codes below 11000 63908 Page 2 G 10 Control P C Board Schematic Codes below 11000 63908 Page 3 G 11 Control P C Board Assembly Codes below 11O0012000 21 G 12 Control P C Board Schematic Codes above 11000 G4762 Page 1 G 13 Control P C Board Schematic Codes above 11000 G4762 Page 2 G 14 Control P C Board Schematic Codes above 11000 G4762 Page 3 G 15 Control P C Board Schematic Codes above 11000 G4762 Page 4 G 16 Control P C Board Schematic Codes above 11000 G4762 Page 5 G 17 Control P C Board Assembly Codes above 11000 4763 1 2 G 18 Protection P C Board
58. 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 e 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 In either position the arc start switch functions when connected to the Remote receptacle See Item 11 In 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 6 MAXIMUM OUTPUT CONTROL The large knob is used to set the output welding current over the rated output range of the machine e With the Current Control switch to LOCAL position this knob sets the
59. b D 2202 2212 zat RAA Q E AC STICK ETT HT 1 BALANCE DON 0 022uF Olio POT 34 Ven 86 C 23 IS sur 1 FILTER CAP Rm Tir FAN R2 N TRIGGER END ao Y V GND 357 c HF C C INTERLOCK E GAS 47 oam LSDFT START SV L20AMPS e o WATER Pear Ang 95 orc 3 i 7 Veg e 5 2 222 oe sif 1 8 sms i V ono gt p ARCEST 2 SCH TT 0 2 g GAS_TIMEZX gt PC6 ANo 19 TP0STFLOM 2 EZ an Ale Jen i D s 13 5 2 AC PC7 VRH 0221 75 g o o g 05 AEN 54V 1326 M GND 15 1 5K cic Se l C h x cea V nn 2 0 022uF if Mem S gt 0217 TRIGGER Sov 35v KH A rea Je d p z ER o ASS m a i GND l 178 E a i E see F327 per 15V xi 0217 109 z ap T z OPEN 1 2 WHEN 2 aSK eh 2 7 POSTFLOW DESIRED 013 qe Di n Z m GAS TIMEZX Vpk 1A 400V n i C102 p SWITCH Ji sed te GND 1000y Ha 249 249 A1 100 H i SV ex Ex 70V DC MAX RN TMS 2 HELM mule th amp ELECTRODE LI NOT LISEDL lt 1 Ny Vsetpt 35V EA m x sy D FOTON NOT INSTALLED o 323 SH GG 249 2 1249 4 gt 101 ELG vrei lt NOT USED 64 amp g 2 Vprein caesos S V GND a 5 ALIFT Ti i 5 m EE b NOT USED 8 5 n d Je ano V ARCEST Ds comp 6 b Varek ia 330708 x 0 0047uF 7 Ey LOOK 60 AAT VOLTS m E A Sege 15 15V jey Vare 2 7 A D V A N L E p 1 a 10 VOLTS OUT Zi 2 i 2 A M LIONE 77 77
60. b 12345678910 K R210 99 OUTPUT INDUCTOR CHOKE Qa Ove o8e de de e de ET HIGH FREQ INDUCTORS o 2299 07 T SC f 5 77 RF TOROID CHOKES 0 d dn Lg LT 2 R210 OUTPUT CONTROL POTENTIOMETER 10K l 1 1 1 2 olo usd 5 SES sr 401 1 m BALANCE CONTROL POTENTIOMETER 10K L10 Er 7 2 Q 2 J POST FLOW POTENTIOMETER 10K cic STEP AN PULSE ON Ma dd 242 d MIN OUTPUT POTENTIOMETER 10K m Nr H 405 54 z PHASE SHIFT RESISTOR 200 100 5 5 E G B 406 202 O 5 Mia HOLDING RESISTOR 50 225 ES D 575 Mi ez T 407 7 EX EC N RESISTOR 20 100 o 5 L WW 408 8 a E FAN O S RESISTOR 5 50 tc l D 409 92 o lO FREQ CONTROL POTENTIOMETER 10K T 2 pos GEE pr 410 d0 5 P 21307 97 ON TIME CONTROL POTENTIOMETER 10K t 411 112 I 5 m C TRANSFORMER BACKGROUND POTENTIOMETER 10K TRIGGER PULSE J w 4x E m mu PRIMARY DOWN SLOPE POTENTIOMETER 10K 2 N BYPASS THERMOSTAT TRANSFORMER 1 1 AH ETABILPER SECONDARY INPUT POWER SWITCH 260 N PC BOARD THERMOSTAT POLARITY SWITCH 4 2 2 233 MICROSWITCH ON POLARITY SWITCH SC T MAIN POVVER SCR S GAS VALVE a in GAS SOLENOID VALVE 115VAC JE J2 235 SV1 irr WATER SOLENOID VALVE 115VAC OPTIONAL a nb MAIN TRANSFORMER a JSA 231 J C ger HIGH VOLTAGE TRANSFORMER m B i F HIGH
61. built in storage provisions for welding equipment and components The Precision TIG 275 includes advanced features such as a Digital Meter Presettable control Auto Balance 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 The Precision TIG 275 has enhanced Features which includes the following e MicroStart Codes Below 11000 MicroStart Codes Above 11000 Auto Balance optimized e Menu button added Spot On selection added 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 40 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS OTL o Of a o lx ole cre Sla ol o cic Return to Section TOC Return to Master TOC RECOMMENDED PROCESSES AND EQUIPMENT RECOM
62. firing signals to the output SCR bridge The control board regulates the firing of the output SCRs which control the output of the machine See SCR Operation The control board also monitors the thermostats and controls the gas solenoid the thermal light the high voltage transformer and the cooling fan The optional advanced control panel also plugs into and interfaces with the control board PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo Ir C ib ope bo 165 o lx ole cic ol o cic Return to Section TOC Return to Master TOC E 4 THEORY OF OPERATION E 4 FIGURE E 4 HIGH VOLTAGE HIGH FREQUENCY CIRCUIT BACKGROUND CIRCUIT FROM CONTROL CS BOARD REAR GANG WORK POLARITY SWITCH BYPASS a BOARD FRONT ELECTRODE 63 5 VAC OPTIONAL POWER FACTOR correction capacitors T POWER SWITCH 2 HIGH FREQUENCY TRANSFORMER m 3 REAR ELECTRODE AC DC HIGH VOLTAGE SCR TRANSFORMER BRIDGE 4H RECONNECT PANEL AC GAS SOLENOID FEEDBACK THERMOSTAT 115 VAC CONTROL BOARD L ADVANCED CONTROL LED s PANEL RECEPTACLE MINIMUM OUTPUT CONTROL STICK Sg BOARD TIG SWITCH C BALANCE POST dn CONTROL FLOVV MAXIMUM OUTPUT CONTROL REMOTE RECEPTACLE HIGH VOLTAGE HIGH FREQUENCY CIRCUIT The control board passes the 115 VAC voltage to the primary of th
63. gt 1 1 301 220 230 VOLT CONNECTION L2 V 1 OF 5 a ES 2 cf CONNECT STRAP TO 0 o a MEE LOW H2 ela E PROTECTIVE BONDING CIRCUIT 220VAC EG 6 RECEPT i HA H3 H A ee RECONNECT PANEL SUPPORT L1 U CB2 VIEWED FROM REAR O GND1 O O GND H O O END HO 0004 GND5 O GND6 O 50 SA 6 b See m m ejl 251 L5 CONTROL PC BOARD 50A 4 CONTROL CASE T1 TO GROUND PER CASE 115VAC GAS NER Len O d C2 Hi MINIMUM NE PANEL FRONT TRANS NATIONAL BACK RECEPT VALVE LEE 19 m7 oO ES OUTPUT DISPLAY FOOT ELECTRIC CODE COM N 301 Le GROUND O RECONNECT PANEL 22577 o Q 5 303 I 1 OPTIONAL S X5 e 267 m J8 63 5VAC E ee aie a REM X6 e 26 P I RES gt N H3 380V o 8 S g 5 306 lt 6 ip DE wzz TO CROUNDPER H4 415V 2 231 25 R222 NATIONAL 250 e H5 440V 115VAC 231A ELECTRICAL CODE olo 2 311 1 lt L4 r S OIO 1 31388 3 31334 204 C 105VAC 4 8 FE MAXIMUM 318 se m 55 7 els STICK BALANCE LOCAL OUTPUT POST FLOVV 316 282 L12 gX 5 317 7 d as pe S Y 318 lt 8 lt 51 Gi AN W209 20VAC 78VAC Old Il 319 9 lt 32 1 4 xx tC R210 D 320 lt 0 EC dx Ee s oiz E ar vU v s13A L 321118 545 G4 06 op 322 42 mecs y bus T1 olg MODE gt 965 217 POLARITY SWIT
64. insulator washer placement upon removal REPLACEMENT PROCEDURE d 2 Replace the SCR bridge Replace the four SCR bridge mounting bolts previously removed Note Be sure to replace insulating wash ers in their proper positions Reconnect lead 218 and Pos lead previ ously removed Replace the shunt and lead 220A previous ly removed Replace the 1 2 bolt securing lead 216 and the aluminum lead X1 originating from the main transformer Reconnect the negative lead to the free wheeling diode Replace the 1 2 bolt securing leads B and 217 previously removed Reconnect leads G1 G2 G3 and G4 oplice solder and insulate as necessary Replace case sides and top PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope ao Of a lz ole cre 5 5 ol o cic Return to Section TOC Return to Master TOC F 55 F 55 TROUBLESHOOTING amp REPAIR SCR BRIDGE REMOVAL AND REPLACEMENT continued Figure 14 SCR BRIDGE CONNECTIONS LIFT BAIL STABILIZER 217 X1 Negative G4 Shunt 61 220 218 Bridge Mounting Bolts PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a o lx ole cre 512 ol o r l Return to Section TOC Return to Master TOC F
65. meter reading to that of the test volt meter The open circuit voltage readings about 50 VDC should match within 3 1v If not adjust the trimmer so that the panel meter accuracy is cor rected NOTE If the Arc Start switch is held closed longer than about 15 seconds the machine will shut down to protect internal holding resistor from over heating PRECISION TIG 275 LINCOLN F 22 NOTES PRECISION TIG 275 LINCOLN E F 22 NOL Je1seyy 0 Winey NOL Je1Se A 01 Ulm ki NOL 491SEVN 01 Ulm ki NOL Je1Se A 0 Winey OOL Uooes in ki OOL uonoes o OOL Uooes o inl ki OOL uonoes o in ki Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope 1 Of a lz ole cre 515 ol o cic Return to Section TOC Return to Master TOC F 23 TROUBLESHOOTING amp REPAIR HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Dep
66. minimum Amptrol Start level 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 time 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 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 Fleetvveld 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 Fleetvveld 47 DC 75 95 100 145 135 200 Jet LH MR DC 85 110 110 160 130 220 Blue Max 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 AC Ap
67. not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating 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 Aug 06 Return to Master TOC Return to Master TOC O O E 9 i B o an Return to Master TOC SAFETY 2 4 7 WELDING SPARKS s 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 in Welding and Cutting ANSI Stand
68. option installed Refer tol Figure B 3 ig 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 Remote receptacle functions in 2 Step or 4 Step mode 44 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 output 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 Figure B 3 for 2 Step operation during Downslope with Restart feature selected to be dis abled instead of enabled as shipped PRECISION TIG 275 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a o lx ole cre 512 ol o r l Return to Section TOC Return to Master TOC B 8 OPERATION B 8 The 4 Step position allows welding without contin 14 PULSE FREQUENCY CONTROL This knob is uously holding the start switch trigge
69. passes through zero into the negative portion of the sine wave If the SCR is turned on early in the positive half cycle the conduction time is longer resulting in greater SCR output If the gate firing occurs later in the cycle the conduction time is less resulting in lower SCR output PRECISION TIG 275 LINCOLN E 8 THEORY OF OPERATION PROTECTION CIRCUITS Protection circuits are designed into the PRECISION Tig 275 machine to sense trouble and shut down the machine before the trouble damages internal machine components Both thermal protection and current over load are included Return to Section TOC Return to Master TOC FAN AS NEEDED F A N The PRECISION Tig 275 has the F A N circuit feature which means that the cooling fan will operate only while welding then for about eight minutes after weld ing has stopped to assure proper machine cooling This helps reduce the amount of dirt and dust drawn into the machine along with the cooling air The cooling fan will operate briefly when the machine power is ini tially turned on and continuously while the yellow Thermal shutdown light is lit THERMAL 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
70. rent rises above the Background Current level and ends when the output current drops below this level e SPOT ON position provides the peak current level set by the Maximum Output Control for a time deter mined by the SPOT TIME control A red panel light is ON to indicate SPOT mode 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 PULSE ON TIME CONTROL PULSE ON SPOT TIME CONTROL for codes above 11000 96 ON TIME controls the duration of the peak cur rent 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 e SPOT TIME sets the duration of the SPOT pulse 0 5 to 5 0seconds on the red scale PULSE BACKGROUND CURRENT CONTROL This knob controls the level 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 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 b
71. setting Set for total heat of Peak current Lower reduces distortion and burn thru Background Current ee a Downslope 40 60 is a typical initial setting Advanced Panel Set as low as will maintain a pulse arc Will not drop below Min Output setting 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 trig ger 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 ZERO For no arc out delay Controls It is important to note that even with the Precision TIG s new MicroStart Technology some tungsten 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 reli able starts as well as minimum crater fill levels can be consistently obtained at the minimum Amptrol inacti vated state FIGURE B 6 shows Precision TIG setup for TIG welding with an Amptrol PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TO
72. the Polarity Switch is set to AC the TIG mode provides continuous high frequency to stabi lize the arc for AC TIG welding Hi Freq turns on after preflow time with the arc start switch closure and turns off when the arc goes out after the arc start switch opens Arc voltage and current are sensed to determine if the arc is established or out PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a o lx ole cre 312 ol o cic B 5 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 DC polarity can also be used for balling of the tungsten for AC TIG welding AC BALANCE CONTROL The potentiometer control permits AC wave balance adjustment from Max Penetration 85 negative wave with the control at Max 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 Balanc
73. to 185 F TRANSFORMER INSULATION CLASS 180 C H 1 ALSO CALLED INVERSE TIME OR 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a o lx ole cre 512 ol o r l Return to Section TOC Return to Master TOC A 4 INSTALLATION SAFETY PRECAUTIONS Read entire Installation Section before installing the Precision Tig 275 Ai WARNING ELECTRIC SHOCK can kill Only qualified personnel should per form this installation Turn the input power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equipment Do not touch electrically hot parts Always connect the Precision Tig 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 to a power supply grounded in accordance with the National Electrical Code and all local codes SELECT SUITABLE LOCATION Place the welder where clean cool air can freely circu late in through the rear louvers and out through the bot tom opening Dirt dust or any foreign material that can be drawn into the machine should be kept at a min
74. welding output level PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a o lx on PS cre 515 ol o r l Return to Section TOC Return to Master TOC B 6 7a MENU BUTTON AND DISPLAY SWITCH Codes above 11000 Pressing and holding the Menu Button for about 5 seconds enters the menu display which allows Selection of up to seven programmable parameters Preflow Upslope Hot Start Arc Force etc on the digital meter is achieved by momentarily pressing and releasing the MENU button to step through the parameters Setting of the desired level displayed on the digital meter for the selected parameter is done by press ing the DISPLAY momentary switch toggle to the right to increase the level setting or to the left to decrease it DIGITAL DISPLAY SELECT SET DISPLAY DISPLAY TIG Mode Menu Setting Description Selection 1 HF High Freq Scratch start TIG No Hi Freq Normal Hi Freq start and weld Lift TIG Touch start w o Hi Freq PF Preflow time No Preflow Selection 3 SS MicroStart Start Pulse 0 No AC pulse Low DC pulse soft start High AC DC pulse forceful start HS setting see below for each pulse when Pulse mode welding anodized aluminum Default Factory Setting Indicated by blinking decimal point Onl
75. 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 Cannot be used with a water cooler C 2 ACCESSORIES FOR CODES BELOW 11000 C 2 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 K963 3 Hand Amptrol Fastens to torch for convenient thumb activation of arc start switch and output control with 25 plug cable K963 1 is for PTA 9 17 and PTW 20 Torches K963 2 is for PTA 26 and PTW 18 Torches e 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 PTA 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
76. zx B BLACK OR GRAY CAPACITOR MFDVOLTS 14311 214 o 212 RECEPTACLE 220V 5A RESISTOR OHVSMATTS B 1 O ORANGE a D 3J22 5J23 D 2 5J5 n 1 TSTAT Make sure that the rear EXTERNAL R REDOR PINK 2 2 m E 7J5 gt opto com 12 baffle is inplace and not damaged OPTIONAL UBLUE CONNECTOR PIN NUMBERS 8J11 209 e x7 213 215 WATER WMHITE EX 12 PIN CONNECTOR O 188 F 1J5 20VAC E Ge sv 4 50 60HZ MACHINES ONLY O S alee 6J5 16J11 CONTROL BOARD X8 p k NIME N C N C 115VAC T1 Y YELLOW 12 gt 6 ElE l PROTECTION toroo a to thermo m E NE P IMARYTSTAT SECONDARY TSTAT 4 pu E 2OVAC OF MAIN TRANSFORMER T1 n e y COMMON 7 OPTIONAL AMPTROL REMOTE m TRIGGER CIRCUIT PRECISION TIG 375 ae 7 12 c CONTROL AND ARC START 00 SCHEMATIC M16115 15J11 204 e X10 TOP FAN turns off SCR s ONLY deni h A 77 FRAME GROUND m 2 T CONTROL PCB n 5 LATCH ol K870 foot pedal jumper AUX WINDINGS OF x PE J EARTHGROUND VIEWOF CONNECTOR ON PC BOARD 5 SCHEMATIC Gats X MAN TRANSFORMER T ial l ure de THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED o in Robotic molex position USA PROPRIETARY amp CONFIDENTIAL other PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC ALE
77. 00 10RO RESISTOR MF 1 4W 10 0 1 Dm R53 R54 R308 ROT FOR PARTS ORDERS INCLUDE 1 52559PRINT PARTS ORDERS ALL COMPONENTS AND MATERIALS USED IN THIS INSTRUCTION SHEET ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 MANUFACTURED AS THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED G3909 2H1 PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC UNLESS OTHERWISE SPECIFIED TOLERANCE REFERENCE page Tort PART NUMBER IDENTIFICATION CODE ON PLACE DEGAS 02 Ge EQUIPMENT TYPE PRECISION TIG PAGE 1 OF S i i D T SUBJECT CONTROL P C BOARD ASSEMBLY ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE NUNBER WITH PUBLISHED STANDARDS MATERIAL APPROVAL PROJECT a e 3291207 ENGINEER SOLID EDGE STRP Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC boa
78. 00V olo R337 xi y lg GNO 1 i tC REMOTE GREEN LZMA 1 bo a ala c GND V ann el E S Bs x C152 JA ao l 0 022uF 0218 SOV 51V t5 nGAS 1w 72 7 HT 3 im 33074 m D cial GL Awer Ven a PHASE_FIRE xt END nFANSHT 3 2 CIRCUIT FOR DISPLAYING gt BG SHT 3 MAX POT SETTING IN FILTER CAP A 5 0 n t STICKSHT 3 5 625 TIG REMOTE NOT WELOING 859 V ono en ho E 1A gt nOC_STICK SHT 3 y 18 500V i i gt 1 T202 0LK i ST TRIGGER 5 193 BN r 1 025 gt n 15V d v pms JE TE i E TOROID 00V i SiV us 6 2793 m i ALEM IN 4 022uF Bg i SHT i Don i E I 12 nSHUTBOWN nSHUTDOWN n a O O C sir 3 i 10K 10K FIRE SCR e R473 DATA2 AUTOBAL LED AUTOBAL LED i i I Ta C129 0213 CLOSED IN DC 2 HM qeoFT START CARE 10 on 8 9 ns FT STA nSUFT START I wo D lt EE R352 sa O 1400V em AG DGAS TIME2X nLIFT TIG i Ze 7 5 nBAS TIME2X S nLiF T TIG d Zem S GND DE u i F 2 a Sov PSOL GNB AC DC Lori did hw sm 2 SND pl uu uM uites R Y 3 1 18V o 1 n m taria er m ON SET PM cia 4a S IU EC o y 1 1 15V AH 332K n 1 1 TRIGGER 2i LOK 9 aif sev lt 1 515 ASS Sy 8 oi 1 TOR C172 z um POST_FLOW 477 i d og Ai 0227 5
79. 0744 PA ee 271 Say 40668 40658 Ski 224N 30V PROPRIETARY amp CONFIDENTIAL to OTHER PARTIES OR USEU FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC bb M SINCE COMPONENTS OR CIRCUITRY ON A lee INFORMATION PAGE 01 OF 03 o 9 ro T oy ANTE CU Boe Ee VE aa ees foe YPE PRECISION TIG 7 T 2 27 77 20 0 ABILITY OF A COMPLETE BOARD THIS i SUBJECT SCHEMATIC CONTROL PC BOARD dn DIAGRAM MAY NOT SHOW THE EXACT ENGINEER T SAES m UTEM COMPONENTS DR CIRCUITRY OF CONTROLS E 5 mv Vo HAVING A COMMON CODE NUMBER APPROVED ORAWING pisposition N E DATE 3 29 2007 ive CRM36844 FS 3908 2H1 519 Gc NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual PRECISION 275 G 10 ELECTRICAL DIAGRAMS G 10 SCHEMATIC CONTROL PC BOARD BELOW CODE 11000 G3908 PAGE 2 MOV D 16V_UNREG 9 m 15V 007 HE ion SHT 1 o 0 10K o R358 gt Imin prescale o 2 hoe z 10K 10K 10K 4 s R286 i i 50V 2 8 J9 BK aK GND z POSTFLOW du cw E n 2 E MIN OUTPUT 10 R329 e 2 5 10K Ta TR 3 pss S 10x ur 5 2123 JUMPER FOR 375 Fe n L SHUTDOWN cc CC oM GNO T2 15V LOW THERMOSTAT OPEN STICK SW Dy 4330 SI v R r gn ARCEST DO R175 iov 224K N GNO R122 D E Ge
80. 1 Of a lz ole ci lz ol o cic Return to Section TOC Return to Master TOC F 35 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The Active SCR test will determine if the device is able to be gated ON and conduct cur rent from anode to cathode MATERIALS NEEDED 3 8 Nut Driver TIG 275 Wiring Diagrams An SCR Tester as Outlined in this Procedure PRECISION TIG 275 LINCOLN F 35 F 36 TROUBLESHOOTING amp REPAIR F 36 ACTIVE SCR TEST continued Figure F 7 Plug J4 Location Return to Section TOC Return to Master TOC 00000 00000 0 lo elg sis o GA ele cic TEST PROCEDURE 4 Construct the circuit outline in 2 3 One 6V lantern battery can be used Resistor 1 Remove main supply power to the PRECI values are 10 The voltmeter scale SION TIG
81. 100 ele Lo NC gt 7 gt 201 D RESISTOR DE CAMBIO DE FASE 200 100 J3 545 1 204 L13 229 268 R6 RESISTANCE DE MAINTIEN 50 225 270 262 CAE PYY 401 ged el WIE 8 W209 Em 263 RESISTOR DE SOSTENIMIENTO 50 225 Old Dao O o o 230 2352022 el RHo 7 201 4 7 4 E 557 TE TFF Q 5 E ah J T 2 24 26999 R7C R7D R SISTANCE 5 50 RESISTORES 5 50 ms rae roe J1 R8A R8B kl E 44 Deo St INTERRUPTEUR DE PUISSANCE D ENTR E j 401 412 M 7 9 4 STEP SPOT L10 J 402 O of en Ay INTERRUPTOR DE ENERGIA DE ENTRADA lt 3 LEIR 52 5 SEE RR lu T 5 EES v 1 HR Vei Z Ke 8 lt 3 OT F OF se ele 7 br m Rn 00006 S2A MICRORUPTEUR SUR SELECTEUR DE POLARITE t 315 see de ox O b PUNTO FEE 214 0 MICROINTERRUPTOR EN EL INTERRUPTOR DE x m us S T G B H b DO FAN BYPASS STABILIZER PC BOARD IS POLARIDAD E ME ea ee H 409 lt 9 OOm e CI D RIVATION STABILISATEUR S3 INTERRUPTEUR MENU 2 TENPS PULSE oy SHEE GIN 2575 S m Oz VENTILADOR S C TARJETA ELECTRONICA DE AIPRMARY T1 SECONDARY SCR1 2 3 4 REDRESSEURS DE PUISSANCE PRINCIPAUX Q DERIVACI N 7 THERMOSTAT SCR S DE ALIMENTACI N PRINCIPAL d j w Q THERMOSTAT p 3 m J20 Bon 5 ESTABILIZADOR T1 PRIMAIRE T 7 SV1 SOUPAPE SOL NOIDE DE GAZ 115 VAC 7 THERMOSTAT V LVULA DE SOLENOIDE
82. 119 R123 R126 o C28 C36 C41 C46 C50 R127 R130 R132 R133 tC 57 C61 C69 C70 C71 R159 R160 R163 R175 C76 C77 C78 C85 C86 R203 R204 R209 R212 C89 C90 C103 C105 R240 R246 R247 R250 45 1519400 1002 RESISTOR MF 1 4VV 10 0K 196 C106 C122 C123 C124 45 516668 11 CAPACITOR CEMO 0 1 50V 1096 601005 LIS R253 R289 R293 R294 cias CIA Cis CER R296 R297 R299 R300 cies Cl 168 Coo R302 R321 R332 R352 C171 C172 C173 C176 R353 R358 R384 R386 an 00 R394 R403 R4 C6 C16 C20 C35 C59 R25 R67 R125 R134 C100 C118 C143 C155 9 513490 42 CAPACITOR TAEL 1 0 35V 10 R158 R211 R242 R251 11 1S19400 2212 RESISTOR MF 1 4W 22 1K 1 C8 C9 C11 C26 C27 R281 R392 R419 C32 C42 C44 C56 C65 R38 R254 R298 R313 r Hae CH ob CO 7 S19400 9091 RESISTOR MF 1 4W 9 09K 1 C92 C101 R42 R128 R164 R169 C10 C24 C58 3 516668 3 CAPACITOR CEMO 100pF 100V 5 R215 R216 R245 R260 10 1S19400 4752 RESISTOR MF 1 4VV 47 5K 1 CH C15 C141 3 513490381 CAPACITOR ALEL 22 63V 2096 R261 R339 C18 C19 C37 C38 C62 R43 1 5194002213 _ RESISTOR MF 1 4W 221K 1 C72 C73 C74 C75 C79 R45 R66 R85 R108 EN C80 C88 COL C104 57 S19400 2002 R MF 1 4W 20 0K 196 C107 C112 C128 C134 31 516668 5 CAPACITOR CEMO 022 50V 20 R57 R371 19400 2210 R MF LAN 221 176 C142 C144 C145 C146 R59 R252 R259 R377 E C147 C150 C151 C152 R389 K ji d S 19400 3321 R MF 1
83. 15 ELECTRICAL DIAGRAMS SCHEMATIC CONTROL PC BOARD ABOVE CODE 11000 G4762 PAGE 3 A 4 1 1 1 I 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 l 1 1 I 1 1 1 I 1 F t E E E 1 i E D t D 1 1 1 1 1 1 1 1 1 1 1 1 i 1 1 1 D 1 i i 1 D D 1 1 1 1 1 1 1 1 1 1 1 i 1 1 1 1 1 1 i 1 i 1 1 1 1 1 1 1 1 1 I 1 1 1 1 1 1 I 1 1 I I I 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 I I 1 n I 1 I 1 1 I 115VAC 412 D 115V AC HF TRANSF 42 42 d 3083 as TY SHT 2 GAS VALVE 15V C81 0 004 7uF 1A00V STICK BOOST RELAYS 375 ONLY lt BE ES oa er ro R EE e xu v PS EYE ETP EP A dnt mi 1124 dan EE vv mem V GND M RI Bu AAA st aran ran Ta FT TY YR ne E m e e ee de Mee Ba edel m n mr az m xn mm xum mur vm mum mn dum mu mir run m am m PR uq T TEST EN ME FE mr mv vv vu PL AAS ren m Pr le m a de m Re a R zz A Ha A RA Aaz m ok a maz z m AA m z da m m m a a m na ma na a m nn nam AA x xx x x x x Et in vur rak vi rl PO MAN uy ma oa EE 5 OHMS 50 W 63 5 A
84. 2 _ RESISTOR MF 1 4W 13 7K 1 C10 C24 C58 3 1816668 3 CAPACITOR CEMO 100pF 100V 5 R37 R335 R342 19400 2 RESISTOR ME 1 4W 200 1 DEL 4344 Rods 6347 6 S19400 2000 SISTOR MF 1 4W 200 1 C31 C34 C37 C38 R39 R79 2 S19400 3011 RESISTOR MF 1 4VV 3 01K 196 C40 C45 C62 C64 R42 R128 R164 C72 C73 C74 C75 C79 C80 C88 C91 7 Ge 5 S19400 4752 RESISTOR MF 1 4VV 47 5K 1 C104 C107 C112 37 516668 5 CAPACITOR CEMO 022 50V 20 C128 C134 C142 has RBS R86 R108 C144 C145 C146 2 19400 2002 RESISTOR MF 1 4W 20 0K 1 C147 C150 C151 R171 k 152 153 154 R57 R69 8194002210 RESISTOR MF 1 4W 221 1 C156 C159 S aZ Gia Cia 2 STA CAPACITOR TAEL 47 JET R59 R173 R252 R259 S19400 3321 RESISTOR MF 1 4W 3 32K 1 3 NB r SOLDER CAPACITOR C178 1 08AS SHOWN C15 C141 C164 3 Tag CAPACITOR ALEL 22 63V 20 R64 R65 R73 R74 1 20 7 ND COVER WITH E286 1SEALANT C22 C51 2 T1157754 CAPACITOR CD 750PF 1000V 10 Baz F A mida C23 039 C52 3 S13490 183 CAPACITOR ALEL 120MF 50V 2096 2 y i ND ND 16 80 oe Cab gt 15166687 CAPACITOR CEMO 6200F 50V 5 R135 R170 R205 19400 1003 RESISTOR MF 1 4VV 100K 194 10 68 C53 1 S13490 92 CAPACITOR ACEL 3300 50V 30 10 R258 R270 R292 C81 C82 C98 C99 R295 O O C117 C131 C133 R71 R83 R87 R118 C135 C136 137 15 T11577 58K I CAPACITOR CD 0047 3000V 2096
85. 275 Amps at 275A 40 Duty Cycle with out Standard Power 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 Voltage Super Lag Rating Stee Ground Wire in Super Lag Ampere 55 Ground Wire in phase or Breaker Rating on 40 C 104 F Conduit AWG or Breaker Rating 40 C 104 F Conduit AWG Frequency Nameplate Ambient IEC Sizes Size Ambient IEC Sizes 208 1 60 10 14 21 2 mm2 6 13 3 mm2 70 124 3 26 7 mm2 6 13 3 mm 230 1 60 21 2 13 3 pmo 26 7 m 6 13 3 mm 2Amps DC to STICK AND TIG CC Constant Current AC DC GTAW Stick SMAW 220 230 1 50 60 NONE 4 21 2 13 3 ar ME N SE MT 4 21 2 6 13 3 mm 380 4001 5060 ss s f e Ti 133 mm 415 1 50 60 8 8 4mm 8 8 4mm2 6 13 3 mm PHYSICAL DIMENSIONS Height idth K1826 1 2 31 0 in Oin Oin Approx 397 Ibs K1827 1 787 mm 180 kgs K2619 1 2 K1825 1 49 7 in 28 0 in 41 0 in Approx 641 Ibs 1262 mm 711 mm 1041mm 291 kgs TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 20 C to 40 C 04 to 104 F 40 C to 85 C 40
86. 31A 057 258 77 265 T ol oi o PRECISION TIG 375 REMOTE 2 L ONLY O O c i A 5 CLOSED FE E LOCAL 316 il 8 300W IN DC E pe 5 d E X 316A low BOOST BOOSTe R14 Le 226 Kee SHOWN IN REMOTE o 115VAC 115VAC m lt lt POLARITY CAPACITORS 250 oig 2 POST FLOW O 23100 227A 2208 2 S OO 5 m E 10 52 M gt 2 5 313A 4 313 2 large cap and 231B 5V common Si PT375 STANDARD C1 C2 C3 60 460V resistor filter o 2 MINA O 321 BACKGROUND CIRCUIT 375 ONLY PT275 OPTIONAL 25 L E ENABLED IN BOTH TIG EF o O A 3166 8 STICK AC amp DC current limiting resistors 275 ONLY w TIG i to main rectifier d E left ROR lawer 275 5 50W 4 ea VOLT O 315 STICK 319 TOROID ooo S15 25 25 4 ea ols ol 2 8 lt 5 ml o je m m ale DISPLAY SWITCH MODE SWITCH IA TER GAP PS 271 BYPASS STABILIZER D SHOWN IN STICK 3318 BACKGND FILTER CAP NEG EN r CONTROL PANEL stick 77 271A PCB W y g tc 331 z ght 8 209 B SKGKEND AS SC pour 2 2 SCHEM TIC S22530 auto aw BACKGND AC IN RA E lo BACKGND LED AUTO BALANCE REMOTE GAS l THERMAL 332 E ok ad RESISTORS e x5 GREEN GREEN GREEN YELLOW 33 OOV clamp R remote w BACKGND cz 63 5V B v 33 p 229 B W B W B Ww B Ww B gas w 14 334 z r vi d m Ww gt P1375 use ONLY 331 332 T Hj thermo p min current range HOLDING RESIST
87. 3320 RESISTOR MF 1 4W 332 1 V l Ge 7 R165 1 819400 3323 RESISTOR MF 1 4W 332K 1 Fee bel e GE Ded E R166 1 1519400 5621 RESISTOR MF 1 4W 5 62K 196 E D Po pe Deo Deo Del 46 T12199 1 DIODE AXLDS 1A 400V R167 R174 R284 C d NC 084 D65 086 087 R285 R301 R326 S19400 1501 RESISTOR MF 1 4W 1 50K 195 g 072 073 079 080 R327 E ELE 3 qx 081 082 083 084 R178 T14648 24 RESISTOR WW 5W 0 5 5 SQ a NC D89 R R R 185 R186 R187 LAL 3 2 D24 D62 D63 3 TT2705 23 D ODE SCHOTTKY AXLDS 1A 30V 1N58T8 pies Rise Bion HBBg H X 7 D47 D48 049 5 T12705 14 DIODE AXLDS 3A 200V 1N5402 R191 R192 R193 als 4 De 069 D70 D71 4 Tiz199 2 DIODE AXLDS 1A 1000V R194 R195 R196 TI fo DZ1 DZ3 DZ9 DZ14 4 T12702 29 ZENER DIODE 1W 15V 596 1N4744A R197 R198 R199 Y E DZ2 DZ5 DZ20 3 T12702 53 ZENER DIODE 1W 3 3V 5 1N4728A R200 R201 R219 RE EE esii m a DZ4 DZ11 DZ12 DZ13 4 T12702 27 ZENER DIODE 1W 10V 596 1N4740A R220 R221 R222 77 2 El m DZ6 DZ10 2 112702 19 ZENER DIODE 1W 12V 5 1N4742A R223 R224 R225 5 IC SS NC ND DZ7 DZ8 2 r1270223 ZENER DIODE 5W 15V 595 1N5352B R226 R227 R228 o Deeg DZ15 DZ16 DZ17 R229 R230 R231 8 y D 7 DZ19 DZ21 7 T12702 52 ZENER DIODE 1W 5 1V 5 1N4733A R232 R233 R234 S 0223 0224 DZ25 3 112702 45 ZENER DIODE 1W 18V 5 1N4746A J2 33 2 S21134 10 CONNECTOR MOLEX MIN
88. 46 J8 6pin 8 Menu Switch hold to get to TIG options not used O cur 27 BYPASS ASSEMBLY N T olo lift TIG upslope T 2 221 218 MAIN C4 Menu Switch hold to get to Stick options SHUNT X n reconnec ig hot start levels micro start actore level R 222 TRANSFORMER re flow after flow time extended hot start levels TOROID TOROID PT375 86 vac entero e mounted on its side e cw see IM for details and more LJ 2 PT275 75 vac T1 0047 3KV MAX R1 i 311 TERT MICRO SWITCH ON POLARITY SWITCH 265 W 221 4 to X2 Be o 2 OUTPUT M 312 100 MICRO SWITCH ON POLARITY SWITCH o 8 NI Ha HIGH POWER SWITCH J oe 214 VOLT FEEDBACK ELECTRODE 252 R PT375 ONLY if 309 MINOUTPUT 0 1 5V VOLT FEEDBAGK WORK 253 OUTPUT De 22 2 O lt MIN GE E AC amp DC STICK OCV BOOST CIRCUIT adie Section es RECONNECT BYPASS PCB 5 R4 316 V PRESENT ONLY ON PRECISION TIG 375 PANEL SCHE S24206 X E OUTPUT 317 REMOTE 15V right front lowe B 75vac L1A o 10 C 318 POSTFLOW 0 15V 375 only 313B 321 DISPLAY MIN A 15 SEO P x2 e i C 315 DISPLAY VOLT 15V Bee 224 a pe VS BALANCE R2 319 STICK 15V je 256 225 228 1 ii DC AC 4 7 SWITCH x 10K y 313 COM EI 115VAC IN 255 1 1 ai CR3 N Hi Esch M 4 DC STICK CR2 z SS CR3 Sets weld tables bin 0 313C R either is ref CR2 ER amp CR2 CR3 control AC N olo controller to 2
89. 4W 3 32K 196 ae MB ve 2 3 4 5 7 C154 C156 C159 R72 R101 R102 R276 19400 26R7 RESISTOR MF 1 AW 26 7 196 ES ni ub 16 80 C22 C51 2 T1157754 CAPACITOR CD 750PF 1000V 10 R73 R74 R131 R135 O C23 C52 gt s13490 183 CAPACHOR ALEL DOME Sov 2092 R170 R205 R270 R292 S19400 1003 RESISTOR MF 1 4VV 100K 196 O C53 I 513490 92 CAPACITOR ALEL 3300 50V 30 10 R295 O C60 1 8166687 CAPACITOR CEMO B20pF SOU 506 R77 R385 2 s194006811 RESISTOR ME 1 4W 6 81K 1 Q CBL C82 C98 C99 R78 I 5194003321 RESISTOR MF 1 4W 3 92K 1 LY C117 C131 C133 C135 R79 R MF 1 4W 3 01K 1 O cix C137 C140 cieo n 1577 52K CAPACITOR CD 0047 005 1400V 20 R83 R87 RIIS R168 gt S19400 1004 R MF 1 4VV 1 00M 196 c s Pe Ria pa 2 161 162 163 R248 R249 R277 R280 o e o C84 I s1349040 CAPACITOR TAEL 2 7 50V 1096 R92 R103 R104 R129 o alee N lt li C95 C96 C97 3 1577 46K ___ CAPACITOR CD 05 600V 80 20 R140 R161 R179 R202 E D re ilg C102 C138 2 5166689 CAPACITOR CEMO 150pF 100V 5 R206 R207 R239 R243 O 113 114 115 116 4 513490 81 CAPACITOR PEF 0 1MF 400V 10 RADIAL R263 R267 R273 R274 S 19400 1001 RESISTOR MF 1 AW 1 00K 196 L C119 C120 2 5166682 CAPACITOR CEMO 47pF 100V 5 R279 R305 R312 R314 D d d o pi d e Ea C121 1 13490 19 CAPACITOR TAEL 1 8 20V 10 R315 R320 R364 R388 o T O CUS 1 16551 CAPACITOR CEM ZQF 100
90. 5 LINCOLN F 33 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O lo OTTO P Cl OTL Ola o c ope cE 515 ol o cic Return to Section TOC Return to Master TOC F 34 TROUBLESHOOTING amp REPAIR F 34 STATIC SCR TEST continued Figure F 5 Plug J4 Location OOOO OOOOO TEST PROCEDURE 1 Remove main supply power to the PRECI SION TIG 275 and remove the case top and 4 Repeat Step 3 testing SCR2 SCR3 and left side SCRA 2 Locate and remove plug J4 from the control To further check the SCR s functions use an board See Figure F 5 SCR tester and proceed to the Active SCR 3 Using an analog ohmmeter test the resis Test tance from anode to cathode of SCR1 NOTE Also check diode D1 Reverse the meter leads and check from cathode to anode of SCR1 See Figure F 5 If 6 Replace plug J4 on the control board a low resistance is indicated in either direc 7 Replace the case top and left side tion SCR1 is faulty Replace the SCR Bridge Assembly See iSCR Bridge Assembl Figure F 6 SCR TEST POINTS LIFT BAIL STABILIZER DIODE D1 S 9 Es fi NG PW 46 gt 7 SCR4 CATHODE om p SCR3 CATHODE SCR1 SCR2 CATHODE SCR3 SCR4 ANODE SCR2 ANODE PRECISION TIG 275 LINCOLN E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io P Cl ope
91. 537 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms i Low UNLESS OTHERWISE SPECIFIED DIODES 1A 400V UNLESS OTHERWISE SPECIFIED mp Ne mi E EE il A BE A A A a ll nn BB SINCE COMPGNENTS OR CIRCUITRY ON A PRIMTED CIRCUIT BOARD MAY CHANGE WITHGUT AFFECTING THE INTERCHANGE ABILITY GF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER A NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual PRECISION TIG 275 G 14 SCHEMATIC CONTROL PC BOARD ABOVE CODE 11000 G4762 PAGE 2 ELECTRICAL DIAGRAMS G 14 D 10Vref 15 DIS iM SY 1 5 0 LOK 15V I I R356 gt Imin prescote 1 cua 8206 C165 pol PEAK_LIM_EN o 9 SOV Sch i CLOSED YQ od 7771 1 de 4 1324 m Sov i ACTIVATE MENU C i S SR cp MiS GND 1 400v E b ARCEST D J9 j 1 JUMPER IN 1 La MIN OUTPUT 10 2 E FOR PT355 1 10i P E T S 760k 106 y 1 SIT ZS LJ cus A JUMPER FOR 376 PS 3 zak a 98 ac m 7 EE SV S AMPS oc GND GND 2 e I i he m 1 6 H 10K i HB Sy RITA em SV R330 Lg mu fore i 33074 i I PT275 PT375
92. 56 F 56 TROUBLESHOOTING amp REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS CONT D PROCEDURE 1 Loosen the appropriate diode nut and remove the diode that is to be replaced Clean the area on the heat sink around the diode mounting surface using a putty knife or similar tool DO NOT SCRATCH THE DIODE MOUNTING SURFACE Polish each heat sink s mounting surface using NO 000 fine steel wool Wipe surface clean with a lint free cloth or paper towel Inspect the mounting surfaces of each new diode Remove all burrs and wipe clean Do not use steel wool or any abrasive cleanser on the diode mounting surface Apply a thin 0 0003 to 0 0007 uniform layer of E1868 Dow Corning 340 heat sink compound to the heat sink mounting surface a Do not apply compound to diode stud or mounting threads b he diode threads must be clean and free of defects so that the nut can be finger tightened before applying torque A slip type torque wrench must be used to tighten the diode nut Tighten the diode nuts to the specifications in the following table a The nuts for diodes with steel studs are to be started by hand and then torqued as per the following table b The nuts for diodes with copper studs are to run on all the way by hand then torqued as per the following table c Turn a minimum of 1 2 turn more while torquing per the table DIODE STUD FOOT INCH SIZE POUNDS POUNDS 25 27 300 324 10
93. 7 5 ERE j 22pF 15 E Di 016 D17 D18 020 77 R278 R336 S19400 4750 RESISTOR MF 1 4VV 475 196 o o G4763 1 D21 D28 D36 D37 038 12 T1270534 DIODE AXLDS 1A 400V FR 1N4936 R100 R27L R334 R337 y o PRECISION TIG CONTROL 039 090 R340 RAT 6 1S19400 5110 RESISTOR MF 1 4W 511 1 c et A p D10 DIL DD DIS R110 R111 2 1619400 2001 RESISTOR MF 1 AW 2 00K 196 Dia D19 D22 D25 D36 R112 1 S19400 9092 RESISTOR MF 1 4W 90 9K 1 5 031 035 040 041 042 R121 R124 R244 R318 4 S19400 7681 RESISTOR MF 1 4VV 7 68K 196 D54 055 D58 D59 R137 R138 R181 R217 D51 D54 D55 D58 D59 i 6 519400 1211 RESISTOR MF 1 4VV 1 21K 196 nd ER 060 061 064 065 Dee gt 112199 1 DIODE AXLDS 1A 400V R262 R304 o D67 D72 D73 D79 D80 R139 R180 R218 R264 4 1S19400 2670 RESISTOR MF 1 4W 267 1 081 082 083 084 085 R162 R173 R333 R338 D82 D83 084 085 7 519400 3320 RESISTOR MF 1 4W 332 1 086 087 089 096 R372 R373 R374 al us R165 I S19400 3323 RESISTOR MF 1 4VV 332K 1 D7 D91 D92 D93 D94 R FE DIODE SCHOTTKY ANS 0 2A 30V BATA2 R166 I S19400 5621 RESISTOR MF 1 4W 5 62K 1 NC D95 R167 R301 2 1S19400 1501 RESISTOR MF 1 AW 1 50K 196 im 046 047 048 049 D50 5 270514 DIODE AXLDS 3A 200V 1N5402 R178 I RESISTOR WW 5W 0 5 5 5Q D62 D63 2 2705 23 DIODE SCHOTTKY AN DS 1A 30V 1N5818 R182 R183 R184 R185 D68 D69 D70 D
94. 71 4 T 2199 2 DIODE AXLDS 1A 1000V R186 R187 R188 R189 021 DZ3 029 0229 4 2702 29 ZENER DIODE IW 15V 596 IN4744A R190 R191 R192 R193 alle 024 022 DZ13 D226 6 11270227 ZENER DIODE 1W 10V 596 1N4740A R194 R195 R196 R197 DET DE R198 R199 R200 R201 DZ5 D220 2 1112702 53 ZENER DIODE 1W 3 3V 5 1N4728A R219 R220 R221 R222 S19400 68R1 RESISTOR MF 1 4W 68 1 1 9 026 0210 2 T12702 19 ZENER DIODE 1W 12V 5 IN4742A R223 Hood MODE 275 2 2 DZ7 DZ8 DZ14 3 2702 23 ZENER DIODE 5W 15V 5 1N5352B r o o EADS DADAS R227 R228 R229 R230 o o 0219 d 5 T12702 52 ZENER DIODE 1W 5 1V 5 1N4733A R231 R232 R233 R234 DZ23 0224 DZ25 3 2702 45 ZENER DIODE 1W 18V 5 IN4746A R235 R236 R237 R238 12 13 2 53113410 CONNECTOR MOLEXMINIBLIND F 10PIN R265 R266 R306 R351 4 518380 1 THERMISTOR P 1C 56 OHMS 90MA NC ND 15 113 J 5A 3 s240208 CONNECTOR MOLEX MINI PCB 8 PIN TIN R269 R307 2 519400 2673 RESISTOR MF 1 AW 267K 196 NF 16 1 52402026 CONNECTOR MOLEXMINI P CB 2 PIN GOLD R272 1 5194003222 RESISTOR MF 1 4W 39 2k 1 17 18 112 3 524020 6 CONNECTOR MOLEXMINI PCB 6 PIN TIN R286 R328 2 13S19400 2802 RESISTOR ME 1 AW 28 0K 196 J9 1 52402012 CONNECTOR MOLEXMINI PCB 12 P IN TIN R303 1 5183803 THERMISTOR P TC 08 0 19 OHMS 1 85A Ju I s2402016 CONNECTOR MOLEXMINI PCB 16 P IN TIN R310 1 S19400 6810 RESISTOR MF 1 4W 681 1 20 114 1 5182484 CONNECTOR MOLEX MINI PCB 4 PIN R316
95. 9 I S15128 16 IC OP AMP QUAD HIGHPERF 1014 TRIMMER MAXIMUMITEM 7 HEIGHT NEAR CONNECTOR J 2 IS 50 INCHES R423 NA X20 X21 2 1525073 9 IC CMOS PSOC 8 BIT CY 8C27443 DIP 28 55 N F KEEP TOP SURFACE FREE OF ENCAPSULATION MATERIAL INCLUDING RTV N H PROGRAM X21 WTHITEM 9 AND LABEL X21 WTH PART NO CF ITEM 9 2 NJ COVER WITH TAPE AFTER PROGRAMMING UNLESS OTHERWISE SPECIFIED NK APPLY ITEM 7 ON COMPONENT SIDE ONLY AS SHOWN MAXIMUM ITEM 7 HEIGHT IS 50 R E VIS lO N C 0 NTRO L CAPACITANCE MFD VOLTS INCHES A INDUCTANCE HENRIES N L APPLY ITEM 7 TO CONNECTOR S PLASTIC MOUNTING PINS ON NON COMPONENT SIDE RESISTANCE OHMS G4763 1A1 NS PART NO IDENTIFICATION COLE ALL COMPONENTS AND MATERIALS USEDIN THS TEST PER E4298C ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 COAT WITH E1844 AND E3668 SCHEMATIC REFERENCE 4762 1 a MAKE DETAIL O MANUFACTURE PER E1911 2 BOARDS PER PANEL PR SES 27 FOR PARTS ORDERS 4LAYER BOARD BLANK PANEL SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION INCLUDE 1 S25597PRINT PARTS ORDERS o UU INSTRUCTION SHEET 25 PROPRIETARY CONFIDENTIALE A EET ya E MAN E aner PERDE DESIG N INF OR MATIO N REFERENCE EQUIPMENT TYPE PRECISION TIG PAGE 1 OF 1 Q o ON 3PLACE GECIMALS 2 002 DRAIN BY JB G3909 DOCUMENT tor 9 a WA ATA s sa mum sip NERT CONTROL P C BOARD ASSEMBLY NUMBER so 5 c c 7 APPR OVED 11 2772 N
96. A 255 7 27 2007 HE CRM38261 G4763 1 A 5 5 STRP E o o cc Cc NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine PRECISION TIG 275 Return to Section TOC Return to Section TOC O O O o FEL JE ois oiz ejg S5 olo cc Cc Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC G 19 SCHEMATIC PROTECTION P C BOARD M16115 31191 IN NUMBER THIS SHEET CONTAINS PROPRIETARY INFORMATION UNLESS OTHERWISE SPECIFIED TOLERANCE Jos Sht Nos 15 EQUIP OWNED BY THE LINCOLN ELECTRIC CO ANDIS ON HOLE SIZES PER E2056 some pp THE LINCOLN ELECTRIC CO rn Up pp SA NOT TO BE REPRODUCED DISCLOSED OR USED pg joe CLEVELAND OHIO U S A WITHOUT THE EXPRESS PERMISSION OF ON ALL ANGLES IS 5 F A DEGREE 7777 EE Store NONE MATERIAL TOLERANCE TO AGREE PO IESO 1 NOTE NOTES ELECTRICAL DIAGRAMS L4 J23 J22 39mH ii gt de
97. ALT OLE RANCE t TO AG REE WITH PUB LIS HE D STAN DARDS SOLID EDGE o O O E CIS JE ois oia 918 JE kd olo cc Cc NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN scr PRECISION TIG 275 G 28 G 28 SCHEMATIC TIG OPTION P C BOARD ABOVE CODE 11000 G4760 PAGE 1 ELECTRICAL DIAGRAMS PS DOWNSLOPE ger A AA A A a a A AA m A Ps ms IPULSE LED Return to Section TOC Return to Master TOC t DOWNSLOPE TIME n 1 PULSE_LED NI e ATRIGGER INTRIGER gr Ve P dd sm O 23 RESTART EF O 5V _RESTART 4STEP SP 01W b Hemin PULSE SPOT ON TIME JRULSE SPOT ON TIME FR c RS SL RAMPDUWILO en CHE 41 USED FT o 45 O o S a La de o 15 792 RES C aSPOTWEL
98. Board from the static shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the machine OFF before working on equipment If the PC Board uses protective shorting jumpers Do not touch electrically hot parts don t remove them until installation is complete Return to Section TOC Return to Master TOC If you return a PC Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis Sometimes machine failures appear to be due to PC Board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC Boards 4 Test the machine to determine if the failure symp olo please use the following procedure tom has been corrected by the replacement PC O JO B IC oard 2 1 Determine to the best of your technical ability that RRRARARERERRRRESEERRARERSESEARARRERERERARRRREREERRRRRRSERRRARERERRARRRAESEERRRRRRRESRSERRRRERSSARRRRREE o ix the PC Board is the most likely component causing NOTE It is desirable to have a spare known good PC els the failure symptom Board available for PC Board t
99. C OPTION EM E D gt 11 gt 229A 4 INTERRUPTOR AUTOM TICO 15 AMPS PANEL DE CONTROL AVANZADO OPCIONAL co 7 P s 56 265 M 217A d CR4 BOBINE RELAIDE 12V CC 24e j 266 A 7 o BOBINA DE RELEVADOR DE 12V DE DC ON TIME BACKGROUND DOWN SLOPE J11 R7C O 01 DIODE ROUE LIBRE EL TIEMPO FONDO ABAJO CUESTA 12345678910 13 263 a RZD O 271A O FREQ N o 4R8A L1 INDUCTEUR DE SORTIE STARTER 5 pou TI EY ru TEE gt 4 213 Jo INDUCTOR DE SALIDA ESTABILIZADOR E R11 R12 OR ge Sg 1213 INDUCTANCES HF cix R9 R10 Rf1 R12 ET rm e R 204 262 4 L13 STARTERS TORODE Eu m 473 LE 401C VISSE 8 W209 253 e ESTABILIZADORES TOROIDAL RF Old 12345678910 Rao l 215 288 288 882 T YTTYTYYIYT 57 204 TT OO RESTORE CAMBIO DE FASE AN y YY C MET pn E EUN LL PT J1 W209 R6 R SISTANCE DE MAINTIEN 50 225 o 9 aos a dM See Ass X 401 1 M 2 R210 gt RESISTOR DE SOSTENIMIENTO 50 225 cle a EE J dar 0 M 5 7 iz 155 m PUNTO M 404 46 gt FO T R7C R7D R SISTANCE 5 50 RESISTORES 5 50 512 c ES oz SPOT M 405 5 OS 315 x PACHE Ae 6 COOO INTERRUPTEUR DE PUISSANCE D ENTR E oO 5 18 SH O e PUNTO M 407 7 m EF uE a INTERRUPTOR DE ENERG A DE ENTRADA cc c 1 Y io 408 lt 8 lt o BYPASSISTABILIZER PC BOARD S S2 I
100. C ES mu ua ra e vr E E mr e EE e EE E bb tr se ker ds sk Ra ld one en det dl sikir d l kh SS xun uv run dun mun ums uk murs bt rum rum rei rn d re En a ele MAR ly dt A lt YA A PSE UU UR NE UA qun mv Eh i RR u ET HSV 1 C178 013 T 012 77 t 400V 1A 100V A00V i SHT 1 I el i 2179 m Z2iK juF AR i GNO GAIN 16 78 V eno i M Varc d 1 R42 E BH 330744 i 60 ARC VOLTS SDK 10 VOLTS OUT 45V 60 ARC VOLTS if 330708 7 6596 VOLTS GUT 15K an 09 BEI l g zl z ER 05 3 01K iz il i Varc E a i i 80 ARC VOLTS T 5 VOLTS OUT 3 92K i V GNO 1 m paz x x x qax x x x x n EE m z m mu mu mu mu mu xy Ye pm 45V DND Sech SHT 1 SHT 4 L Ae SND mett EE EE EE EE EE EY EE EN ng ee Se A A A mm eee VOLT FEEDBACK p P THERMAL rm d pn M Eg pl I ke EE EE ETP PP A A
101. C Return to Master TOC OO O Io Ir CHS ojeg 1 Ola o lx ole cre Sla ol o cic Return to Section TOC Return to Master TOC MAKING A TIG WELD WITH AN AMPTROL 1 Install welding equipment per Section A 5 2 Setup controls per Section B 9 3 Turn on the shielding gas supply and torch coolant input supply if used Note The Precision TIG Under Cooler or Water Solenoid connected to the Cooler receptacle runs with 6 the Fan As Needed machine cooling fan See Maintenance Section D so the cooler fan and water pump will also not run continuously in idle but will run while welding 4 With the torch held safely away from everything 7 close the Arc Start Svvitch of the Amptrol and set the gas flovv meter Then open the svvitch The vvelder is now ready for welding 5 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 14 OPERATION B 14 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
102. C TIG 60 AC DC Stick Balance TIG Unbalance 70 Penetration AC TIG 100 AC DC Stick Balance TIG Unbalance 70 Penetration AC TIG Shown on Front of this IM manual with Under Cooler Cart and Advanced Control Panel Refer to Optional Equipment Exceeds NEMA Unbalanced Load Specification comparable for Auto Balance PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir C OTL ao Of a o lx on PS cre 5 5 ol o r l Return to Section TOC Return to Master TOC p INSTALLATION 23 RATED OUTPUT IEC 60974 1 K1827 1 Duty Cycle Applications Volts at Rated Amperes ps 40 AC DC Stick Balance TIG 31 0 Unbalance 7096 Penetration AC TIG 20 2 6096 AC DC Stick Balance TIG 29 0 Unbalance 7096 Penetration AC TIG 18 0 10096 AC DC Stick Balance TIG Unbalance 7096 Penetration AC TIG ADDITIONAL OUTPUT CAPACITY Maximum Open Type of Output Circuit Voltage Output Current Hange Auxiliary Power K1825 1 K1826 1 K1826 2 15Amp Circuit Breaker and NEMA 5 15R Duplex Receptacle for up to 115VAC 8Amp Auxiliary Power Receptacle 115VAC weld Switched Cooler Receptacle load K1834 1 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
103. CH MICRO SWITCH N 4 Es pp SE 7 220 1 A C D E B F OPEN cic A 67290 E am DC B D C E A F G H CLOSED ez LS 58 9 218 B D C F G H CLOSED j 5135 ee a 2 216 a Hava o Do REAR GANG MICRO SWITCH cic m we STICK AUTO BAL REMOTE P FLOW THERMAL 3318 Lc o Ke ene o NN NAVY rz W lt 2 lt HRS BR HER HR AVS BOT BOS BOSS BN NN W 2 Ww Ww Ww Ww B Ww 333 10 e e S W A4c 5 3 3 3 3 p ete 3 d N C id 335 WE E 263 gt i GH B 4106 9 gt 253 i SV2 gt 21269 4 POLARITY i REAR VIEW SHOWN NF WATER VALVE 7 5 N z ae 8 IN AC POSITION ee N D rn 3 220B ha SE nos SH I y7 EK NC e 265 b POWER FACTOR CAPACITORS 50 460 OPTIONAL 5 UAM PANEL 55 0 B a 31D 266 A M BY PASS CAPACITORS 0047 665 5 262 L Y o BACKGROUND HIGH VOLTAGE CAPACITOR 0015 12kV O m m 1234 Y vv y Y SC 263 ecco N GE R7 RECTIFIER PHASE SHIFT CAPACITOR 15uF 250VAC FREQ ON TIME BACKGROUND DOWN SLOPE s y HIGH FREQ PROTECTION CAPACITORS 22 400 O pio TITYITYLIYT 942 213 r 269 O R8 O 267 O pru ecco 4 Y 271 2 CIRCUIT BREAKER 15 AMP Fir R41 R42 OR uu 68 CIRCUIT BREAKER 5 AMP R10 VNC 3 7 T 201 262 12 RELAY COIL O C ge Eds ci 270 263 FREE WHEELING DIODE 15 AH Corc db CS pit gt wane gt BACKGROUND DIODE o n li
104. COLN F 41 TROUBLESHOOTING amp REPAIR F 41 TYPICAL AC VOLTAGE WAVEFORM MACHINE LOADED TO 50 AMPS AC TIG MODE HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC AC BALANCE CONTROL IN AUTO This is the typical DC output voltage waveform generated from a properly operating machine Note that each ver tical division represents 20 volts and that each horizontal division represents 5 milliseconds in time OO O Io Ir CHS ope bo Of a lz ole cre Sla ol o cic NOTE Scope probes connected at machine output terminals probe to electrode probe to work SCOPE SETTINGS PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC F 42 TROUBLESHOOTING amp REPAIR F 42 TYPICAL AC VOLTAGE WAVEFORM MACHINE LOADED TO 2 AMPS AC TIG MODE HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC AC BALANCE CONTROL IN AUTO OUTPUT CONTROL AT MINIMUM This is the typical AC output voltage waveform generated from a properly operating machine Note th
105. CONTROL 0 00 Yo Se p 2 SOEN INTERLOCK 4C 9 Cm 2K en E Y GENERAL INFORMATION N 7 70 0 10V LOW FOR ROBOTIC TRIGGER D510 B O A 108 av uF ELECTRICAL SYMBOLS PER E1537 SENSED SIGNAL Varc 3 27 329 301 Ej 35v CAPACITORS MFO 1 022 50V UNLESS OTHERWISE SPECIFIED 7 75K RESISTORS Ohms i fW UNLESS OTHERWISE SPECIFIEO LABELS a O p T E NI le so Gon DIODES 1A 400V UNLESS OTHERWISE SPECIFIED AA SUPPLY VOLTAGE NET 2 i doit i A V POWER SUPPLY SOURCE POINT o 2 55 ND AZ R 14 2 COMMON CONNECTION s la a I 2 400V e V GNO 7 FRAME CONNECTION 2 2 us enr 16V_UNREG V 5 16 _UNREG SND EARTH GROUND CONNECTION ASS 7 SHT 4 GND du THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATEU ARCEST GNO PROPRIETARY amp CONFIDENTIAL to OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC s n M 15V 066 HIGH ARC ESTABLISHED AEN NM 45 SHT Loa 1A SINCE COMPONENTS OR CIRCUITRY OH A s r gt MA ae INGE COMFOWENTS OR CIRCUTTIN ONA Dues INFORMATION rercaence EQUIPMENT TYPE PRECISION TIG PAGE 02 OF 03 WITHOUT AFFECTING THE INTERCHANGE i 5V iov 10V ABILITY OF A COMPLETE BOARD THIS UI Mik SUBJECT SCHEMATIC CONTROL PC BOARD DOCUMENT DOCUMENT V sir DO MO ei 7 UV 7T V SCALE T
106. CR A A A LED LIGHTS TOROID 275 2 to 55A Ri max current range 50 100W 375 340A 251 base ffon FREQUENCY ON TIME DOWN SLOPE om WORK C 1 401C 401D bottom behind fan HIGH VOLTAGE m JORK I TRANSFORMER ead mounted MN SCH 257 ELECTRODE right front O10 Lon low low a se 512 Ee 751 D I He Hk Olio ZC e 402 405 y a 407 x 15 E L2 Cg NOTET Fir 10K 10K 10K SCHEMATIC G4760 X MEA B RAR b i i min a p min mim ORIS OPTIONAL ON PT275 gt 233A S 12 5 OHM TYP 0015 12KV LEAD 250 FROM POWER FACTOR CAPACITORS O o 406 7 Je FAN 115VAC 060 ula a E RENE CONNECTS ACCORDING TO THE INPUT VOLTAGE MT m m 402 FREQ 08 15V 3 TYP GAP HIGH FREQ a o T SPOT SPOT 403 DS o 72717 015 TRANSFORMER 5 115V common 208 230 460 S B BACK GROUND aos METEO 055 o RED 120 oo LEAD 250 CONNECTS TO HIGH TERMINAL ON o 2 1 Ww 5 408 1 7 DOWNSLOPE 2 E a 2 T3 RECONNECT PANEL ALONG WITH CORRECT LEAD o E o o OFF 4 STEP CW m T Dip Switches select N HELE CIRCUIT sg SKV FROM MAIN TRANSFORMER T1 gt a re start enable 115V bat 5 W z 4 joa PULSE ON GSV 7 mt uu 220 380 415 c 2 5 i m 10K 401 15V m c see IM for details REAR LEAD 250 CONNECTS TO THE H5 LEAD OF PULSE 3 2 5 411 23TEP 15V d GAS THE MAIN TRANSFORMER 11 5 GF TRIGGER Y PULSE 410 w PULSE LED d most old options se side box r
107. CR acts very much like a switch When a gate sig nal is applied to the SCH it is turned ON and there is current flow from anode to cathode In the ON state the SCR acts like a closed switch When the SCR is turned OFF there is no current flow from anode to cath ode Thus the device acts like an open switch As the name suggests the SCR is a rectifier so it passes cur rent only during positive half cycles of the AC supply The positive half cycle is the portion of the sine wave in which the anode of the SCR is more positive than the cathode When an AC supply voltage is applied to the SCR the device spends a certain portion of the AC cycle time in the ON state and the remainder of the time in the OFF state The amount of time spent in the ON state is con trolled by the gate NOTE AS THE GATE PULSE IS APPLIED LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED An SCR is fired by a short burst of current into the gate This gate pulse must be more positive than the cath ode voltage Since there is a standard PN junction between gate and cathode the voltage between these terminals must be slightly greater than 0 6V Once the SCR has fired it is not necessary to continue the flow of gate current As long as current continues to flow from anode to cathode the SCR will remain on When the anode to cathode current drops below a minimum value called holding current the SCR will shut off This normally occurs as the AC supply voltage
108. CTION The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced elec trical Wiring Diagrams and Schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 A WARNING HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and wave form checks with high frequency circuit OFF Perform High Frequency Disable Procedure PRECISION TIG 275 LINCOLN F 3 TROUBLESHOOTING amp REPAIR F 3 PC BOARD TROUBLESHOOTING PROCEDURES A WARNING Remove the PC
109. CUMEN TAINS PROPRIETARY INFORMATIONO WNEDBY LINCOLNG LOBAL INC ANDMA Y NOT BE DUPLICATED COM MUNICATED PROPRIETARY amp CONFIDE NTIAL O THER PARTIES OR USEDFOR AN Y PURPOSE WTHOU THE EXPRESS WRIT PERMISSION OF LINCOLN GL OBAL INC H R F ACTURING TOLERANCE PER E20 DESIG NINFORMATIO REFERENCE EQUIPMENT TYPE INDUSTRIAL TIG PAGE lor 1 DRAWN BY J barto qadan uns au SUBIECT CONTROL PC BOARD ASSEMBLY Juve eae APPROVED ELY NA PROVA azo 3 5 2007 OCT RMB CRM38259 G4761 1 A STRP SOLID EDGE NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN scr PRECISION TIG 275 Return to Section TOC Return to Master TOC SVM ERROR REPORTING FORM We need to know if there are errors in our manuals We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you Return to Master TOC lf you discover new or different Problems or Symptom
110. D ON RE y RAMP LOOK Rate cux 2 8 RAMP DATA gt RAMP DATA 9 mech a Ii um me sm gt m 48V ZAK BOOST1 BOOST st R5 GO LIFT TIG OUT my emer Du SS seg SHT 2 en SS MIN LEVEL 277 4 gt SUK c R Sif 2 NL PUSE CINTROK 3 Ah LO PULSE CONTREL 2 JLo PULSE CONTROL DATA 3 DATA ENSEM e iv GND sir 2 m SPI CO oe cu H 3 SPLOK SPOTWELD LED lt 7 x APA 051 O 0 y 4170 MOS Se Y o O i R OV O E iy F E END SPISS E 1 5 D ess e 55 mr OG Tn xf jg Ries m E MW t via 7 07 0 I aw o xi BE Msg LA gt d 2 ii Z E 8 O 10K 2 9 DIP SWITCH an GI cose n 2 JE 5 3 rr o cc 22 10V POWER SOURCES GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFO 1 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohma i 1 10W UNLESS OTHERWISE SPECIFIED DIODES 14 600Y UNLESS GTHERWISE SPECIFIED G B OG LABELS Oi4 D n TP 5 A SUPPLY VOLTAGE NET C POWER SUPPLY SOURCE POINT Y COMMON CONNECTION F FRAME CONNECTION EARTH GROUND CONNECTION PROPRIETARY amp CONFIDENTIAL fi ren PARES UN USED PON ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION DE DECH PAINTED CIRCUIT BOARD Change EST ET EQUIPMENT TYPE PRECISION TIG BOARD THI TERN GG ce mens Lee SUBIECT SCHEMATIC ADVANCED CT
111. D REPLACEMENT continued Figure F 13 Control Board Plug Locations Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC J4 J5 J6 J8 J9 J10 J11 J12 Ir CHS ojeg o Of a lz ole cre Sla ol o cic PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC F 52 NOTES PRECISION TIG 275 LINCOLN E F 52 NOL Je1sey 01 Winey NOL Je1Se A 01 Ulm ki NOL 491SEVN 01 Ulm ki NOL Je1Se A 0 Winey OOL uoroes inl ki OOL uonoes o OOL Uooes o inl ki OOL uonoes o in ki F 53 TROUBLESHOOTING amp REPAIR F 53 SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT A WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the SCR bridge fo
112. D VOLTS RECEPTACLE TOP FAN BOTTOM FAN o T1 R RED 145VAC FAN FAN 115VAC 1 234 ei 231 U BLUE gd E WHEN ADVANCED CONTROL TORO D 263 ML RESISTORS U A 4J22 PCB IS NOT INSTALLED 260 W WHITE OHMS WATTS MAX A DISCONNECT FOR 5311 COOLER 12VDC IN TIG WELDING 262 260A C8 09 Y YELLOW 10K N gt B 1322 2J23 x DOUBLE PRE POST FLOW SE c _ COOLER RECEPTACLE 22 400V 22 400V CB2 R gt C 2J22 3423 q B PRECISION TIG 275 ONLY HH pre CONNECTOR PIN NUMBERS 4J23 2 2 BD 3922 c 1411 TSTAT 214 212 S u RECEPTACLE 220V 5A EXAMPLE THIS PININ 5J23 D pos TSTAT CONNECTOR J11 IS 6 11 O WE 6J22 7J23 E Y OPTIONAL 123 1 awac 09 E L Jam 2 50 60HZ MACH NES ONLY gt F E 5422 P 16411 CONTROL BOARD eY X8 118VAC KIT L Torop PROTECTION ToO 7311 201 x 11 PRIMARY TSTAT SECONDARY TSTAT a PCB TRIGGER CIRGUIT 3 OF MAIN TRANSFORMER T1 PRECISION TIG 375 OPTIONAL AMPTROL REMOTE x10 d VIEW OF CONNECTOR ON PC BOARD CONTROL AND ARC START SWITCH SCHEMATIC M16115 CONTROL PCB F 204 ONLY AUX VVINDINGS OF V SCHEMATIC G3908 X MAIN TRANSFORMER T1 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIA OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC MANUFACTURING TOLER NCE P X
113. D X o RES STOR SMD METAL FILM 1 10W 13 7K 19 50805 L CLONE R20 1 525000 15015 RESISTOR SMD METAL FILM 1 10W 1 50K 196 5 0805 os NH RESISTOR SMD METAL FILM 1 10W 22 1K 1 50805 0000005 OO C 7 E Den Y NJ V4 R24 R44 R110 R178 4 1525000 12119 RESISTOR SMD METAL FILM 10W 1 21K 196 50805 0 el 2 El E RESISTOR SMD METAL FILM 1 10W 332K 1 S0805 X BBBB 0 7 m a BEB gg B opp gunge Tos X R34 R37 R38 R50 R67 pu A 8 00 ode e Bow V NOTES R75 R76 R127 R131 12 525000 51105 RESISTOR SMD METAL FILM 1 10W 5110HMS 196 5 0805 joo am B NA CAUTION THIS DEVICE IS SUB ECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 R132 R133 R181 NJ UO m III i NB PROGRAMX 4 WTHITEM 2 ANDLABEL X14 WTHPART NUMBER OF ITEM 2 KE Red RG ROY T S pp on 2 m ang NC APPLY TEM 3 TO COMPONENT SIDE OF BOARD AS SHOWN RIS R126 R166 R167 S25000 4751SMT RESISTOR SMD METAL FILM 1 10W 4 75K 196 S 0805 BBB go X NE KEEP MOUNTING HOLES FREE OF ENCAPSULATION MATERIAL 5 PLACES R41 R172 R176 R182 R n 4 ganan 2 N G KEEP TOP SURFACE OF DIP SWITCH FREE OF ENCAPSULATION MATERIAL R42 R43 R47 R64 R68 cla e ep J 2 J 3MOUNTED N H APPLY ITEM 3 AROUND BASE OF J 2 6 3 ON BACK SIDE OF BOARD LIMIT HEIGHT TO R71 R83 R88 R90 R91 olo 9 ON BACK OF BOARD 125 49 0625 INCHES R107 R109 R112 R121 19 S25000 10015MT RESISTOR SMD
114. DE GAS 115 VCA 4 5 a 7 8 910 y 233A O SV2 SOUPAPE SOLENOIDE EAU 115 VAC DREAD E E SOLENOIDE DE AGUA 115 SV Hn Ti TRANSFORMATEUR PRINCIPAL 235 233A TRANSFORMADOR PRINCIPAL pp 2310 T2 TRANSFORMATEUR HAUTE TENSION pe m 231A TRANSFORMADOR DE ALTO VOLTAJE T i T3 TRANSFORMATEUR HAUTE FR QUENCE PROTECTION PCB A A COMPONENT VALUE UNITS UNIDADES DE VALOR DE COMPONENTES TRANSFORMADOR DE AFTA FRECUENCIA SS CI PROTECTION ioi L2 AL RESISTORS OHMS WATTS RESISTORES OHMS WATTS e 77 P 00 CAPACITORS MFD VOLTS CAPACITORES MFD VOLTIOS ET CB DE PROTECCION S o C6 O AE 3 1 gt N UNITES DE VALEUR DES COMPOSANTS O gt B gt B sp gt 2 gt 260 115VAC CABO T3 R6 RESISTANCES OHMS WATTS O O FE A d 32 J12 EA 235 d T2 5 1 CONDENSATEURS MFD VOLTS et d p Do D Ri Dm m Ea Se 236 ABERTURA CONNECTOR PIN NUMBERS NOMBRE DE CONTACTS CONNECTEURS loan lb Eee 5 J22 cea 54 233A 2 DE CHISPA 284 285 N MEROS DE PINES DE CONECTORES EAD COLORING CODE oO MINIMUM m E A L3 e EXAMPLE THIS IS PIN 1 A23 7 5 CODE DE COULEUR DES CABLES T Soe F E 16 277 a ii OF CONNECTOR J5 9 o ol C DIGO DE COLORES DE CABLES 5 2 F 456 237 O I e FRONT EXEMPLE C EST LE CONTACT 1 lo o ooo oo 123 za erre RRED WWHTE REMOTE RECEPTACLE WORK DU CONNECTEUR J5 R d 2 Aero PRISE
115. DISPLAY TOGGLE SHOWN IN MIN AMP POSITION a o 5 to SD SEE N F PLUGS INTO LOWER SWITCHED RECEPTACLE ni B VERE S OPTIONAL o 3 REMOTE REMOTE 8 57 ape WORK VIEW OF CONNECTOR ON PC BOARD RECEPTACLE 2 ae 02 AMPTROL a C7 ARC STARTER AS BLY ELECTRICAL SYMBOLS PER E1537 ole E REAR 2 236B c c ELECTRODE B 4031 5 cc NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine ELECTRIC PRECISION TIG 275 G 3 ELECTRICAL DIAGRAMS 5 WIRING DIAGRAM ENTIRE MACHINE CODE 10807 G4031 1
116. E aa lv VIL 15V tox M 24V SEN x3 UY37192 021 31 41 50 61 71 6190 101111 2211320141151 NO BERE H T 15V PULSE LEG m La 241 DAN SW eg Sr Re3 kr 55 ER Ven 415V C46 4 I jj ow L67K SIN 82 V R Van em uF SON 10V 10 LIK V Do LW d r HOOK mx E GI Van G 25 B 014 Jak aiw 125 KHz OSL EL 26 TS PROGRAMMING PORT 22 3 JTAG EN Ry gg IK 2 67K n Van LAN eu GO jos 014 V ap 5V 10 DIN ADV Y i Kg A se GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 4 1 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohma 1 10W UNLESS OTHERWISE SPECIFIED LABELS t VREF SHT 2 DIODES 1A400V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET 15V SC SHT 2 C POWER SUPPLY SOURCE POINT 5V 45 gt SHT 2 VM COMMON CONNECTION 7 FRAME CONNECTION WNED BY LINCOLN GLOBAL INC AND MAY NOT BE BUPLILA COMMUNICATED PROPRIETARY amp CONFIDENTIAL TH DOCUMENT CONTAINS PROPRIETARY BEORMATIDN OWNED BY IN Ar PERMISSION OF LINCOLN GLOBAL SINCE COMPONENTS OR CIRCUITRY ON Torsion INFORMATION rererence EQUIPMENT TYPE PRECISION TIG PAGE OLOF 02 o J SUBJECT SCHEMATIC ADVANCED CONTROL PCB In 5 ABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT AYIN A CON COE NUMBER APPROVED BRAWN Medie NA f
117. ECOMMENDED COURSE OF ACTION 1 Check the input power switch reconnect panel and associated wires for loose or faulty connec tions 2 The input power switch may be faulty 3 Perform the T1 Transformer CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Make sure the polarity switch is in the proper position and func tioning correctly Return to Section TOC Return to Master TOC No welding output The 115 VAC is 1 present at the receptacle 1 Check for loose or faulty connec tions on the heavy current carry ing leads Polarity switch out One of the thermostats may be put choke output terminals etc tripped Allow the machine to cool The thermal light will be 2 Check for faulty connections or a on defective thermostat Check leads 213 and 214 See the Wiring Diagram The thermal light will be on 3 Perform the T1 Transformer Make sure the welding cables torch and connections are in good operating condi
118. EL ALONG WITH CORRECT LEAD 10K 10K 10K SCHEMATIC G4039 X EN mo 236B e n e E OLIVA e d I E FROM MAIN TRANSFORMER T1 i OPTIONAL ON PT275 C7 12 5 OHM TYP 5 403 pu 406 e TOROID s FAN 115VAC 269 15 250 5 5 OHMS 70 a 220 380 415 o g 402 TRES 08 181 21 TYP TYP se 5 5 LEAD 250 CONNECTS TO THE H5 LEAD OF 12 a 31 og L3 THE MAIN TRANSFORMER T1 15 D 5 p A 5 gu C F 230 460 575 G2 2 ul 2994099 9 02 401A B 407 HE 55 g 8 GEES 18 LEAD 250 CONNECTS TO THE MID TERMINAL olo ON 4 STEP ES Low Em 256 ON THE RECONNECT PANEL ALONG WITH CORRECT r z z ger SE 1031 L LEAD FROM THE MAIN TRANSFORMER T1 c OFF 2 STEP l o wei kin 15V 7 m REAR 460 575 d 41 1 2 STEP asv 4 1J1 GAS 5 y PULSE 410 PULSE LED SOLENOID LEAD 250 CONNECTS TO THE LOW TERMINAL n 55 GREEN te Y P 115VAC EEEVIBUBE ON THE RECONNECT PANEL ALONG WITH CORRECT olo L ME m 234A Hee LEAD FROM THE MAIN TRANSFORMER T1 Y HOT START TRIMMER er CB1 RECEPTACL HEN ELECTRICAL SYMBOLS PER E1537 ADVANCED CONTROL PANEL OPTIONAL ON PT275 Y ARC FORCE TRIMMER d ul TOP na E COOLER RELAY 233 O 232 J3 Q I2VDO snap LEAD COLORING CODE COMPONENT VALUE E UNITS PRECISION dc POSER B BLACK MOVE THIS PLUG FROM TIG 375 ONLY O 231F 0 RECEPTACLE G GREEN CAPACITORS REMOTE J5 TO J5A FOR ROBOTIC INTERFACE O ORANGE MF
119. ENTRE EL PIN 1 Y PIN 2 EN J3 TIERRA PANEL DE RECONEXION In H3 230V F X6 e Si C4C5 BY PASS CAPACITORS 0047 DISPLAY v 230V AFFICHAGE PARA DUPLICAR LOS TIEMPOS DE PRE Y POSTFLUJO EE GSE H4 460V gx 291 6 HIGH VOLTAGE CAPACITOR 0015 12kV PANTALLA E EL INTERRUPTOR DE PALANCA DE LA PANTALLA SE MUESTRA EN LA TO GROUND PER A 231A 7 PHASE SHIFT CAPACITOR 15uF 250VAC MIN OUTPUT 07 ELECTRIQUE NATIONAL id Sy gt 115VAC NATIONAL 2 201 CBC9 HIGH FREQ PROTECTION CAPACITORS 22 400 SALIDA F ENCHUFES EN RECEPTACULO CONMUTADO INFERIOR EL CTRICO NACIONAL 204 F oly Sols x EE NF ii GX o Jg 31 5S9 2 x 3 il LA ji 2 216A w209 x 78VAC 4 L13 RF TOROID CHOKES Olov bk J M 311 1 lt L4 coo 20VAC 14 L143 RF TORO D CHOKES Cd BALANCE L6 312 1226 216 GER R5 PHASE SHIFT RESISTOR 200 100 O STICK ALANCEAD TPE 313 134 x e i IECTRODE R MAXOUTPUT POST FLOW 314 x4 T1 R7B E VARILLA LOCAL amp RENDEMENT ECOULEMENT DE POTEA I 315 5 M R7C R7D RESISTOR 5 50 olo Se SALIDA FLUJO DEL POSTE 316 6 jg L12 SCR1 N na pep 5 7 G1 9 st INPUTPOWERSWTCH 2 319 9 sol G3 218 52 POLARITY SWITCH gt 320 Ae 3 1 p 218A MICROSWITCH ON POLARITY SWITCH 02 A VW lt g R VW 313A 321 11 34 G4 G2 e MENU SWITCH olo TIG REMOTE 2 322 12 391 82 4 A SCR2 on EN SCR1 2 3 4 MAIN POWER SCRS r
120. ER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could effect the machine s electrical characteristics or if any electrical components are required or replaced the machine must be retested INPUT IDLE AMPS Input Volts Hertz Maximum Idle Amps Maximum Idle Amps without PFC without PFC 208 60 230 60 32 460 60 16 575 60 13 OPEN CIRCUIT VOLTAGES MAXIMUM AC OPEN CIRCUIT VOLTAGE 75 VAC MAXIMUM DC OPEN CIRCUIT VOLTAGE 68 VDC MAXIMUM ACCEPTABLE OUTPUT VOLTAGE AT MINIMUM OUTPUT SETTINGS DC TIG Mode 2 Amps 20 Volts MAXIMUM ACCEPTABLE OUTPUT VOLTAGE AT MAXIMUM OUTPUT SETTINGS DC TIG Mode 300 Amps 32 Volts RECOMMENDED METERS FOR MACHINE OUTPUT TESTS VOLTMETER AC and DC True RMS Meter Fluke 8922A or equivalent AMMETER Columbia Type AX AC or DC Tong Ammeter IMPORTANT IF OTHER TYPE METERS ARE USED RESULTS MAY NOT BE ACCURATE PRECISION TIG 275 LINCOLN amp F 62 NOTES PRECISION TIG 275 LINCOLN E F 62 NOL Je1sey 01 Winey NOL Je1Se A 01 Ulm ki NOL 491SEVN 01 Ulm ki NOL Je1Se A 0 Winey OOL uoroes inl ki OOL uonoes o OOL Uooes o inl ki OOL uonoes o in ki Return to Master TOC Return to Master TOC O O E 9 i 2 o an Return to Master TOC ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Dlaqrams Secilon pereo so inbox anta plar aco
121. ETE R102 R103 R104 R107 R116 R120 R123 R128 R130 S 25000 10025 RESISTOR SMD METAL FILM 1 10W 10 0K 196 S 0805 6 BOARDS PER PANEL R135 R137 R138 R139 R140 R141 R143 R151 R152 s Ee R153 R154 R155 R157 4 LAYER BOARD BLANK PANEL I 525058 15MT SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION R9 R34 R37 R38 R50 R67 R127 R131 R132 R133 10 52500051105 MT 2500047505 MT 2500013725 MT 25000 10ROSMT 25000 15015MT 25000 22125MT 25000 20025 MT 525000 12115 RESISTOR SMD ME TAL FILM 1 10W 1 21K 196 5 0805 R11 R42 R49 R51 R111 R134 R161 R162 R20 R23 R62 R86 R136 R158 R24 R44 R91 R110 R121 Return to Section TOC Return to Master TOC R9 R34 R37 R38 R50 R67 R127 R131 4132 RIS RIL R42 R49 R51 RIII R134 R161 R162 Lr A 423 R62 R86 RI36 RI 0000 25000 33235 MT 25000 47525MT 25000 33205 MT 25000 47535 MT 25000 10005 MT 25000 47R5SMT 25000 33215 MT NES 25000 18215 MT 25000 68115 MT 25000 39225 MT JI i 25000 10035MT PRECISION TIG R71 R76 R94 R97 R118 525000 75015 RESISTOR SMD METAL FILM 1 10W 7 50K 196 S 0805 S25000 26715MT RESISTOR S MD METAL FILM 1 10W 2 67K 196 5 0805 de 25000 18225M1 nooo 25001 12105MT 25000 35705 unnannun 22280 agona 25000 20008 MT 25000 68105MT 10812 41 buscan 25000 16525 MT B BBB SI 55555 TT 1 15198608 SV
122. FLOW 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 Gas preflow time for TIG mode is fixed at 0 5 sec onds 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 11 panel light turns on if the machine output is shut down because internal overheating has occurred and turns off when the thermostat resets 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 receptacle con trols the TIG or Stick mode output within the range preset by the Maximum and Minimum Output con trols See Item 6 7 and 8 for meter display B 7 OPERATION B 7 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
123. FREQ TRANSFORMER NB SR gt LEAD COLORING CODE SOME ONENI VALUE L9 m Lore i PROTECTION PCB L2 L N A CONNECTION IS PIN TO PIN BETWEEN J23 AND J5 B BLACK U BLUE RESISTORS HN ne TW S amp C6 N B ROBOTIC INTERFACE CONNECTION 7775770 5 olo OT E T3 R6 N C REMOVE JUMPER PLUG IN J3 WHEN INSTALLING RED MEDIVOLTS O16 33 235 T2 7 TIG OPTION PC BOARD c 2 A 4 5 CONNECTOR PIN NUMBERS H L8 BE N D DISCONNECT JUMPER LEAD BETWEEN PIN 1 AND A JI p p gt pn 61595 284 285 EXAMPLE THIS IS PIN 7 p E CE 192 J23 545 9334 5 PIN 2 IN J3 TO DOUBLE PREFLOW amp POSTFLOW TIMES 1233 7 OF CONNECTOR J5 10K A B l gt E gt gt E B i L3 3 olo RR 55 55 E F DISPLAY TOGGLE SHOWN IN MIN AMP POSITION SESE TS 515 Mu gor Lelo 4 N F PLUGS INTO LOWER SWITCHED RECEPTACLE 25 0 5 9 98 oo o o o oo O OPTIONAL go 14 123 5 8 REMOTE o FRONT WORK J5 o REMOTE s LATCH 2 T RECEPTACLE NR5 C7 ELECTRODE 00 AMPTROL de ARC STARTER AS BLY VIEW OF CONNECTOR ON PC BOARD olo ws BEAR ELECTRICAL SYMBOLS PER E1537 e 5 236B 7 c c ELECTRODE B 3 G4031 2 olo cic NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine ELECTRIC PRECISION TIG 275
124. Figure F 10 High Voltage Transformer Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope ao Of a o lx ole cre 512 ol o r l Return to Section TOC Return to Master TOC M 7 Ip 2 7 Y S LIL 222 UY YY yy LY 227 Yi 4 My mz 7 2 9 C J m HIGH VOLTAGE TRANSFORMER REMOVAL PROCEDURE 1 Remove input power to the TIG 275 machine 2 Using the 3 8 nut driver remove the case sides and top 3 Using a 3 8 nut driver remove the case back Note The case back will be connected to the fan assembly and will have leads connected to it so just set aside 4 Cut any necessary cable ties 5 Disconnect black lead from the high voltage transformer connecting to leads 231D and 231E 6 Disconnect the black lead from the high voltage transformer connecting to the capacitor It may be necessary to cut lead 7 Using a 7 16 nut driver disconnect heavy black leads S and F See Figure F 11 8 Using a 3 8 nut driver remove the screw securing the spark gap assembly box See Figure F 11 This will allow access to the igh voltage transformer mounting screws 9 MOUNTING SCREW Z INSULATORS Using an off set phillips head screw driver remove the four high voltage transformer mounting screws Note insulator position ing See Figure F 10 10 Remove
125. HOWN IN REMOTE j 266 POLARITY CAPACITORS o i g R3 e i 227A 250 E POST FLOW ge 231C 0 Der sg b dep 5 5 7 S2 o L 313A 6 313 4 2318 PT375 STANDARD C1 C2 C3 60 460 d gt MINA O 321 PT275 OPTIONAL e 27 o 9 A r 316C TIG c VOLT 315 STICK H 319 e 2 DISPLAY SWITCH MODE SWITCH oo BYPASS STABILIZER o SHOVVN IN STICK 331 B BACKGND FILTER CAP POS 271 BAGKGND RESISTOR PCB C CONTROL PANEL P 331 Ww BACKGND FILTER CAP NEG R7 286 y 7 C R BACKGND AC OUT 63 5VAC IN DC TIG 2008 SCHEMATIC 522530 332 _ BACKGND AC IN 63 5VAC BACKGND DIODE STICK AUTO BALANCE REMOTE GAS THERMAL 332 N 267 e X5 RED GREEN GREEN GREEN YELLOW 33 5 50 63 5V T1 333 W R8 O 267 i DC TIG BACKGROUND BACKGND TRIAC 268 3 X6 W B W B VV B VV B VV 33 CIRCUIT CURRENT LIMITING RESISTOR H d H T d ane 3358 PISIS ONLY BACKGND RECTIFIER i 331 332 333 x 334 335 NG HOLDING RESISTOR LED LIGHTS TOROID NOTE A 50 100 LEAD 250 FROM POWER FACTOR CAPACITORS FREQUENCY ON TIME DOWN SLOPE HE CONNECTS ACCORDING TO THE INPUT VOLTAGE 401C 401D HIGHVOLTAGE R3 FRONT VVORK TRANSFORMER 3 25 ELECTRODE 208 230 460 O lo o bow low Mu 200 100 T2 28 o PRESENT ONLY ON LEAD 250 CONNECTS TO HIGH TERMINAL ON 1 2 402 Zen 405 407 GAS 115VAC A P 4 X RECONNECT PAN
126. HS MATERIAL APPROVAL PROJECT Geer COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON cone NUMBER APPROVED be ORAWING oisposrtion NA pate 3 29 2007 Numper ERM36844 G 3908 2 1 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ROBOTIC COMMON Return to Section TOC Return to Master TOC PRECISION 275 wn ELECTRICAL DIAGRAMS G Ti SCHEMATIC CONTROL PC BOARD BELOW CODE 11000 G3908 PAGE 3 1 5 2 re 115V AC Return to Section TOC Return to Master TOC 516495 27 15 F TAIZ C80 0 02 2uF 50V 1i 0016 Return to Section TOC Return to Master TOC DE STICK SHT 212 5 A STICK BOOST RELAYS 375 ONLY AC STICK 4 Ka SHT2 gt JUS 4 15V BACKGROUND CIRCUIT 20 HMS 100 W O O O o FIRE GC ois oiz 918 Els cic 5 OHMS 50 W 50 OHM HOLDING BEI CURRENT RESISTOR 15V NEG St 4 OUTPUT LAST NO USED GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 2 SER PAGE 1 CAPACITORS MFO 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS 1 4 UNLESS OTHERWISE SPECIFIED LABELS DIODES 14 400V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET C POWER SUPPLY SOURCE POINT COMMON CONNECTION FT FRAME CONNECTION r EARTH GROUND CONNECTION THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LI
127. I BLIND F 10 PIN 238 ND A J4 J10 2 Sz4020 10 CONNECTOR MOLEX MINI PCB 10 PIN TIN R265 R266 R306 S18380 1 THERMISTOR PTC 56 OHMS 90MA S NF J5 J5A 2 524020 8 CONNECTOR MOLEX MINI PCB 8 PIN TIN R351 5 LJ J6 1 S240202G CONNECTOR MOLEXMINI PCB 2 PIN GOLD R268 R309 R343 gt J7 J8 J12 3 524020 6 CONNECTOR MOLEX MINI PCB 6 PIN TIN R346 3 919400 2490 al NG Weer ee 1 20 O Jo 1 82402012 CONNECTOR MOLEXMINLPCB 12 PIN TIN R269 R307 2 1819400 2673 RESISTOR MF 1 4VV 267K 196 255 R272 1 1819400 3922 RESISTOR MF 1 4W 39 2K 1 0 AE CODEN SEM R286 4328 S19400 2802 RESISTOR MF 1 4W 28 0K 1 O O NC ND OCH OCH OCI5 OCI8 4 515000 16 OPTOCOUPLER TRIAC DRIVER ZVC 3083 R303 S18380 3 THERMISTOR PTC 08 0 19 OHMS 1 85A NF LL OCH 2 S15000 31 OPTOCOUPLER TRIAC DRV RANDOM 800V R310 19400 6810 RESISTOR MF 1 4W 681 1 O O ND ND sn NF NC ND NC ND ran OCI6 OGI7 2 51500010 OPTOCOUPLER PHOTO Q 70V CNY17 3 R322 S19400 3570 RESISTOR MF 1 4W 357 1 20 Q1 Q4 Q18 3 T12704 69 TRANSISTOR PNP TO226 0 5A 40V 2N4403 R348 R349 R362 E 0 6 00 NE 12 00 NC 18 00 _ G2 08 Qs Q6 G7 R363 4 S19400 20R0 RESISTOR MF 1 4VV 20 0 196 c u Q8 Q9 Q12 Q13 T T2 2 T27372 TRANSFORMER PULSE 3 WINDING 1 1 1 014 Q15 016 017 22 mammen TRANSISTOR NPN TO226 0 5A 40V 2N4401 TP1 TP3 TP5 TP6 4 11364025 MOV 130VRMS 90J 20MM 5 D a e e 7 2 1 T13640 16
128. INFO Chg Sheet Naf DESIGN INFORMATION JREFERENCE EQUIPMENT TYPE PRECISION TIG 8 002 XB UF 3 8 DO2A DRAWNBY TN ON ALL ANGLE A RE NCE t TO AGREE ENGINEER TN WITH PUBLISHED STANDARDS DO NO A H DRAWIN APPROVED SUBJECT MACHINE SCHEMATIC n NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ISUPERSEDING EN 170 SCALE NONE DATE 01 29 02 DRAWNGNo G 4075 O Return to Section TOC Return to Master TOC ELECTRIC PRECISION TIG 275 G 8 ELECTRICAL DIAGRAMS oe SCHEMATIC ENTIRE MACHINE ABOVE CODE 11000 G5691
129. INISY NOL Je1Se A 01 Ulm ki NOL 491SEVN 01 Ulm ki NOL Je1Se A 0 Winey OOL uonoes oj uinjed OOL uonoes o OOL uonoes o inl ki OOL uonoes o in ki Return to Master TOC Return to Master TOC O O E 9 i B o an Return to Master TOC b TABLE OF CONTENTS OPERATION SECT ON Upertaiion css ni Section B nr a m B 2 A 6 1 og EE EE s B 2 Recommended Process and 4 B 3 kN B 4 Weding DCT AE OM EL EE B 5 B 8 Internal Set Up CONTO Susa EEN B 9 PTE B 10 4 Step Tigger NE B 11 TG Weld Oye CARa dE B 12 Set Up for TIG Amptrol WeIGIAG EE B 13 Making a TIG Weld with an Amptrol 22 B 14 Recommended Electrode Amperage Hangdes eese eene nennen nnn nnns B 14 PRECISION TIG 275 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope bo Of a lz ole cre 515 ol o cic Return to Section TOC Return to Master TOC B 2 OPERATION SAFETY PRECAUTIONS Read and understand this entire section before operat ing the machine WARNING ELECTRIC SHOCK CAN KILL Only qualified personnel should per form the installation Turn the input power OFF at the dis connect switch or fuse box Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and gr
130. ION 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 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 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 NOTES C 4 PRECISION TIG 275 LINCOLN E C 4 NOL Je1Se A 0 NOL Je1Se A 0 Ulm ki NOL 491SEVN 0 Ulm ki NOL Je1Se A 0 Winey OOL uoroes o uinjed OOL uonoes o OOL Uooes o inl ki OOL uonoes o in ki D 1 TABLE OF CONTENTS MAINTENANCE Maintenance EEE 00000 Section D ac uie m a D 2 3 Routine and Periodic Maintenance D 2 o Overload ProteCtiON ara R sauce ves z Daud UE ER yaaa y a au CEN Eme UE D 2 5 Fan As Needed EAN tt tt EEE HERE E L I EEEE E I EEEE E AI nen D 2 is e AA EEE NE NE D 3 Component Location and ACCESS occccccoccccccncncccnnnnnnnnnnononenonnnnnnnnnnnononnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnncnns D 3 Spalk Gap cac EE Tm D 3 NL D 4 Return to Master TOC O O E 9 i B o an PRECISION TIG 275 LINCOLN amp Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Mast
131. IS R SCR3 SCR4 ANODE 220 a D1 Bn 205A OR 20 DM 5 R E FREE WHEELING DIODE 50HZ MACHINE ONLY VIEWED FROM REAR 3 2 TOROID Seen N 217 BYPASS ASSEMBLY D D w221 248 C4 tc TOROID Ey SHUNT R222 MAIN EN 50 60HZ MACHINE ONLY Q l ES TE i 222 50 SHUNT R 0047 3KV MAX R i 311 TT m MICRO SWITCH ON POLARITY SWITCH 265 m W 221 o 400A 200mV OUTPUT e SR MICRO SWITCH ON POLARITY SWITCH 266 BE m 314 VOLT FEEDBACK ELECTRODE 252 PT375 ONLY H3 4 320 MIN OUTPUT 0 1 5V VOLT FEEDBACK WORK 253 OUTPUT ep 4 oa Fi O d MIN Lon 322 BALANCE 0 10V STICK OCV BOOST CIRCUIT RESTOR ND RECONNECT BYPASSPCB 5 R4 316 5V PRESENT ONLY ON PRECISION TIG 375 PANEL SCHE 24206 X OUTPUT REMOTE 15V 10 q 317 PosTFLOW 0 15V 313B a DISPLAY MIN A 15V KR J P x2 H1 B L 315 DISPLAY VOLT 15V TOROID 224 pct oe 311A Low 219 _ STICK 15V 115VAC IN AC STICK 256 225 225A 228 pe AC AC E MICRO SWITCH 75 BALANCE R2 115VAC INDC STICK Ae o N O 313 COM 7 CR3 M H1 N 10K CR2 B EE CR3 OCV BOOST a 2 H E RECTIFIER 3 3136 082 AC Olio J 257 258 i 265 pct DC pc ci cj c PRECISION TIG 375 REMOTE o 317 Ne N O O co s CLOSED E e 8 300 IN DC N C LOCAL 316 DC CR3 CR2 AC POWER FACTOR 316A VV BOOST BOOSTe R14 Le 226 d L c Ko S
132. ISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS OTL o Of a o lx ole cre 512 ol o r l Return to Section TOC Return to Master TOC 8 DIGITAL METER AND DISPLAY SWITCH A 3 digit LED meter is used to monitor the preset and actual welding procedure based on the Display momentary switch position e 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 Item 5 the digital meter displays the preset weld ing amps set by the Remote control See Item 11 e 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 racy within 4 2A of reading At any time in TIG mode pressing the Display switch to left causes the digital meter displays the amps preset by the Minimum Output control knob See Item 7 At any time in Stick mode pressing the Display switch to left causes the digital meter to display the minimum amps rating of the machine See Item 7 n either mode while pressing the Display switch right to Volts position the digital meter displays actual output volts Volts is displayed with O 1 volt resolution XX X and accuracy within 3 1V of reading POST
133. ISSION OF LINCOLN GLOBAL INC DESIGN INFORMATION L om Kr m m po r n E rn co UU rm I T m D ES m ci wa Cc EJ KAN un LA 1 ui a r LA 2 EREK SCHEMATIC CONTROL PCB DOCUMENT SCALE THIS MATERIAL APPROVAL PROJECT rnm38761 G 4762 1A1 DRAWING oisposition NA DATE 7 27 2007 NYMBER PRECISION TIG 275 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o FIRE ix S o s RE E 5 olo cc Cc Return to Master TOC G 16 SCHEMATIC CONTROL PC BOARD ABOVE CODE 11000 G4762 PAGE 4 min gt ipreset P gt lare L gt ARCEST ET NTRIGGER ISS as POST_FLOW gt DATAL gt su gt MENS miso r 51 ELECTRICAL DIAGRAMS gt MDATA gt SPLCLK P Jjnm 80ARD pres vise min vise v ninTERLOEK Canon COLA MOSLP CEA L PSPLSS P GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 G 16 LAST MU USED CAPACITORS MED 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS hms 1 4W UNLESS OTHERWISE SPECIFIED DIODES 1A 400V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT Kei COMMON CONNECTION F T FRAME CONNECTION slo EARTH GROUND CONNECTION THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY
134. LEUR DES CABLES GK MINIMUM F gt E E 4 lt 6 37 TE F N OF CONNECTOR J5 lAs s e C DIGO DE COLORES DE CABLES O Se F 1 be 297 Loge 2370 e Lo I 4 Onn 5 11 GEN 7 CONTACT I 5 o o 0 0 00 123 8 lama RRED WWHITE gt 8 gt C WORK 5 f z o 2 REMOTE RECEPTACLE c EE z ELECTRODE PIECE EJEMPLO ESTE ES EL PIN 1 DEL Bes VIEW OF EG ON PC BOARD 7 7 ane 00 PRISE A DISTANCE R9 OZ ELECTRODE AVANT CONECTOR J5 VUE DES CONNECTEURS SUR CI B BLUE Y YELLOW AMPTROL A TRABAJO 7 G GREEN olo 7 RECEPTACULO REMOTO ARC STARTER ASBLY REAR ELECTRODO FRONTAL VISTA DEL CONECTOR EN LA VERT BLEU JAUNE cle 5 236B ENSEMBLE DEMARREUR DARC _ ELECTRODE ELECTRICAL SYMBOLS PER E1537 TARJETA ELECTRONICA VERDE AZUL AMARILLO c ev ENSAMBLE DE ARRANCADOR DE ELECTRODE ARRIERE SYMBOLES LECTRIQUES SELON E1537 O ORANGE A Y ARCO ELECTRODO POSTERIOR SIMBOLOS ELECTRICOS CONFORME A E1537 NARANJA ELECTR ic G5692PRINT D CLEVELAND OHIO oc Ir NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine ELECTRIC PRECISION TIG 275 G 6 ELECTRICAL DIAGRAMS WIRING DIAGRAM ENTIRE MACHINE CODE 11159 G5692 1
135. LIMITS MAX i SCR FIRING ANGLE T 310 1 i 1 1 1 i Mm 1 B Ge 1 1 1 1 1 t2 1 7 SV Sov 1 1 1 1 1 GND 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X J E 1 i y H I i 1 DV 1 1 H I gt i 10K i 1 i 019 2 Ka i 016 AUTO BALANCE GREEN 12mA B i 1 1 i i i 1 i i t L 15V qum ay t m ram mmm 4 UNUSED I i 225 a S NOT USED 251 S not usto TAS 6 S NOT USED BAK g NOT USED Asa NOT USED Ts s NOT usto I re emi vn ee A A A A bt Hd inan mm nar P 10V POWER SUPPLY LAST NO USED R 423 X 71 T 2 OG 8 C 179 o 29 TRI amp LABELS D 96 07 29 1 2 TR 12 A SUPPLY VOLTAGE NET 0 POWER SUPPLY SOLACE POINT Y COMMON CONNECTION 7 FRAME CONNECTION 1 EARTH GROUND CONNECTION THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL to OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC REFERENCE EQUIPMENT TYPE PRECISION TIG 275 375 r SUBJECT SCHEMATIC CONTROL PCB GC REVISION APPROVED 5 gsposirin N NA r 7 27 2007 7 27 2007 JOET 261 G 4762 1A1 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1
136. LINCOLN GLOBAL INC AND MAY NOT SE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL 10 OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC SINCE COMPONENTS DR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE ABILITY DF amp COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS DR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER REFERENCE EQUIPMENT TYPE PRECISION TIG 275 375 amb aA Pyg MA SUBJECT SCHEMATIC CONTROL PCB duc A encineen 8 mw LE PROJECT s n MAJE nce F AT es o 4762 101 Return to Section TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ELECTRIC PRECISION TIG 275 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o FIRE oiz RE 15 ki olo cc Cc Return to Section TOC Return to Master TOC G 17 ELECTRICAL DIAGRAMS SCHEMATIC CONTROL PC BOARD ABOVE CODE 11000 G4762 PAGE 5 BALANCE gt TJ nGAS TIME 2X 9 ARCEST2 CS AC gt FAN nurT Ti L Lane AUTOBAL LEO nSHUTDOWN TER Cap Cas sm nSOFT_START L gt FIRE SCR Data gt HO sax gt C Ll STICK PHASE FIRE J 1202 08 ar AS KT WATER xs EYBE27443P1 KR G 17 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537
137. MENDED 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 to Equipment Limitations as well as many industry standard 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 B 3 OPERATION B 3 EQUIPMENT LIMITATIONS The Precision TIG machines are protected from over loads beyond the electrical ratings and duty cycles per th Specifications Section A 2 A 3 with Thermostat protection of the primary and secondary transformer coils The Precision TIG machines do not have Hi Frea available at the Stick electrode stud therefore stud connection adapters such as LECO S19257 series cannot be used for torch connection RECOMMENDED EQUIPMENT INTERFACE FOR CODES ABOVE 11000 TIG water cooled Machine Input Cable Clamp Gas Reg Hose Magnum Torch Magnum Parts Work Clamp Lead User provided included PTW20 included 15 ft included R R Oe PT275 Welding Package K2618 1 KP510 and K918 2 included TIG air cooled PT275 K261 9 1 2 User provided LE Harris 3100211 PTA9 or PTA17 KP507 or KP508 K2150 1 Work Lead Assembly Foot Amp
138. MPS ON 275 i E syn GNO 37 VOLTS FOR 418 AMPS ON 375 i 1 T d 014 bas 1 1A m 60 ge 1 BE tr vil 1 Ve E 1 2K 1 preset sv n IR oe aa E nsn nu 1 i METER ACTUAL i 10 VOLTS 600 AMPS 1 1 I 1 Tare i d I Eo 1 E i 100 f ACSW 10K R246 put R356 i I 5 R302 10Vref 1 1 SHT 2 C105 1 DAuF m 15K t i amp 10k Sov i E P i GND E i iM iz 10 1 i 1 A 12 WOULD MAKE 392K d i V GAINZ33 4 1 i R272 A Laza 1 SHUNT gt i H 1 H 1 1 1 1 1 1 1 1 1 1 1 1 1 H I 1 1 1 1 1 1 1 H 1 i a m i i 1 1 I i i I i 1 D H D I H 1 1 D H 1 1 D I 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 i i i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 i 1 i 1 1 1 1 1 1 1 1 1 1 1 dere ura vus vis res dew us rers rum E arro re fe qnem re nmm m 1 24V SW SHT 3 15 i SHT 2 i 014 SHT 3 16V UNREG 24 EN 1A n SHT 2 isle 400V 13 iA 400V 10K ant 3 E i 1 1 49 1 5 3A ni 303 EW 2004 16 7 jH ri es d 29V AC 525 j C131 120u 1 ni 090470 Sv 38 j 0 022uF 047 ov C95 i G d GND 600V SHT 2 SHT 3 S pn MCCC
139. NCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL ro OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC Pan DL eS NA Cape DESIGN INFORMATION EQUIPMENT TYPE PRECISION TIG PAGE 030F 03 WITHOUT AFFECTING THE INTERCHANGE DRAVN BY MIK DOCUMEN ABILITY OF A COMPLETE BOARD THIS o SUBJECT SCHEMATIC CONTROL PC BOARD firem DIAGRAM MAY NOT SHOW THE EXACT ENGINEER TN SCALE THIS ORAWING COMPONENTS OR CIRCUITRY OF CONTROLS MATERIAL APPROVAL PROJECT G 3908 241 HAVING COMMON CODE NUMBER APPROVED jw piseosimion NA f DATE 3 29 2007 UE 3 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only lt may not be accurate for all machines covered by this manual ELECTRIC PRECISION TIG 275 G 12 ELECTRICAL DIAGRAMS G 12 PC BOARD ASSEMBLY CONTROL BELOW CODE 11000 G3909 2 0 606 0 ENGINEERING CONTROLLED CHANGE DETAIL ADDED C178 AND REVISED DZ14 PART NUVEER MANUFACTURER No REVISED MANUFACTURE AS IDENTIFCA TON CODE AND SCHEMA TC REFERENCE PART NUMBERS REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW R20 R40 R41 R44 R55 R60 R75 R76 ADDED SOLDER AND SEALANT NOTE FOR C178 TOASSEMBLY REFERENCES QTY NUMBER DESCRIPTION R80 R90 R107 R136 CT C7 C178 3 1S16668 8 CAPACITOR CEMO 330pF 100V 5 R176 R210
140. NTERRUPTEUR DE POLARIT G B D O Np 1 L n H 409 96 Om re ae Cl DERIVATION STABILISATEUR 2 INTERRUPTOR DE POLARIDAD PULSE gt Y PULSE ac O Y VENTILADOR lt lt C TARJETA ELECTRONICA DET T4 PRIMARY T1 SECONDARY S2A MICRORUPTEUR SUR SELECTEUR DE POLARITE 2 TEMPS PULSE N PULSACION ll w 4x FA 82 DERIVACION THERMOSTAT THERMOSTAT MICROINTERRUPTOR EN EL INTERRUPTOR DE L E PR ui ESTABILIZADOR T1 PRIMAIRE TIER DARE POLARIDAD E J20 Q THERMOSTAT A AALAAAXAAA 233A PRIMARIO DEL TI SECUNDARIO INTERRUPTOR DE MEN E le 12345678910 r e DEL T1 SCR1 2 3 4 REDRESSEURS DE PUISSANCE PRINCIPAUX 2 TTTTTTTTTT ly m SCR S DE ALIMENTACI N PRINCIPAL a K N 8 1256 231D V LVULA DE SOLENOIDE DE GAS 115 VCA SES a 5 5 F V LVULA DE SOLENOIDE DE AGUA 115 VCA 8 L11 PROTECTION PCB Honn eeo eO RESISTORS OHMS WATTS RESISTORES OHMS WATTS B PRINCIPAL OIO E SA FREIDEPBOBESCION yer r S Q T UNIT S DE VALEUR DES COMPOSANTS TRANSFORMADOR DE ALTO VOLTAJE 0 ET TS 5 280 SPARK GAP o 3 R6 RESISTANCES OHMS WATTS T3 TRANSFORMATEUR HAUTE FR QUENCE o O ki 3 PE n gt 235 4 12 CLATEUR y CONDENSATEURS MFD VOLTS TRANSFORMADOR DE ALTA FRECUENCIA elie E L8 B PE 331 3 Fan a CONNECTOR PIN NUMBERS NOMBRE DE CONTACTS CONNECTEURS o 10K m o 3 Ee 55 ge 5 a J5 gt 4 gt 1 233A L3 3 SC m EXAMPLE THIS IS Nt SN ei en 77 i 2 CODE DE COU
141. NTROL a BOARD REAR GANG WORK POLARITY SWITCH BYPASS E BOARD FRONT ELECTRODE OPTIONAL POWER FACTOR CORRECTION CAPACITORS T POWER Return to Section TOC Return to Master TOC HIGH FREQUENCY TRANSFORMER SWITCH m O Sans ELECTRODE l am S RECONNECT HIGH VOLTAGE SCR TRANSFORMER BRIDGE AC SOLENOID THERMOSTAT 115 VAC FEEDBACK 115 VAC a 5 115 VAC 20 VAC THERMOSTAT LED s CONTROL BOARD Return to Section TOC Return to Master TOC ADVANCED CONTROL PANEL RECEPTACLE MINIMUM OUTPUT BOARD TIG SWITCH POST CONTROL FLOW MAXIMUM OUTPUT CONTROL REMOTE RECEPTACLE OUTPUT RECTIFICATION CONTROL BOARD AND FEEDBACK OO O o Ir C ib ope 1 Of a lz ole cic 312 ol o cic Return to Section TOC Return to Master TOC The AC output from the main transformer secondary is rectified and controlled through the SCR bridge Output current is sensed at the shunt as a low voltage signal and fed back to the control board The control board senses the status and settings of the various operator controls such as the Stick TIG switch the output controls the remote control receptacle the local remote switch the balance control and the post flow control Circuitry on the control board evaluates these commands compares them to the feedback information received from the shunt and sends the appropriate gate
142. OK NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced Process panel or harness is defective 1 None 1 Check the leads and connec tions between the meter and the control board See the Wiring Diagram 2 The meter may be faulty 3 The control board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN E F 18 NOTES PRECISION TIG 275 LINCOLN E F 18 NOL Je1sey 01 Winey NOL Je1Se A 01 Ulm ki NOL 491SEVN 01 Ulm ki NOL Je1Se A 0 Winey OOL uoroes inl ki OOL uonoes o OOL Uooes o inl ki OOL uonoes o in ki m TROUBLESHOOTING 8 REPAIR m METER CALIBRATION ADJUSTMENTS A WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any r
143. PAIR F 49 CONTROL BOARD REMOVAL AND REPLACEMENT A WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the control board Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 8 Nut Driver Phillips Head Screwdriver Wire Cutters OO O Io Ir CHS ope 1 Of a lz ole cre Sla ol o cic PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c o o 69 E o Return to Section TOC Return to Master TOC O O 9 i B o F 50 TROUBLESHOOTING amp REPAIR F 50 CONTROL BOARD REMOVAL AND REPLACEMENT continued Figure F 12 Case Front Sc
144. R168 R248 R249 19400 1004 RESISTOR MF 1 4W 1 00M 196 Q Q C140 C160 C161 R256 R277 R280 C162 C163 C84 1 13490 40 CAPACITOR TAEL 2 7 50V 10 R72 R101 R102 R276 4 S19400 26R7 RESISTOR MF 1 4VV 26 7 196 Bi C93 C108 2 516668 1 CAPACITOR CEMO 22pF 100V 5 C95 C96 C97 3 Ti1577 46K CAPACITOR CD 05 600V 80 20 R77 AIO B L B 1519400 2001 PA O MEN C102 C138 2 51666859 CAPACITOR CEMO 150pF 100V 5 R81 R313 2 S19400 9091 RESISTOR MF 1 4VV 9 09K 196 l C110 1 S16668 4 CAPACITOR CEMO 2700pF 50V 5 R82 R316 R357 S19400 3012 RESISTOR MF 1 4W 30 1K 1 o T7 2777 4 813490 81 CAPAC TOR PEF 0 TMF 400V 10 RADIAL 7 5 B S19400 5110 RESISTOR MF 1 4W 511 1 o MZA C119 C120 2 S16668 2 CAPACITOR CEMO 47pF 100V 5 412 S19400 9092 RESISTOR MF 1 4W 90 9K 1 o 121 1 81349019 CAPACITOR TAEL 1 8 20V 10 R113 S19400 2211 RESISTOR MF 1 4W 2 21K 196 132 1 513490 186 CAPACITOR ALEL 1800 160V 2096 R121 R124 R244 Di D4 D7 D16 D17 i S19400 7681 RESISTOR MF 1 4W 7 68K 1 G3909 2 018 020 021 D23 57 o D28 D34 D36 037 16 T12705 34 DIODE AXLDS 1A 400V FR 1N4936 R137 R138 R181 S19400 1211 RESISTOR ME 1 4W 1 21K 1 4 PRECISION TIG CONTROL ND Bic Doo ba R217 R262 R304 d MF 1 4VV 1 21K 196 e Ie c pons 7 7777 4 S19400 2670 RESISTOR MF 1 4VV 267 195 ES JE zt a D15 D19 D22 D25 R162 R333 R338 3 1819400
145. R213 C2 C3 C5 C17 C21 R214 R241 R275 19400 4751 RESISTOR MF 1 4VV 4 75K 196 C25 C28 C33 C36 C41 C46 C48 C50 C54 C55 C57 C61 R282 R283 R287 R288 R291 R319 669 C70 C71 C78 R323 R324 R325 C77 C78 C85 C86 R329 R330 R331 C89 C90 C94 C103 46 S16668 11 CAPACITOR CEMO 0 1 50V 1096 R355 R359 R361 C105 C106 C109 R23 R62 R63 R78 C111 C122 C123 R92 R103 R104 C124 C125 C126 R105 R129 R140 C129 C130 C139 C148 C149 C157 R161 R179 R202 R206 R207 R208 Return to Master TOC C158 C165 CA C C9 CTI CIZ R239 R243 R257 19400 1001 RESISTOR MF 1 4W 1 00K 1 C26 C27 C29 C32 R263 R267 R273 o O o Ce o o U o fed 5 T o m C42 C43 C44 C47 R274 R279 R305 22 S16668 6 CAPACITOR CEMO 4700pF 50V 10 C56 C65 C66 C67 R312 R314 R315 C68 C83 C87 C92 R320 R364 Sieg R27 R43 2 1819400 2213 RESISTOR MF 1 4W 221K 1 R28 1 1S19400 3921 RESISTOR MF 1 4W 3 92K 1 100 C118 1 13490 42 APACITOR TAEL 1 0 35V 10 3 3 7 SEE PAPAGO RR R30 R35 R36 R66 4 S19400 137
146. RAP TO LOW H2 c METER styl 344 N D DISCONNECT JUMPER LEAD BETWEEN PIN 1 AND A Pe CONNECTER LA BRIDE SUR BAS H2 5 COMPTEUR 4222 347 PIN 2 IN J3 TO DOUBLE PREFLOW amp POSTFLOW TIMES P DECONNECTER LE CABLE DU CAVALIER ENTRE LES CONTACTS 1 E 7 SUJETADOR DE CONEXI N A BAJO H2 5 4 N 2 DANS J3 POUR DOUBLER TEMPS DE PR GAZ ET POSTGA de 1291 213 MEDIDOR 53 gt 345 N E DISPLAY TOGGLE SHOWN IN MIN AMP POSITION Z L1 U l A j 212 E m rd ii nee gl NIGH LOW CRA C1 C2 POWER FACTOR CAPACITORS 50 460 316D O ora A LA CONEXI N ES DE PIN A PIN ENTRE J23 Y J5 hs yes G exl 0 SI BY PASS CAPACITORS 0047 e H1 234 C6 HIGH VOLTAGE CAPACITOR 0015 12kV 344 TABLEAU DE CONEXI N DE LA INTERFAZ ROB TICA sw OF 1 Se 345 TARJETA ELECTRONICA REMUEVA EL CONECTOR DE PUENTE EN J3 CUANDO INSTALE LA 776 COM Git 4 ST RE L5 346 DE CONTROL TARJETA DE PC TIG OPCIONAL PANNE N Err PANEL DE R DISPLAY D DESCONECTE EL CABLE DEL PUENTE ENTRE EL PIN 1 Y PIN 2 EN J3 TIERRA i ECONEXION Ss R CR4 12V DC RELAY COIL AFFICHAGE PARA DUPLICAR LOS TIEMPOS DE PRE Y POSTFLUJO AN gt D1 FREE WHEELING DIODE MIN OUTPUT qe E EL INTERRUPTOR DE PALANCA DE LA PANTALLA SE MUESTRAENLA GROUND PER O ABON 7 RENDEMENT 57 POSICION MINIMA DE AMPERIOS NATIONAL SEDE AE 7 SALIDA 7 J8 F ENCHUFES EN RECEPT CULO CONM ELECTRICAL CODE ELECTRIQUE NATIONAL H4 575V s x3 231 L4 L13 RF TOROID CHOKES
147. 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 1 POWER SWITCH Input line switch turns input power ON or OFF as indicated by the on or off sta tus of the front panel displays 2 POLARITY SWITCH The 3 position rotary power switch has detente positions for DC AC and DC selections for the Electrode output welding polarity 3 MODE SWITCH The mode switch allows vertical ly positioned selection of the two machine welding modes The selected mode is indicated by a lit col ored panel light which permits viewing the machine setting from a distance 3 a STICK mode Top position A WARNING Red panel light ELECTRIC SHOCK can kill e When the Power Source is ON in STICK mode the Electrode circuits of both the Stick and TIG torch cables are electrically HOT to Work e The CC Stick mode may be used for general pur pose stick vvelding SMAVV vvithin the capacity of the machine The capacity is too limited for air car bon arc gouging CAC A In this mode the output terminals are activated electrically HOT gas flow is not activated and HOT SIART and ARC FORCE levels are fixed or Advanced Panel selectable See Section B 7 with no front panel adjustment 3 b TIG mode Bottom position No panel light When
148. RECOMMENDED EIS SYMPTOMS MISADJUSTMENT S COURSE OF ACTION 1 Check spark gap adiustment See the Maintenance Section 2 The current control may be set 2 This may be a welding proce a welding arc The machine has a too low dure problem Contact the normal open circuit voltage Refer l E Lincoln Service Department tol Technical Specifications in the 3 The tungsten electrode may be Technical Sales group at 1 888 Installation section contaminated Replace or 935 3877 sharpen 4 The electrode may be too large OT for the process If a helium blend is being used as a shielding gas reduce the percentage of helium Check the welding cables for loose or faulty connections When AC TIG welding the arc is erratic and there is a loss of clean ing of the work piece 3 The tungsten electrode may be small for the process Use a larg er diameter tungsten or a pure tungsten If a helium blend is used as a shielding gas reduce the per centage of helium Check the balance control set ting Check components R5 and C7 in the high voltage transformer pri mary circuit Perform the SCR Bridge Test Arc pulsates in AC polarity DC TIG is OK 1 Check that the machine controls are set correctly for the process Micro switch S2A may be faulty It should open in the AC mode See the Wiring Diagram Ai CAUTION If fo
149. REIN E 5 AG Welding OLDU M E 6 io o E E 7 Protective CICUS bb E 8 S Fan As Needed l M a E 8 E Tema PORN EE E T T Te E 8 a Overload Protec RETI TOT E 8 3 FIGURE EI PRECISION TIG 275 BLOCK LOGIC DIAGRAM or POLARITY E SWITCH BYPASS m BOARD ELECTRODE HIGH FREQUENCY TRANSFORMER CORRECTION CAPACITORS T POVVER SWITCH 2 EE e 5777 ELECTRODE AY 5 E J 5 AC DC o LLI m HIGH VOLTAGE SCR TRANSFORMER BRIDGE 115 VAC 21 Po m o O O E 9 i B o an FEEDBACK THERMOSTAT CONTROL BOARD ADVANCED CONTROL PANEL RECEPTACLE MINIMUM OUTPUT CONTROL STICK ME BOARD TIG SWITCH m BALANCE POST 7777 CONTROL FLOW MAXIMUM OUTPUT CONTROL RECEPTACLE PRECISION TIG 275 LINCOLN amp Return to Master TOC E 2 THEORY OF OPERATION E 2 FIGURE E 2 GENERAL DESCRIPTION AND INPUT POWER CIRCUIT BACKGROUND CIRCUIT FROM CONTROL o BOARD REAR GANG POLARITY SVVITCH BYPASS BOARD HI T ege paraa ELECTRODE Lu E o 5 AC DC SCR BRIDGE ie SHUNT WORK OPTIONAL POWER FACTOR CORRECTION FRONT CAPACITORS T ELECTRODE NCY POWER ER SWITCH 12 Return to Section TOC Return to Master TOC aH RECONNECT Return to Section TOC Return to Master TOC OO O Io Ir C ib ope o Of a o lx ole cic lz ol o cic Retur
150. RL PCB RENT Ss 271 SUBJECT SCHEMATIC ABVANCED CTRL PCB REVISION HAVING COMMON CODE NUMBER Em Wap cm NA DA A TE E 3 5 2007 NNER cRM30259 16 4760 1401 A O o FE C ix oia 918 JE clic NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ELECTRIC PRECISION TIG 275 G 29 ELECTRICAL DIAGRAMS G 29 SCHEMATIC TIG OPTION P C BOARD ABOVE CODE 11000 G4760 PAGE 2 o a ee es m J P ey O O O O Fle 6 5 PG s 2 m BOOST Old o yn 2 fp ATK Q e CIE 3 iMi LR 2182 TEA iv Uhr 02 12 757779 m E H 04W L Si sogn ne hr Ai TL DEN Ve c E ha n 8 10K 10K ie Ee Pz Es ub KS E e 4 BY 4 vsafpt 9 5 G E x aim e tg 2 ag H 01W Return to Section TOC Return to Master TOC Be ajaz Lr MD gt 8 STICK CONTROL co x Es TE DM ki olo O o FIRE o s RE E 5 olo cc Cc n C
151. Refer to Diagrams on A 7 K2166 1 7 8 Torch Connector for PTA 26 one piece K2166 2 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 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS OTL o Of a o lx ole cre 312 ol o cic Return to Section TOC Return to Master TOC OPTIONAL EQUIPMENT FACTORY INSTALLED OPTIONS The basic Precision TIG 275 machine is factory equipped with A 3 8 Adapter S20403 4 for air cooled torch con nection of a PTA 9 or PTA 17 Accessories that are factory installed with the Domestic model K1826 1 to make up the Domestic Welding Package K1825 1 include K1828 1 Under Cooler Cart 3100211 Harris Argon Flow Regulator with 10 Hose K870 Foot Amptrol e 1784 4 25 PTW 20 water cooled TIG Torch K918 2 Zippered Torch Cover e KP510 Parts Kit for Torch e K2150 1 Work Lead Assembly See below for more detailed descriptions 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 K2621 1 Pr
152. S FREQ CONTROL POTENTIOMETER 10K cc a d LU 409 oe m 7 ON TIME CONTROL POTENTIOMETER 10K y m 3 J 410 40 213 07 BACKGROUND POTENTIOMETER 10K 2 STEP OFF Y Qs lt M 411 41 57 E DOWN SLOPE POTENTIOMETER 10K TRIGGER PULSE DOM x w 4 Bb di 2 8 PRIMARY 00 INPUT POVVER SVVITCH i y y 5 577 THERMOSTAT SECONDARY POLARITY SWITCH d 260 N THERMOSTAT MICROSWITCH ON POLARITY SWITCH Fl y PC BOARD 2 3 4 MAIN POWER SCR S Hac 12345678910 da GAS SOLENOID VALVE 115VAC 492 dali lala WATER SOLENOID VALVE 115VAC OPTIONAL 3 J2 SAS VANE Z SV1 H MAIN TRANSFORMER 42 V 285 0 HIGH VOLTAGE TRANSFORMER m s J5A 3346 220 7 d HIGH FREQ TRANSFORMER 6 E F LEAD COLORING CODE ENE LIE ssl L11 i UNITS B BLACK U BLUE RESISTORS 1 19 H0 vv c E PROTECTION FER I2 1 N A CONNECTION IS PIN TO PIN BETWEEN J23 AND J5 ee GUE d AR e um R 77 EN B 8 C6 N B ROBOTIC INTERFACE CONNECTION R RED MEE VOLTS 115VAC N C REMOVE JUMPER PLUG IN J3 WHEN INSTALLING O e Bo B 20 T2 SPARK 9 T3 R6 CONNECTOR PIN NUMBERS O10 5 m DEE 235 5 TIG OPTION PC BOARD L8 EAN N D DISCONNECT JUMPER LEAD BETWEEN PIN 1 AND EME PIN e p gt D D B e 6 236 1232 7 OF CONNECTOR J5 cla 4 ar C426 122 323 349 233A 1 p Se PIN 2 IN J3 TO DOUBLE PREFLOW amp POSTFLOW TIMES oS 3 9 s m dmm p L3 2 N E
153. Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope 1 Ola o lx ole cre Sla ol o cic Return to Section TOC Return to Master TOC PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION No high frequency The machine is in the TIG mode and has normal output NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced Process panel or harness is defective TIG WELDING PROBLEMS 1 If the machine is in a dirty envi ronment with conductive contam inants check and clean the spark gap with a low pressure air stream per the maintenance instructions 2 Check the spark gap operations and setting Normal is 0 015 Refer to the of this manual 3 Check circuit breaker Reset if necessary CB1 4 Check connection J12 on the control board 1 Check the high voltage trans former T2 The normal resis tance of the secondary winding is 12 5k ohms A WARNING 9 ELECTRIC SHOCK CAN KILL When 115 VAC is applied to T2 a very high voltage is devel oped on the secondary winding For assistance call the Lincoln Electric Service Department 1 888 935 3877 2 Check R5 C6 C7 L2 and L3 Replace if defect
154. Schematic 16115 G 19 Protection P C Board Assembly M16062 1 cooocccccocncccccncoccnconcnocncocononoconnononnnnnnnnnonenonnnnonons G 20 ByPass Stabilizer P C Board Schematic S22530 1 Code 10806 amp 10807 G 21 ByPass Stabilizer P C Board Assembly L10121 1 Code 10806 amp 10807 G 22 ByPass and CE P C Board Schematic 524206 Code 10893 G 23 ByPass and CE P C Board Assembly L10882 1 Code 10893 G 24 TIG Option P C Board Schematic Codes below 11000 G4039 Page 1 G 25 TIG Option P C Board Schematic Codes below 11000 G4039 Page 2 G 26 TIG Option P C Board Assembly Codes below 11000 IGA040 21 G 27 TIG Option P C Board Schematic Codes above 11000 G4760 Page 1 G 28 TIG Option P C Board Schematic Codes above 11000 G4760 Page 2 G 29 TIG Option P C Board Schematic Codes above 11000 G4760 Page 3 G 30 TIG Option P C Board Assembly Codes above 11000 4761 1 2222 G 31 PRECISION TIG 275 LINCOLN amp G 2 ELECTRICAL DIAGRAMS WIRING DIAGRAM ENTIRE MACHINE CODE 10806 G4031
155. T SENSING RESET MCU SS NA CAUTION THS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 ES 7 7 X19 1 15128 16 IC OP AMP QUAD HIGH PERF 1014 BEFORE HANDLING 0 55 Yi 1 S16665 2 CRYSTAL QUARTZ 4 0000MHZ HC 18 U NB KEEP THIS AREA FREE OF ENCAPSULATION MATERIAL 2 50 MIN BOTH SIDES OF 7 7 5 BOARD R133 R157 R159 N C SQUEEZE COMPONENTS TOGETHER BEFORE APPLYING ITEM 2 AND OR R160 R163 R175 62 S19400 1002 RESISTOR MF 1 4W 10 0K 196 ENCAPSULATION MATERIAL R203 R204 R209 UNLESS OTHERWISE SPECIHED R212 R240 R246 ND APPLY ITEM 2 ON COMPONENT SIDE ONLY AS SHOWN 27 75 5 tied NE APPLY ITEM 2 ON BOTH SIDES OF BOARD AS SHOWN EXCEPT TOP SURFACE OF R254 R255 R289 7 TRIMVER R290 R293 R294 RESISTANCE OHMS NF KEEP TOP SURFACE OF TRIMVER FREE OF ENCAPSULATION MATERIAL INCLUDING RTV 7 5 7 0 P C BOARD BLANK REFERENCE INFORMAT ON ENCAPSULATE WITH E1844 R12 R25 R26 R58 BUY BLANK COMPLETE AS G3909 H 4 LAYER BOARD PER E3281 MAKE PER E1911 ROHS Ris mise Ren 14 S194002212 RESISTOR ME AW 22K 1 MAKES 2 BOARDS PER PANEL SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION 2 R242 R251 R281 TEST PER E3937 C R13 R88 2 T14648 4 RESISTOR WW 5W 40 5 SQ R14 R18 R141 R142 SCHEMATIC REFERENCE G39082H1 R146 R147 R148 R149 R150 R151 R152 R153 R154 18 S19400 47R5 RESISTOR MF 1 4VV 47 5 196 R155 R156 R15 R19 R47 R48 R49 R50 R51 R52 12 1S194
156. TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope ao Of a lz ole cre 515 ol o cic Return to Section TOC Return to Master TOC F 26 TROUBLESHOOTING amp REPAIR F 26 PROTECTION BOARD TEST continued 1 Using a 3 8 nut driver remove the case top 3 Unplug P5 from the control board Measure and sides resistance at P5 See Figure F3 See tables 2 Check that P5 is connected to J5 not J5A SC See the Wiring Diagram Table F 1 RESISTANCE BETWEEN READING TRIGGER Pins 5 amp 7 Open when trigger open short when trigger closed B C Pins 3 amp 4 Increasing from O to 10K when working on remote amptrol from min to max Decreasing from 10K to 0 when working on remote B A Pins 2 amp 3 amptrol from min to max 4 f the readings above are OK the protection 7 If readings below are OK protection board board is OK If not go to step 5 is bad 5 Unplug P23 from the protection board and 8 If readings below are wrong remote amptrol check continuity from P23 to P5 If OK go or remote receptacle is bad to step 6 See Wiring Diagram 6 Unplug P22 from protection board Measure resistance at P22 See Tables Table F 2 RESISTANCE BETWEEN READING TRIGGER Pins 3 amp 6 Open when trigger open short when trigger closed B C Pins 1 amp 2 Increasing from 0 to 10K when working on remote amptrol from min to max Decreasing from 10K to O when w
157. TOC Return to Section TOC Return to Master TOC OO O Io Ir Cl ope o Of a o lx ole ci lz ol o cic Return to Section TOC Return to Master TOC F 28 TROUBLESHOOTING amp REPAIR F 28 T1 MAIN TRANSFORMER TEST continued Figure F 4 Plug J11 G3909 TEST PROCEDURES 1 Using the 3 8 nut driver remove the two screws from the front control panel Carefully lower the panel This will allow access to the control board 2 Locate plug J11 on the control board See Figure F 4 WARNING ELECTRIC SHOCK can Kill With input power ON there are high voltages inside the machine Do not reach into the machine or touch any internal part 3 Carefully apply the correct input power making cer tain the reconnect configuration at the reconnect panel is correct for the input voltage applied Turn the Precision TIG 275 ON 4 Using the voltmeter carefully test for the correct transformer secondary voltages per Table F 3 5 Carefully check for 63 5 VAC at leads 267 to lead 268 Lead 268 is located at the background rectifi er Note Lead 267 is located at resistor R8 See Wiring Diagram 6 Carefully check for 115 VAC at leads 231 to 232 Note Lead 231 is located at the 115 VAC recepta cle on the back of the machine Lead 232 is located at the 15 amp circuit breaker CB1 7 If all of the secondary voltages are correct the T1 transformer is functioning properly a If a
158. V TCH D P SPST 8 C RCU TTS 7SET SWITCH POSITIONS ma B NA PT S S ST SMT I SMD COMPARATORQUAD290D 001 NAD X X6 Xa Xixis 6 SI512845MT OP AMP SMD QUAD GEN PURPOSE 2241 00 1 NApg 0077577 T 1 S25070125MT lC SMD CMOS CPLD CY37192 160TqFP 55 O N A X9 X12 2 S 15018 6S MT IC SMD CMOS SWITCH ANALOG QUAD 4066BD SS Olo NA M0 0007777 1 SZ505725MT POTLSMDDIGITALIX LCHNLSOIC8 Fir 1 oo E DOG s E cl a Ba me E J Be 12 MOUNTED o o m R ON BACK OF BOARD E d 7 UNLESS OTHERWISE SPECIFIED 2 uo CAPACITANCE MFD VOLTS o a v INDUCTANCE HENRIES o 0 20 2 60 NF 5 50 RESISTANCE 5 QD 5 30 918 12 2 E NOTES N A CAUTION THIS DEVICE IS SUB ECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 BEFORE HANDLING N B PROGRAM X3 WITH ITEM 2 N D DO NOT COAT WITH ENCAPSULATION MATERIAL N E KEEP MOUNTING HOLES FREE OF ENCAPSULATION MATERIAL 5 PLACES N F KEEP TOP SURFACE OF TRIMMERS FREE OF ENCAPSULATION MATERIAL 2 PLACES N G KEEP TOP SURFACE OF DIP SWITCH FREE OF ENCAPSULATION MATERIAL ALL COMPONENTS AND MATERIALS USED IN THIS ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 MAN ACTURING TOLERANCE PER 06 DESIG NINFOR MATION REFERENCE EQUIPMENT TYPE INDUSTRIAL TIG pace Lor ls 1 of 1 E SUB ET ADVANCED CONTROL PC BOARD ASSEMBLY rec REVISION a ur Biz 316007 G40402 B STRP ONALLANGLESIS 5 OFA DEGREE MATER I
159. VALVE 115VAC 2 TTV GAS VALVE xu WATER SOLENOID VALVE 115VAC OPTIONAL nb J2 SV1 11 MAIN TRANSFORMER uru 235 233A HIGH VOLTAGE TRANSFORMER TAS J5A 231D J HIGH FREQ TRANSFORMER ase TT LEAD COLORING CODE COMPONENT VALUE T N B RK alt B BLACK U BLUE RESISTORS PROTEG TON ECS D N A CONNECTION IS PIN TO PIN BETWEEN J23 AND J5 c c MEE OHMS WATTS n L2 o O ORANGE Y YELLOVV CAPACITORS 9 A Sl x S715 S pt C6 N B ROBOTIC INTERFACE CONNECTION R RED MFD VOLTS olo 329 280 115VAC R6 N C REMOVE JUMPER PLUG IN J3 WHEN INSTALLING o a 11B5 B SH 235 4 2 SPARK Y CONNECTOR PIN NUMBERS O J Ee IFA R lz GAP 2 TIG OPTION PC BOARD e E 41 L8 B 16 Set 236 N D DISCONNECT JUMPER LEAD BETWEEN PIN 1 AND ius GN cix ER is es E CES um 54 233A S PIN 2 IN J3 TO DOUBLE PREFLOW amp POSTFLOW TIMES 6 9 6 9 9 6 9 2 og XC MONTIUM Ed F L3 2 N E DISPLAY TOGGLE SHOWN IN MIN AMP POSITION ur Soba d b i 5 n m F 5 0 287199 e lo me N F PLUGS INTO LOWER SWITCHED RECEPTACLE aes EUM X REMOTE M CUM 8 BER 7 ene WORK VIEW OF CONNECTOR ON PC BOARD y AMPTROL RS C7 ELECTRICAL SYMBOLS PER E1537 APT A ARC STARTER AS BLY El 46 2368 7 REAR c et ELECTRODE B 515 G4031 1 olo cc Cc NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclos
160. WITCH CONTROL FLOW the reconnect panel When the input power switch is turned on the input voltage is applied directly to the primary winding of the main transformer The main transformer changes the high voltage low current input power to a low voltage high current out put available at the main secondary winding X1 and X2 This 78 VAC winding supplies power to the weld ing arc In addition four auxiliary windings are incor porated in the main transformer The 115 VAC winding supplies power to the 115 VAC receptacle Through the control board it also powers the gas solenoid the high voltage transformer and the cooling fan The cooling fan is activated only when welding current is sensed The 63 5 VAC winding provides power for the DC background current This circuit is active in the DC TIG welding mode The 20 VAC windings are included in the main transformer assembly The 20 VAC winding is rectified on the control board and is used in the trig ger circuitry The other 20 VAC winding is used by the control board for phase detection This AC voltage is also rectified to several DC voltages and regulated to 15 VDC and 5 VDC power supplies that operate the circuitry on the control board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRECISION TIG 275 LINCOLN amp E 3 THEORY OF OPERATION E 3 FIGURE E 3 OUTPUT RECTIFICATION CONTROL BOARD AND FEEDBACK BACKGROUND CIRCUIT FROM CO
161. X7R S 0805 o O o Ce o o 00 o fed 5 T o m Return to Master TOC C3 C8 C58 C64 C66 25020 2S MT CAPACITOR SMD CERAMIC 0 022MF 50V 10 X7R S0805 CAPACITOR SMD CERAMIC 2700pF 50V 5 X7R 5 0805 C9 C27 C28 C46 4 S25020 275MT _ CAPACITOR SMD CER 0 1MF 50V 20 80 Z5U S 0805 cn RE LA CAPACITOR SMD CERAMIC 47pF 50V 5 COG 50805 C35 C36 C37 C48 4 1525020 245 CAPACITOR SMD CERAMIC 1 OMF 25V 10 X7R S1206 207777 NG Da 1 1S2504645MT 12 DIODE SMD 0 5W 12V 5 S0D123 DZL 1 1 1S2504635MT ZENER DIODE SMD 0 5W 18V 5 SOD123 1 152402012 X CONNECTORMOLEXMINLPCB L2PININ o ND fy 602 O 7 I 524020 2 CONNECTOR MOLEX MINI PCB 2 P IN TIN o K 1 15240204 CONNECTORMOLEXMINLPCBAPINTN OO O O Fir D s m R6 R10 R13 R14 R16 o R17 R18 R21 R26 R28 R29 R32 R33 R48 R52 O R58 R59 R6L R65 R72 OI R82 R84 R85 R89 R92 R101 R102 R103 R104 525000 10025 RESISTOR SMD METAL FILM 1 10W 10 0K 196 S 0805 cic R116 R120 R123 R128 R130 R135 R137 R138 o iz R139 R140 R141 R143 ER NC R151 R152 R153 R154 ojo E 1 R155 R157 Sc NE RII R35 R36 R106 gt 7 PRECISION TIG I R12 R45 R169 R170 cy on 5
162. actical PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a o lx ole cre 512 ol o r l Return to Section TOC Return to Master TOC A 5 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 and all connections tight to reduce high frequency leakage 5 The work terminal must be connected to a ground within ten feet of the welder using one of the follow ing methods A metal underground water pipe in direct contact with the earth for ten feet or more A 3 4 19mm galvanized pipe or a 5 8 16mm solid galvanized iron steel or copper rod driven at least eight feet into the ground 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 recom mended 6 Keep all access panels and covers securely in place 7 All electrical conductors within 50 feet 15 2m of the welder should b
163. ard 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 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 F4 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 hazard
164. are 8 28 2006 G4039 2F0 A NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual PRECISION TIG 275 Return to Section TOC Return to Master TOC Return to Section TOC olo O o FIRE o s RE E 5 olo cc Cc Return to Section TOC Return to Master TOC Return to Master TOC G 26 ELECTRICAL DIAGRAMS G 26 SCHEMATIC TIG OPTION P C BOARD BELOW CODE 11000 G4039 PAGE 2 rer 22 NN Va W T TRIGGER 10K ae R45 B p ysetpt sin qas pe t SHT dE roo 45V GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MED 1 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 10W UNLESS OTHERWISE SPECIFIED LABELS 010065 14 400Y UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET INC AND MAY NOT DUPLICATED COMMUNICATED PERMISSION OF LINCOLN GLOBAL e rom armee EQUIPMENT TYPE PRECISION TIG BOARD THIS fee OEE SUBJECT SCHEMATIC ADVANCED CONTROL PCB jame revision 6 4039 2F0 A PROPRIETARY CONFIDENTIAL HSN UR USED COR ANY PURSE WITHOUT THE EXPRESS WRITTEN APPROVED yu EET rar Bee NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual PRECISION TIG 275 G 27 ELECTRICAL DIAGRAMS G 27 PC BOARD ASSEMBLY TIG OPTION P C BOARD BELOW CODE 11000 G4040 2 Q O E EE EEE EE EE EE
165. artment for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will disable the high frequency circuit allowing the technician to take volt age measurements without the possibility of high frequency damage to his test equipment MATERIALS NEEDED 3 8 Nut Driver Electrical Insulating Tape PRECISION TIG 275 LINCOLN amp F 23 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope 1 Of a lz ole cic 515 ol o r l Return to Section TOC Return to Master TOC F 24 TROUBLESHOOTING amp REPAIR F 24 HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE continued FIGURE F 2 SPARK GAP ASSEMBLY y NX 4 7 27 LIL f YY fi Y 47 YUU 77 YY Y Lif YY 7 a il Y YUI NN Zi I MOLL MMM Le 0 9 lt A sr MM gt 4 YY Uf 7 ni y Y Yi Y YY YY YY Y 4 2 T JE gat pl e A f i RU f S PES gt PROCEDURE 1 Remove the input power to the PRECISION TIG 275 machine 2 Using the 3 8 nut driver remove the right side case cover 3 Locate the Spark Gap Assembly at the lower rear right side of the machine See Figure F 2 4 Carefully remove the three leads from the Spark Gap Assembly See Fi
166. at each ver tical division represents 20 volts and that each horizontal division represents 5 milliseconds in time OO O Io Ir CHS olo bo Of a lz ole cre 5 5 ol o cic NOTE Scope probes connected at machine output terminals probe to electrode probe to work SCOPE SETTINGS PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC diis TROUBLESHOOTING amp REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED TO 200 AMPS DC TIG MODE HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC This is the typical AC output voltage waveform generated from a properly operating machine Note that each ver tical division represents 20 volts and that each horizontal division represents 5 milliseconds in time NOTE Scope probes connected at machine output terminals probe to electrode probe to work NOTE AC balance control set at Balanced position OO O Io Ir CHS ope 1 Of a lz ole cre Sla ol o cic SCOPE SETTINGS PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC F 44 LO N N Y o Lu E a m o E O a E 2 E LLI fr o LL NOL Je1Se A 01 Winey NOL Je1Se A 01 Ulm
167. c Cc THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO NOTES GENERAL INFORMATION LABELS NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED A CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING ELECTRICAL SYMBOLS PER E1537 SUPPLY VOLTAGE NET 7 7 FRAME CONNECTION THE INTERCHANGEABILITY OF A COMPLETE BOARD CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED C POWER SUPPLY SOURCE POINT SE THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS Ohms 1 4 V UNLESS OTHERWISE SPECIFIED NE OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER DIODES 14 400V UNLESS OTHERWISE SPECIFIED 77 COMMON CONNECTION SCALE DR APM pate 9 29 97 CHK SUPS D G No o 24206 ON ALL ANGLES IS 5 OF A DEGREE y SHI MATER AL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS ge Sht No EQUIP ge 7 THE LINCOLN ELECTRIC CO TYPE ON 2 PLACE DECIMALS IS 02_ CLEVELAND OHIO U S A SUBJEGT SCHEMATIC BYPASS ON 3 PLACE DECIMALS IS 002 NONE TTT Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ELECTRIC PRECISION TIG 275 G 24 ELECTRICAL DIAGRAMS G 24 PC BOARD ASSEMBLY BYPASS AND CE L10882 1 CODE 10893 Return to Section TOC Return to Master TOC
168. ccidental contact with the workpiece or ground 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 61 ARC RAYS 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 Use suitable clothing made from durable flame re
169. ctrode 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 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 U
170. e a H 422 Inin PULSE BACKGROUND Erem Vi GENERAL INFORMATION ee TGN ELECTRICAL 7775 o LABELS 318 E o F je m l O POWER SUPPLY SOURCE POINT Cc LS Vwan 53 Gm SE Y COMMON CONNECTION 815 wm o KN Ra d I PROPRIETARY amp CONFIDENTIAL R SILB PROPRIETARY INFORMATION Ne BY LINCOLN GLOBAL ING AND NAE WT BE DUPLICA COMMUNICATED olo BEE E S ununu ununu xs emaren reres EQUIPMENT TYPE PRECISION 115 WITHOUT AFFECTING THE INTERCHANGE I DRAWN BY nu EE T lus Ven RAMPING See E nme m feer SUBJECT SCHEMATIC ADVANCED CTRL PCB ae E 5 RR CENT 7 DRAWING n r si NA ere 3 5 2007 G 4760 1A0 F olo cc 22 NOTE This diagram is for reference only It may not be accurate for all machines covered this manual ELECTRIC PRECISION TIG 275 G 30 ELECTRICAL DIAGRAMS G 30 SCHEMATIC TIG OPTION P C BOARD ABOVE CODE 11000 G4760 PAGE 3 Return to Master TOC O O o Ce o o 0 o fed T o cc O O O FEL Len Hie AE 00 els EIS 5 0 o PULSE SPOT ON TIME nBOOST EN eosti ET nHOT START EN Vprein P L 3 nTRIGGER 2 a INTERLOCK mt LEV d Cl START VL Game pt 4 n4S RESTART nPULSE ON gt RAMP DATA Return to Sect
171. e Switch Z3 4 Step Trigger Restart Feature See Figure B 4 ON Restart Enabled OFF Restart Disabled as shipped Switch Z4 NOT CURRENTLY FUNCTIONAL e 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 B 10 OPERATION B 10 FIGURE B 3 olo ds sis E o gt o 2 E e START CRATER CURRENT 5 5 2 Step Trigger Modes ES D D DOVVN SLOPE po Torch Button Output Current Pre Flow Post Flow Normal Sequence 2 Step Restart Disabled With DIP Switch 2 OFF 69 D Return to Master TOC wn LL Button Output Current Pre Flow Post Flow Actuate the trigger a second time during down slope to i diatel d down slope Hold the ms to O crater current S FE E ol 1 2 2 Step Restart Enabled 3 With DIP Switch 2 ON As Shipped Orc he e Output E Current Pre Flow ae Gas
172. e control is only functional if the machine is set to AC polarity and TIG mode LOCAL REMOTE CURRENT CONTROL SWITCH A 2 position switch selects how the welding output is controlled for both Stick and TIG Modes 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 indicated by the Green panel light turning on ml OPERATION B 5 e 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 MicroStart Technology minimum current circuit provides for low end welding down to 2 amps previously unobtainable on an SCR platform TIG machine 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 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
173. e enclosed in grounded rigid metal lic conduit or equivalent shielding Flexible helically wrapped metallic conduit is generally not suitable 8 When the welder is enclosed in a metal building several 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 5 INPUT and GROUNDING CONNECTIONS Ai WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the disconnect switch or fuse box before working on this equip ment Be sure the voltage phase and frequency of the input power is as specified on the rating plate located on the rear of the machine Fuse the input circuit with the recommended super lag fuses or delay type circuit breakers Choose an input and grounding wire size according to local or national codes or use Section A 2 Using fuses or cir cuit breakers smaller than recommended may result in nuisance 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
174. e high voltage transformer The secondary of the high voltage transformer is coupled to a spark gap generator and also to the primary winding of the high frequency transformer The secondary of the high frequency transformer is in series with the rear elec trode output terminal The high frequency spark is present at the electrode terminal and is transferred to the Tig torch NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O o 02 a Return to Section TOC Return to Master TOC O O 9 o o an E 5 THEORY OF OPERATION E 5 FIGURE E 5 DC WELDING OUTPUT BACKGROUND CIRCUIT FROM CONTROL BOARD REAR GANG WORK POLARITY O SWITCH BYPASS p BOARD d FRONT ELECTRODE NCY IGH FREQUEI Ol RAN ER FE REAR 5777 ELECTRODE 63 5 VAC OPTIONAL POVVER FACTOR CORRECTION CAPACITORS T POWER SWITCH 2 4p RECONNECT AC DC SC R BRIDGE SOLENOID FEEDBACK THERMOSTAT 115 VAC CONTROL BOARD 1 ADVANCED CONTROL PANEL RECEPTACLE MINIMUM OUTPUT CONTROL PROTECTION METER STICK BOARD TIG SWITCH LOCAL REMOTE BALANCE POST SWITCH CONTROL FLOW MAXIMUM OUTPUT CONTROL REMOTE RECEPTACLE DC WELDING OUTPUT When the polarity switch is placed in either DC positi
175. e 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 220 VAC Schuko type cooler receptacle PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS OTL o Of a o lx ole cre 312 ol o cic Return to Section TOC Return to Master TOC 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 remove it Control Box components and PC Boards refer Sec
176. eason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help aid the technician in meter circuits calibration Return to Section TOC Return to Master TOC MATERIALS NEEDED Voltmeter Ohmmeter 3 8 Nut Driver Wiring Diagram OO O Io Ir CHS ope bo Ola lz ole cre Sla ol o cic PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR F 20 O O METER CALIBRATION ADJUSTMENTS continued i E FIGURE F 1 TRIMMER n E e TRIMMER 301 a di Y JUMPER Note The Precision TIG meter circuits are factory calibrated for the accuracy of the ammeter and voltmeter and should not need adjustment However the factory trimmers are accessible inside the control box Return to Section TOC Return to Master TOC CALIBRATION CHECK The Digital Meter Calibration Trimmer is located on the back of the meter housing near the right side connec tor plug with two leads and a jumper attached This trimmer adjusts calibration of the meter used for both ammeter and voltmeter readings so its calibration should be checked first as follows 1 Set the TIG mode and without closing the arc start switch preset the panel maximum output control so the panel digital me
177. ecision TIG Advanced Control Panel Provides 2 4 step trigger with adjustable Pulser controls 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 K1828 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 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 Cannot be used with a water cooler C 3 ACCESSORIES FOR CODES ABOVE 11000 3 K870 Foot Amptrol Single pedal foot activation of arc start switch and output control with 25 plug cable e K963 3 3 Hand Amptrol Fastens to torch for convenient thumb activation of arc start switch and output control with 25 plug cable e 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 PTA and PTW Series Torches All Air Cooled or Water Cooled Magnum TIG Torches may be used with the PRECIS
178. eck the output current con trols for proper operation Normal resistance is 10 000 ohms See the Wiring Diagram 4 Check leads 221 and 222 between the output shunt and the control board See the Wiring Diagram 5 The control board may be faulty 1 The circuit breaker CB1 may be faulty 2 Check the receptacle and asso ciated leads for loose or faulty connections 3 Perform the 1T1 Transformer Ai CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN amp F 9 F 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The machine makes a very loud 1 Inspect the output terminal insu 1 Diode D1 may be shorted buzzing noise in DC Stick or in DC lators for cracks or signs of over Check and replace if necessary TIG modes There is no current heating 2 Check the polarity switch S2 for draw from the machine s output ter i minals The machine is not exter Xu nections nally loaded 3 Perform the SCR Bridge Tests Return to Section TOC Return to Master TOC Return to Section TOC Return to Mast
179. elding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Ses Section B T Section C Maintenance nennen E PE nennen nnn nnne sena nnn A Section D Theory of Operation ooooocccccccccccooconnnccnnonnconncnononnncnnnonnnnnnnnnnnonononrrnnnnnnnnnnnnnnncnnnannennnnnss Section E Troubleshooting and Repair ooooccnccccocccccccocccnconnnccncnnnnncnnnonnnnnnnonancnnnonnnnrnnnnnnnnnnnnnnnens Section F How to Use Troubleshooting Guide 2 F 2 TA PN F 3 Troubleshooting Guide TM E TE T Im F 4 En eee aaa NE misi F 19 Oscilloscope e EE F 39 Replacement Procedures MNT OE F 45 Retest After Repair rrrnannrnnnnennanennannrnannenannrnnnsrnnnnennnnsrnnnsnnnnrennn
180. electrode and idler by pushing on the throttle control rods work cables If the electrode cable is on your right while the engine is running side the work cable should also be on your right side qe Connect the work cable to the workpiece as close as possible to the area being welded 1 g 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 Return to Master TOC LINCOLN Return to Master TOC Return to Master TOC O O E 9 i B o an Return to Master TOC 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 a high risk of unavoidable or a
181. er TOC OO O Io Ir CHS ope o Of a lz ole cre Sla ol o cic 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a lz ole 1 2 lz ol o r l Return to Section TOC Return to Master TOC F 10 F 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine output is intermittent ly lost Gas flow and high frequen cy are also interrupted NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced Process panel or harness is defective POSSIBLE AREAS OF MISADJUSTMENT S TIG WELDING PROBLEMS 1 The problem may be caused by high frequency interference Make sure that the machine is grounded properly according to the installation instructions If there are other high frequency sources in the area make cer tain that they are grounded prop erly 2 Make sure the Amptrol is operat ing p
182. er TOC OO O Io Ir Cl ope o Of a o lx ole cik 515 ol o cic Return to Section TOC Return to Master TOC SAFETY PRECAUTIONS 44 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 Inspect the spark gap at regular intervals to maintain the recommended spacing See the Service Procedures See in this Section for complete information on spark gap set tings The fan motor has sealed ball bearings which require no maintenance D 2 MAINTENANCE D 2 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 t
183. er 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 8 INSTALLATION A 8 FIGURE A 3 OUTPUT front Panel Air Cooled Torch Torch Adapter DA Le eoe Q cooiant our 58 18 LH For Gas Supply hose with 5 8 18RH male Provided with Weld Package model Return to Section TOC Return to Master TOC Two Cable K2166 2 Opt PTA 9 17 26 Na et v zz et One Cable PTA 26 For Coolant Supply Hoses with 5 8 18LH male Provided with Weld Package model or Under Cooler Cart COOLANTIN 78 14 LH AP ELECTRODE AND OR One Cable PTA 9 17 Return t
184. g on localized Electric and Magnetic Fields EMF Welding 65951 ANGINE PANE o current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated Return to Master TOC EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts e Exposure to EMF fields in welding may have other health when starting operating or repairing equipment effects which are now not known O O E 9 i 2 o an In some cases it may be necessary to remove safety d All welders should use the following procedures in order to guards to perform required maintenance Remove minimize exposure to EMF fields from the welding circuit guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 1 Route the electrode and work cables together Secure Always use the greatest care when working near moving them with tape when possible parts 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 the governor or 2 d 3 Do not place your body between the
185. gure F 2 5 Insulate the leads from each other and from the case VIEWED FROM ABOVE 6 When voltage testing and scope measure ments are complete reconnect the three leads to the Spark Gap Assembly 7 Reassemble the right side case cover PRECISION TIG 275 LINCOLN amp F 25 TROUBLESHOOTING amp REPAIR F 25 PROTECTION BOARD TEST A WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will determine if the Protection board is functioning properly Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 8 Nut Driver Voltmeter Ohmmeter Multimeter Tig 275 Wiring Diagrams OO O Io Ir CHS ope 1 Of a lz ole cre Sla ol o cic PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master
186. handle back onto its shaft Secure polarity switch handle with the phillips head screw previously removed Reconnect leads 265 and 266A previously removed Reconnect all previously removed leads to their proper terminals See Wiring Diagram Replace case sides and top PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope 1 Of a lz ole cre 515 ol o cic Return to Section TOC Return to Master TOC F 59 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the SCRs from the output rec tifier heat sink for maintenance or replacement MATERIALS NEEDED No 000 Fine Steel Wool Penetrox A 13 Lincoln E2529 or Penetrox A
187. hen 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 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 abov
188. i mum Failure to observe these precautions can result in excessive operating temperatures and nuisance 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 cannot be stacked UNDERCARRIAGE LIFTING AND MOVING When the Precision TIG 275 is purchased as a welding 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 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 A 4 The machine may topple over if this precaution is not followed ENVIRONMENTAL RATING Precision TIG 275 power sources carry an 1 215 Environmental rating They are rated for use in damp dirty rain sheltered environments HIGH FREQUENCY INTERFERENCE PROTECTION The frame of the welder must be grounded A ground screw marked with the symbol CL is located on the input connection panel Figure A 1 for this purpose See your local and national electrical codes for proper grounding methods The spark gap oscillator in the high frequency genera tor being
189. ide 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 D 4 LLI N 5 t 2 E a 2 Q E E 1 or E 9 un m et lt a T gt gt gt r Q2 Q E gt nE so QU CME e 25323 6 5 0 Go O usm UI e 0 No amp o D xz 9 O Qu 0 q C5 L NOL Je1Se A 0 Winey NOL 491SEVN 01 UINISY NOL Je1Se A 0 Ulm ki JO Je1Se A 0 Ulm ki OOL uonoes o OOL uonoes o OOL uonoesg o OOL uonoeg o uinjed E 1 Q TABLE OF CONTENTS THEORY OF OPERATION SECTION 9 Theory of Operation Section E 5 CO NO MN TEE EET E 2 cr PTE O RUNE EE E 2 Output Rectification Control Board and Feedback E 3 High Voltage elei Frequency ere EEE TE E 4 BIER CIC mot
190. ight SOLENOID ELECTRODE 233A 4 D SHOWN IN 2 STEP AREE flashes with on menu feature now 115VAC 230 460 575 o L pulse frequency 5LED 15 LED 235 o evr 231A 115V common TIG WELDING ae Ose hoe 413 1 LEAD 250 CONNECTS TO THE MID TERMINAL W 233A eee UT 115V 15A ON THE RECONNECT PANEL ALONG WITH CORRECT ADVANCED CONTROL PANEL OPTIONAL ON PT275 Q ror START TRIMMER pot used see A SC d outside of right side box cu wih Pog BUOY LEAD FROM THE MAIN TRANSFORMER T1 ARC FORCE TRIMMER menu options h 2Ain tig mode 2 COOLER RELAY 233 460 575 d ON 8 minutes after A 12VDC St z SEENEN valla 262 233B dan LEAD 250 CONNECTS TO THE LOW TERMINAL MOVE THIS PLUG FROM TIG 375 ONLY Q 231F mn E ON THE RECONNECT PANEL ALONG WITH CORRECT REMOTE J5 TO J5A FOR ROBOTIC INTERFACE Mann T CR4 pun LO mor TOM ot pha LEAD FROM THE MAIN TRANSFORMER T1 RECEPTACLE 115VAC FAN Fan 115VAC 1 234 OLA 231 T1 i WHEN ADVANCED CONTROL TOROID 263 U A 4J22 I PCB IS NOT INSTALLED E 260 Es ELECTRICAL SYMBOLS PER E1537 DISCONNECT FOR 5J11 COOLER 12VDC IN TIG WELDING 262 em L MAX PLUGGED TO E sok Le N Sle 1322 M 2 23 A 245 DOUBLE PREPOST FLOW 18411 COOLER COMMON gen COOLER RECEPTACLE 22 400V ap read PET cB2 LEAD COLOR CODE COMPONENT VALLE UNITS WIPER R gt C 2J22 3 23 B 1 SUB o8 From es PRECISION TIG 275 ONLY rm FH
191. illumination of the yellow Thermal Shutdown light on the front panel 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 Once the machine cools sufficiently the thermostats are self resetting If the shutdown is caused by excessive out put or duty cycle and the fan is operating normally the power may be left on and the reset should occur with in a 15 minute period If the fan is not functioning prop erly or the air intake louvers are obstructed the input power must be removed and the fan problem or air obstruction corrected Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a o lx ole cre 512 ol o r l OVERLOAD PROTECTION The machine is electronically protected from producing excessively high output currents The output is limited to 350 amps PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION O O 5 Troubleshooting amp Repair Section Section F 5 How to Use Troubleshooting Guide trt itt optata minii mal m F 2 is PC Board Troubleshooting Procedures and Replacement F
192. ing gas is being used reduce the percentage of helium Make sure the tungsten elec trode is the correct size for the process The input line voltage may be low Check the torch and work cable for loose or faulty connections TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 The high voltage transformer T2 may be faulty 2 Capacitor C6 may be faulty 3 The high frequency transformer T3 may be faulty 1 Check the J11 plug on the con trol board See Wiring Diagram 2 Check the background resistor R7 Normal resistance is 20 ohms 3 Check the background diode bridge CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN E TIG WELDING PROBLEMS Return to Section TOC Return to Master TOC OO O Io Ir CHS OTL o Of a o lx ole cre Sla ol o cic Return to Section TOC Return to Master TOC The high frequency spark is pre sent at the tungsten electrode but the operator is unable to establish 1 The torch may be faulty Check or replace F 13 F 13 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines E E detailed in the beginning of this manual opg o i o 5 PROBLEMS POSSIBLE AREAS OF
193. ion TOC Return to Master TOC GENERAL INFORMATION SYMBOLS PER E1537 os LABELS LU A SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION 7 FRAME CONNECTION d EARTH GROUND CONNECTION DIODES 1A 400V UNLESS OTHERWISE PROPRIETARY amp CONFIDENTIAL 195 DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED SPRINTED cinc Boana way CHANGE OSI dee EQUIPMENT TYPE PRECISION TIG ABS TTY OF COMPLETE BOARD THIS qoyar SUBJECT SCHEMATIC ADVANCED CTRL PCB ES eat emn s iP Ms NA EEE vae EET sac 64760 1A0 A Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ELECTRIC PRECISION TIG 275 G 31 ELECTRICAL DIAGRAMS G 31 PC BOARD ASSEMBLY TIG OPTION P C BOARD ABOVE CODE 11000 G4761 1 eM JEE NUMBER DESCRIPTION QV YCvq 1 REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW REFERENCES QTY PART NUMBER DESCRIPTION C1 C2 C4 C5 C7 C10 C12 C14 C15 C17 C18 C19 C20 C26 C29 C30 C31 C32 C33 C24 C38 36 525020 35 39 43 45 49 50 C51 C52 C53 C54 C55 C56 C57 C62 C63 C65 S 9 ENGINEERING he CHANGE DETAIL RELFASEDA 01 FROM X MANUFACTURER CAPACITOR SMD CERAMIC O 1MF 50V 1026
194. ithout closing the arc start switch preset the maximum output panel control so the panel digital meter reads approx 200 amps Using a DC AVG test ammeter with at least 1 accuracy at up to 300 amps connect it to measure the DC current through a short weld cable shorting out the work to electrode studs on the front stud panel Remove the TIG torch if connected Close the arc start switch just long enough to com pare the panel meter reading to that of the test ammeter The short circuit current readings should match within 4 2A If not adjust the trimmer so that the panel meter accuracy is corrected Fa Es N 00 Ui o as am 3 Ol ka 2 RASS IEG SIS ojig Q S a t t ns m o C159 R352 o o o o o o f 11 o o o o o R353 J10 C159 o o o o o o o o VOLTMETER CALIBRATION PROCEDURE 1 Locate the Voltmeter Calibration Trimmer R2 on the control board See Figure F1 2 To prevent maximum OCV output disconnect the SCR gate lead plug from receptacle J4 3 Set to TIG mode with DC polarity without closing the arc start switch 4 Using a DC avg test voltmeter with at least 1 accuracy at up to 100 volts connect it across the work and electrode studs on the front stud panel Remove the TIG torch if connected 5 Press the display panel switch to V volts position then close the arc start switch just long enough to compare the panel
195. ive The control board may be faulty The High frequency is on continu ously in DC TIG or shuts off in AC TIG Check plug J11 on the control board See the Wiring Diagram Check micro switch S2A for proper operation See the Wiring Diagram The control board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope bo Of a lz ole cre Sla ol o cic Return to Section TOC Return to Master TOC F 12 F 12 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS High frequency spark is present but weak Poor arc starting in the DC TIG mode POSSIBLE AREAS OF MISADJUSTMENT S TIG WELDING PROBLEMS 1 The spark gap may be too large Check and reset per instructions in thel Maintenance Section of this manual The work and or torch cables may be in poor condition allow ing the high frequency to leak to ground Use good quality cables preferably those with a high natural rubber content and as short as possible If helium shield
196. ki NOL 491SEVN 01 Ulm ki NOL Je1Se A 0 Winey OOL Uooes in ki OOL uonoes o OOL Uooes o inl ki OOL uonoes o in ki F 45 TROUBLESHOOTING amp REPAIR F 45 HIGH VOLTAGE TRANSFORMER REMOVAL AND REPLACEMENT A WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 O lo RJE opg 10 go 2 2152 DESCRIPTION CIE 3 This procedure will aid the technician in the removal and replacement of the high voltage r m transformer MATERIALS NEEDED 3 8 Nut Driver 7 16 Nut Driver Phillips Head Screwdriver Off set Wire Cutters OO O Io Ir CHS ope 1 Of a lz ole cre Sla ol o cic PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC F 46 TROUBLESHOOTING amp REPAIR F 46 HIGH VOLTAGE TRANSFORMER REMOVAL AND REPLACEMENT continued
197. lenoid is used it can be tested 6 Apply the correct input power to the TIG 275 using the same procedures OO O Io Ir CHS olo 1 Ola o lx ole cre Sla ol o cic PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir C ix ope ao Of a lz ole cre 515 ol o cic Return to Section TOC Return to Master TOC F 33 TROUBLESHOOTING amp REPAIR STATIC SCR TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The SCR test is a quick check to determine if an SCR is shorted or leaky See machine waveform section for normal and abnormal SCR waveforms MATERIALS NEEDED 3 8 Nut Driver Analog Ohmmeter Multimeter Tig 275 Wiring Diagrams SCR Heatsink Assembly Drawing PRECISION TIG 27
198. ll of the secondary voltages are missing or incorrect make certain that the correct input voltage is being applied to the correct primary leads See Table F 3 b If the correct input voltage is being applied to the primary leads and any or all of the sec ondary voltages are incorrect the T1 trans former may be faulty Also check the leads for broken or loose connections between plug J11 and the T1 transformer 8 Replace the case side covers PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c o 02 2 E D Return to Section TOC Return to Master TOC O O ES 9 i o as F 29 TROUBLESHOOTING amp REPAIR F 29 T1 MAIN TRANSFORMER TEST continued Table F 3 T1 Transformer Voltages TEST POINTS ACCEPTABLE VOLTAGES SECONDARY WINDINGS PLUG J11 PIN 8 LEAD W209 TO PLUG J11 PIN 16 LEAD R210 PLUG J11 PIN 7 LEAD 201 TO PLUG J11 PIN 15 LEAD 204 X1 TO X2 PRIMARY WINDINGS H1 TO H2 H1 TO H3 H1 TO H4 SECONDARY VOLTAGES 20 VAC 18VAC 78 VAC PRIMARY VOLTAGES 208 VAC 230 VAC 460 VAC NOTE Ifthe input voltages vary the secondary voltages will vary accordingly Based on 208 230 460 models For other voltage models refer to appropriate Wiring Diagram PRECISION TIG 275 LINCOLN F 30 NOTES F 30 NOL Je1sey 01 Winey NOL
199. lowed part of the equipment frame Keep when warranty reports are to be submitted touching the frame to prevent stat ic build up Be sure not to touch any electrically live parts at the same time NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROB LEM will help avoid denial of legitimate PC Tools which come in contact with the PC Board must Board warranty claims be either conductive anti static or static disipative PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS olo Ola o lx ole cre Sla ol o cic Return to Section TOC Return to Master TOC F 4 Observe Safety Guidelines TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine is dead No weld out put no 115 VAC at the receptacle POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Check the input voltage The input voltage must match the rat ing plate and the voltage con nection Refer tol Reconnect in the Installation section of this manual 2 Make sure that the input power switch is in the ON position 3 Check for blown or missing fuses in the input lines 4 Check circuit breaker Heset if necessary CB1 F 4 R
200. m C4 0047 TN 3000V L5 V J23 J22 lt 89MH P gt UO ude 0047 TN 3000V 2228 V J22 39mH T gt 2 OG al 0047 TN 3000V V J23 J22 E C2 0047 TN 3000V L6 V J23 e lt 39mH T C6 0047 3000V L3 J23 J22 39mH s gt C3 Y 0047 3000V GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V RESISTORS Ohms DIODES 1A 400V UNLESS OTHERWISE SPECIFIED 1 4W UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE G 19 LAST NO USED LABELS SUPPLY VOLTAGE NET C POWER SUPPLY SOURCE POINT V COMMON CONNECTION 777 FRAME CONNECTION EARTH GROUND CONNECTION SQARE WAVE TIG 350 SUP S D G sussect_ PROTECTION P C BOARD SCHEMATIC s M 16115 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may c
201. mponents 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 280 400V and high is 415V Reconnect the jumper strap to the terminal stud corre sponding to the input voltage level used Make sure all connections are tight A WARNING OUTPUT CABLES CONNECTIONS AND LIMITATIONS 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 as well as the TIG Torch connection panel INSTALLATION A 6 Recommended Cable Sizes for Combined Lengths of Copper Work and Electrode Cables using 75 C Wire Machine Rating 0 to 100 Ft 101 to 200 Ft 201 to 250 Ft 275A 40 1 42 4 mm 1 0 53 5 mm 2 0 67 4 mm WORK CABLE CONNECTION A 15 2 0 weld cable with clamp is available K2150 1 or included with the Precision TIG
202. n 100 STICK 9 gt STICK SV 221K 5 b V ona i GND 7 TT C149 Aur VU DIE Sov TH i 50V ERMAL YELLOVW 12mA GND GNB 475K 415K 22 LU en R288 STICK RED Z0MA POT R 475K Air d 504 G Yorein O O GNA O O 32 10 0224 EG Cove ajes c i GND 15 iW O o LOCAL 15 LOOK 48V AEN 16V UNREG 7 pw Kri 19 GNE 6 GNDN 7 1 al n fis e C146 z Nib mh COOLER RECEPTACLE RELAY o Al m 087 12 Y DC COIL 8 o SOV g 10K 1A REMOTE 400V o 9 b 2 72 R325 059 ae 72 5 8 c TER ER r Adv O22uF mH 20 181 20 EN 5 i o 7 15V E 5 3 e 0z23 CIRCUIT FOR DISPLAYING GND no 2 18 MAX POT SETTING IN erg 7 ee olo 1557 IN TIG REMOTE NOT WELOING ane E 2 SCH s cc CC REMOTE GREEN 12m 25 7 lt INTERLOCK 2 320 iw A al 8 GND 03 lt gt 2152 T 10 10k HON p K SiV Bo Lee 352 C STICK SW C78 T x 0 022uF d 400v S e E Jai 7 GN Ven 5 a e GND 500 Ex ma BG e 5V M WATER Dto oo p GND 5 Sy GAS 38 8 T GAS An o1 5 SE Des dal 3 14 F mp 2 HF pin 5 SHT 3 B J5 FAN DHB X17 SHT 3 FAN 8 2 2 3 55 T 3 86 B m E111 X18 1K ERE AC m s E ME 1 6 sh A STICK nm 3 N 22 C146 E oiu R257 Drees 7 ho R323 8287 A 5 022uf m 23 G v B 80845CN Q SHUTDOWN O vi DC STICK gt 4I6 SHT 3 BC STIEK LL T E 5 3 Ves oluf DC STICK lt 7 4 PO TCAP ES kurt mp C93 C108 z KEE O 22
203. n to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS OTL o Of a o lx ole cre 312 ol o cic Return to Section TOC Return to Master TOC OPTIONAL EQUIPMENT FACTORY INSTALLED OPTIONS The basic Precision TIG 275 machine is factory equipped with A 3 8 Adapter S20403 4 for air cooled torch con nection of a PTA 9 or PTA 17 Accessories that are factory installed with the Domestic model K1826 1 to make up the Domestic Welding Package K1825 1 include K1828 1 Under Cooler Cart 3100211 Harris Argon Flow Regulator with 10 Hose K870 Foot Amptrol e 1784 4 25 PTW 20 water cooled TIG Torch K918 2 Zippered Torch Cover e KP510 Parts Kit for Torch e K2150 1 Work Lead Assembly oee below for more detailed descriptions 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 1829 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 K1828 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 1 Undercarriage Includes a dual bottle rack
204. n to Section TOC Return to Master TOC ADVANCED CONTROL PANEL RECEPTACLE MINIMUM OUTPUT CONTROL MAXIMUM OUTPUT CONTROL GENERAL DESCRIPTION The PRECISION TIG 275 is part of a new family of industrial arc welding power sources able to provide constant current and single range square wave AC DC Tig GTAW with new MicroStart Technology It incor porates independent presettable minimum and maxi mum output control with built in high frequency stabi lization for continuous AC Tig welding and reliable DC Tig starting The Precision TIG 275 also has AC DC stick SMAW capabilities This new design includes advanced features such as a digital meter presettable controls auto balance fan as needed and timers for fixed preflow and variable post flow of shielding gas It features a stick output terminal front and a universal Tig torch connection box rear for simultaneous but separate electrode outputs INPUT POWER CIRCUIT The desired single phase input power is connected to the PRECISION TIG 275 through the power switch to the reconnect panel located in the rear of the machine The machine can be configured for any one of three input voltages 208 VAC 230 VAC or 460 VAC by con necting the jumper strap to the appropriate terminal on THERMOSTAT 115 VAC SOLENOID FEEDBACK 0 D 115 VAC LED s CONTROL BOARD PROTECTION METER STICK BOARD TIG RECEPTACLE SWITCH LOCAL REMOTE BALANCE POST S
205. ncoln Electric Service Department for electrical troubleshooting assistance before you proceed Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir C ix ope o Of a lz ole cre 515 ol o cic Return to Section TOC Return to Master TOC F 8 F 8 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION The machine welds at a very high output regardless of the current control setting NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced Process panel or harness is defective Accessories plugged into the volt receptacle do not work OUTPUT PROBLEMS 1 If welding in the TIG mode the remote control device may be defective Make sure the accessory plug and associated leads are in good working condition Make certain the correct input voltage is being applied to the machine The reconnect lead must be in the correct position The circuit breaker CB1 may be tripped Reset if necessary Only the top part of the recepta cle is electronically Hot all of the time 1 Perform the SCR Bridge Test 2 Perform the T1 Transformer 3 Ch
206. o Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a o lx ole cre 312 ol o cic Return to Section TOC Return to Master TOC 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 The bottom outlet of this duplex receptacle 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 e 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
207. ompromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine PRECISION TIG 275 ed ELECTRICAL DIAGRAMS G 20 PC BOARD ASSEMBLY PROTECTION M16062 1 O i e SQUARE WAVE n i PROTECTION 16062 1 L6 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC L3 L2 O O O o FE Cil JE ois oiz 018 S5 kd olo cic O ITEM PART NO IDENTIFICATION C1 02 C3 C4 05 6 6 1577 58 0047 3000 V L1 L2 L3 L4 L5 L6 6 T12218 0F 39 mH HEADER HEADER P C BD BLANK M16062 1 CAPACITORS MFD VOLTS 9 28 2001M NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine PRECISION 275 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o FIRE
208. on the When the machine is in the DC mode the background cir AC voltage from the main transformer secondary is applied Cuitry provides an added boost of voltage to the output to the SCR bridge The SCR bridge and choke circuits are terminals This circuitry is controlled by the control board connected in the conventional full wave bridge and filter configuration resulting in a controlled DC output Since the choke is in series with the negative leg of the bridge and also in series with the welding load a filtered DC is applied to the output terminals The bypass board pro tects the internal circuitry from interference FIGURE E 6 DC WELDING CURRENT GENERATION CHOKE ELECTRODE 9 DC PRIMARY 10 WORK PRECISION TIG 275 LINCOLN E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O o Ir Ci ope o Of a o lx ole cic 312 ol o r l Return to Section TOC Return to Master TOC E 6 THEORY OF OPERATION E 6 FIGURE E 7 AC WELDING OUTPUT BACKGROUND CIRCUIT FROM CONTROL lt gt BOARD OPTIONAL POWER FACTOR CORRECTION CAPACITORS T POWER SWITCH 2 L RECONNECT ADVANCED CONTROL PANEL RECEPTACLE MINIMUM OUTPUT CONTROL MAXIMUM OUTPUT CONTROL AC WELDING OUTPUT Rotating the polarity switch to the AC position changes the welding power circuit One lead X1 of the main transformer secondary is connected to
209. orking on remote B A Pins 1 amp 4 l amptrol from min to max FIGURE F 3 Plug J5 viewed from pin end PRECISION TIG 275 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope 1 Of a lz ole cre 515 ol o cic Return to Section TOC Return to Master TOC F 27 TROUBLESHOOTING amp REPAIR T1 MAIN TRANSFORMER TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will determine if the correct voltage is being applied to the primary of the T1 transformer and also if the correct voltages are being induced on the secondary wind ings of the transformer MATERIALS NEEDED 3 8 Nut Driver Voltmeter Ohmmeter Multimeter Tig 275 Wiring Diagrams PRECISION TIG 275 LINCOLN F 27 Return to Section TOC Return to Master
210. ound Always dry insulating gloves Read and follow Electric Shock Warnings in the Safety section if welding must be performed under electrically hazardous conditions such as welding in wet areas or on or in the workpiece FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire and explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn Wear eye ear and body protec tion Observe additional Safety Guidelines detailed in the beginning of this manual B 2 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 Cooler Cart which is also included in an avail able efficiently integrated entire TIG Welding Package with convenient
211. p ma ao oa V sl None E PRECISION TIG pace 1 DRAWN BY bburkhart DOCUMENT DOCUMEN 018 GA Sze SUBJECT MACHINE SCHEMATIC NUMBER REVISION c 5 0 Gc NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ELECTRIC PRECISION TIG 275 ls ELECTRICAL DIAGRAMS i SCHEMATIC CONTROL PC BOARD BELOW CODE 11000 G3908 PAGE 1 o x 1 15V preset o o SHT 2 CL 15Y D Ew o PRESET SIGNAL TO METER 15V y 1 6 SAME AS REF TO ERROR 15Y 10 153 o V SETPOINT FROM WELD SEQ GNDN 7 gov uu N C30 5V_AEF rox B 0 022uF P 2 10 VOLTS MAX OFF IM DC E UNTIL i re m 2 50V YN 15V 124 ms AFTER ARCEST 1468 a IK 3 sy E Pook nl pi 10 olg S Si S uk iA Slok en R FILTER CAP 10 400V 4 AUTO BALANCE GREEN 12mA c JUMPER FOR 375 i NEP R212 P Sis A sur 2 oily Ke sf A cios RA OR R 7 26N BALANCE olo DU Vis TR es y HIGH STICK MODE OR OC 158 1 cic V aamv 2 AMPS MIN R245 051 EU V og eg bo 50V Van K qu 68 221K P 2244 6 Blu pj a zl 5 66 VOLTS F R 339 AMPS DN 275 50v GND 030 T i por OND 297 VOLTS FOR 418 AMPS ON 375 490v 100 ARC VOLTS PK t 083 R270 APPROX 14 VOLTS HS m 9 09K BOR n 65 Ce VE Odur 022 C go SOV SOY 6604 i Lesen JUMPER FOR 375 e Ag PEN x SHT 2 Rees 12 BALANCE POT Von vel m
212. proximate Argon Electrode Tip Preparation Sharpened Balled Gas Flow Rate EWZr C F H l min El T ectrode 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 15A Up to 15A Up to 15A 3 8 2 4 3 8 2 4 020 Up to 15 A 10 to 15A 5 to 20A 5 10 3 5 5 10 3 5 040 Up to 80A 20 to 30 A 20 to 60 A 5 10 3 5 5 10 3 5 1 16 Up to 150 A 30 to 80 A 60 to 120A 5 10 3 5 9 13 4 6 3 32 Up to MAX A 60 to 130 A 100 to 180A 13 17 6 8 11 15 5 7 1 8 X 100 to 180A 160 10 250 15 23 7 11 11 15 5 7 Tungsten electrodes are classified as follows by the American Welding Society AWS im eh EM green 1 Tonal EWTh 1 yellow 2 MON reis EWTh 2 red 4296 Ceria EWCe 2 orange 1 5 Lanthana EVVLa 1 black 40 15 to 0 40 Zirconia brown 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 PRECISION TIG 275 LINCOLN Return to Master TOC Return to Master TOC O O E 9 i B o an Return to Master TOC TABLE OF CONTENTS ACCESSORIES Aces Section C Optional Equipment for Codes Below 11000 C 2 Optional Equipment for Codes Above 11000 C 3 PRECISION TIG 275 LINCOLN Return to Section TOC Retur
213. r The arc start switch functions in the following manner 1 Closing the switch starts preflow then arc starts at Minimum Start setting level See 15 Item 7 If the trigger is maintained closed after preflow time the output remains at the Start level until it is released 2 Opening the switch initiates fixed 0 5 sec ramp time from Start setting level to Weld setting 3 Reclosing the switch initiates Downslope ramp time setting See item 17 from Weld 16 setting down to the Crater fill level See Item 7 of the machine 4 Reopening the switch after Downslope time holds Crater fill level until it times out then stops the arc and initiates the Postflow Time See Item 9 Reopening switch during 17 Downslope time immediately stops the arc and initiates the Postflow Note See Figure B 4 for 4 Step operation during Downslope with Restart feature selected to be enabled instead of disabled as shipped 13 PULSE MODE SWITCH PULSE SPOT MODE SWITCH for codes above 11000 Turns on the Pulse Mode as indicated by the Green panel light turning on e PULSE ON position provides a Peak current level set by REMOTE and or LOCAL control of the output current See ltem5 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 e Pulsing begins after upslope when the output cur
214. r Gasoline Engines ARC WELDING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Return to Master TOC 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 P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE 1 h To avoid scalding do not remove the powered equipment d e 77 pressure cap vvhen the engine is 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors y ap ELECTRIC AND MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld M may be dangerous ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current flowing through any conductor causes ing to prevent spilled fuel from vaporizin
215. r any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ojeg 1 Ola lz ole cre 515 ol o cic Return to Section TOC Return to Master TOC F 14 F 14 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The stick electrode blasts off when touched to the work piece NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced Process panel or harness is defective Variable or sluggish welding arc when welding in the Stick mode POSSIBLE AREAS OF MISADJUSTMENT S STICK WELDING PROBLEMS 1 Welding current may be too high for the electrode size Reduce current control setting or use a larger diameter electrode Check the work and electrode cables for loose or poor connec tions The welding cables may be too small or too long to permit the desired current to flow The welding current may be set too low TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION
216. r maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 8 Nut Driver 1 2 Nut Driver 7 16 Nut Driver Pliers Crimp Wire Cutters OO O Io Ir CHS ope 1 Of a lz ole cre Sla ol o cic PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a lz ole cre Sla ol o cic Return to Section TOC Return to Master TOC F 54 TROUBLESHOOTING amp REPAIR F 54 SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT continued REMOVAL PROCEDURE 1 Remove input power to the TIG 275 machine 2 Using the 3 8 nut driver remove the case sides and top 3 Label and cut leads G1 and G2 See Figure F 14 4 Label and cut leads G3 and G4 See Figure F 14 5 Remove the 1 2 nut securing leads B and 217 See Figure F 14 6 Using a 7 16 nut driver disconnect Pos lead and lead 218 See Figure F 14 7 Using a 1 2 nut driver disconnect Pos lead and lead 218 1See Figure F 14 8 Using a 1 2 nut driver remove lead 216 and aluminum lead X1 connecting to the main transformer See Figure F14 Note washer placement upon removal 9 Using a 1 2 nut driver disconnect lead 220A and shunt from the output bridge See Figure F 14 10 Using a 3 8 nut driver remove the four SCR bridge mounting bolts Note
217. rd 2 Perform the T1 Transforme 3 The control board may be faulty Ai CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC F 7 TROUBLESHOOTING amp REPAIR F 7 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope ao Of a lz ole cre 515 ol o cic Return to Section TOC Return to Master TOC PROBLEMS SYMPTOMS The machine does not have welding output in the Stick mode The machine operates correctly in the TIG mode SEE NOTE BELOW POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check the electrode cable and holder for loose or faulty connec tions Make sure the Stick TIG switch is in the proper position and operat ing correctly RECOMMENDED COURSE OF ACTION 1 Check the Stick TIG switch and associated leads See the Wiring Diagram 2 The control board may be faulty The machine has welding output in the Stick mode but no output in the TIG mode no gas flow or high fre quency SEE NOTE BELOW Make sure the Stick TIG switch i
218. rd repairs could result in damage to the LINCOLN scr PRECISION TIG 275 Return to Section TOC Return to Section TOC Return to Master TOC O O o fed o o U o fed T o cc Return to Section TOC Return to Master TOC Return to Master TOC O O o o o SL zi G 13 SCHEMATIC CONTROL PC BOARD ABOVE CODE 11000 G4762 PAGE 1 ee ee re bb A A EE EE vat vn en EE PRESET SIGNAL TO METER SAME AS REF TG ERROR AMP i Ipreset 15V SHT 2 V SETPOINT FROM WELD SEQ 10 VOLTS MAX m Vsetpt 4 067 SHT 2 S 7 Lion 768K c 17 A cd F 0 022uF 50V JUMPER FOR 375 ELECTRICAL DIAGRAMS I H I i 1 t 1 1 H H t 1 1 1 I 1 1 1 1 1 1 1 1 1 i 1 1 1 1 1 1 I 1 1 1 1 1 1 1 1 l 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 a FILTER_CAP se LY 0 022uF 50v MT 5004 200mV Tono 1044 ID t TR Va TRIM OFFSET FOR 18 AMPS 544 Tih MODE NO BACKGROUND 0 022uF 50V SHUNT AMPLIFIER I l I 1 1 1 1 l 1 l 1 1 1 1 4 i Ey 158 Ire s y 2 AMPS MIN Qiu S V ip VOLTS 600 AMPS GNO 10K OHMS GIVES 1 S 566 VOLTS FOR 339 A
219. re working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 Return to Master TOC Return to Master TOC O O E 9 i 2 o an Return to Master TOC PR CAUTIONS DE S RET 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 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 le
220. rew Location CASEFRONT SCREWS NRO IN 7 7 227 ZA Uf Ui YY y LND Uf Gy LMU J 2 222 YY Uff Uf Uf 7 Y 7 UY YU p x LY e NIU 4 9 A E A a Bs 4 4 Ga sil Mee i JE S o S Se d Ib D l d S WSS 1 l REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1 Remove input power to the TIG 275 1 Replace the control board 2 Mount the new control board in its proper position using the eight phillips head mount ing screws 2 Using a 3 8 nut driver remove the two screws from the top of the case front See Figure F 12 3 Replace any necessary cable ties 3 The top front control box cover can now be tilted forward to gain access to the control board and its plugs 4 From left to right label and disconnect plugs J4 J5 J6 J8 J9 J10 J11 012 See Figure 5 Cut any necessary cable ties 4 Reconnect plugs previously removed from the control board 5 Secure the control box assembly using the two 3 8 mounting screws previously removed 6 Using a phillips head screwdriver remove the eight P C Board mounting screws See Figure F 13 7 Carefully maneuver the control board out of the front of the machine PRECISION TIG 275 LINCOLN E F 51 TROUBLESHOOTING amp REPAIR F 51 CONTROL BOARD REMOVAL AN
221. rm generated from a properly operating machine Note that each ver tical division represents 20 volts and that each horizontal division represents 5 milliseconds in time OO O Io Ir CHS ope 1 Ola lz ole cre Sla ol o cic NOTE Scope probes connected at machine output terminals probe to electrode probe to work SCOPE SETTINGS PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope 1 Ola lz ole cre Sla ol o cic Return to Section TOC Return to Master TOC F 40 F 40 TROUBLESHOOTING amp REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED TO 200 AMPS AC TIG MODE HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure 1 MNA eA TL LT UI FIY A 1 LLELLLI AC BALANCE CONTROL IN AUTO This is the typical AC output voltage waveform generated from a properly operating machine Note that each ver tical division represents 20 volts and that each horizontal division represents 5 milliseconds in time The machine was loaded with a resistance grid bank NOTE Scope probes connected at machine output terminals probe to electrode probe to work SCOPE SETTINGS PRECISION TIG 275 LIN
222. roperly 3 Check to make sure that the input voltage is correct for the machine in the Installation section of this manual Refer tol Reconnect TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check for loose or faulty con nections on the leads between the remote receptacle the pro tection board and plug J22 on the protection board See the Wiring Diagram 2 Check plugs J5 and J23 on the protection board for loose or faulty connections 3 Perform the Protection Board 4 The control board may be faulty 5 Check the ground connection of the bypass stabilizer P C Board See the Wiring Diagram No gas or water flow with option al water solenoid when the arc start switch or Amptrol is activated in the TIG mode All other ma chine functions are normal 1 The gas or water supply is either empty or not turned on 2 The low regulator may be set too low 3 Check the supply hoses for kinks or blockages 4 The filters may be blocked 1 Perform the Gas Solenoid Test 2 The control board may be faulty Ai CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN E F 11 F 11 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe
223. roubleshooting cik 5121 2 Check for loose connections at the PC Board to NOTE Allow the machine to heat up so that all electri E 2 assure that the PC Board is properly connected cal components can reach their operating tem 3 If the problem persists replace the suspect PC perature Board using standard practices to avoid static elec 5 Remove the replacement PC Board and substitute trical damage and electrical shock Read the warn it with the original PC Board to recreate the original ing inside the static resistant bag and perform the problem following procedures o a the original problem does not reappear PC Board can be damaged by by substituting the original board then the static electricity PC Board was not the problem Continue E Q Remove your body s static charge to look for bad connections in the control Fic before opening the static shielding wiring harness junction blocks and termi S 3 bag VVear an anti static vvrist nal strips Q 3 ATTENTION strap For safety use a 1 Meg ohm b If the original problem is recreated by the ale Static Sensitive resistive cord connected to a substitution of the original board then the ke Devices grounded part of the equipment PC Board was the problem Reinstall the 512 Handle only at frame replacement PC Board and test the rjc 2757 H you don t have a wrist strap machine Workstations touch an unpainted grounded 6 Always indicate that this procedure was fol
224. s that are not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 ST Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 Return to Master TOC SVM Number Page Number if necessary Your Company Your Name Please give detailed description below O O Sh o fed o 0 2 O fed Sh 5 fed o SD287 01 99 Return to Master TOC LINCOLN amp
225. s in the proper position and operating correctly The remote control device may be faulty 1 Check the remote control recep tacle and associated wiring See the Wiring Diagram 2 Perform thel Protection Board 3 Check the J11 plug on the con trol board See the Wiring Diagram The control board may be faulty The machine welds at a very low output regardless of the current control setting NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced Process panel or harness is defective gt If welding in the TIG mode the remote control device may be defective Make certain the input line volt age is correct for the machine s reconnect configuration Check the welding cables and or torch for loose or faulty con nections Check the polarity switch and associated leads Check the interior connections of the heavy current carrying leads Perform the SCR Bridge Test Perform the 71 Transformer Check the output current con trols for proper operation Normal resistance is 10 000 ohms See the Wiring Diagram The control board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con Call 1 888 935 3877 PRECISION TIG 275 LINCOLN tact the Li
226. s or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode if damaged m 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 Cylinders should be located Away from areas where they may be struck or subjected to physical damage A 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 CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box befo
227. selections function only when the Precision TIG is set to Stick mode See Item 3 e Switch 6 Hot Start Level codes below 11000 Provides an extra output boost pulse at the arc strike to enhance arc starting This is factory set for a level about 5096 extra which is usually good for most stick welding applications ON Hot Start level is used as shipped OFF No Hot Start B 9 OPERATION B 9 e Switch 7 Arc Force Level codes below 11000 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 e Switch 6 amp 7 Not functional on codes above 11000 See item 7a for adjustment of Hot Start and Arc Force e 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 Switch 1 Preflow Postflow Time Extension See Item 9 ON Doubles the time ranges OFF Standard time ranges as shipped e Switch 2 2 Step Trigger Restart Feature See Figure B 3 ON Restart Enabled as shipped OFF Restart Disabled
228. 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 be reduced or eliminate re 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 interference radiated from the welding leads Direct interference radiated from the feedback into the power lines Interference from re radiation of ungrounded metallic objects pickup by 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 pos sible and completely enclose them in rigid metallic con duit or equivalent shielding for a minimum distance of 50 feet 15 2 m There must be good electrical contact between this conduit must be connected to a driven ground and the entire length must be continuous 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 6m Tape the leads together when pr
229. sistant material to 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 3 FUMES AND GASES 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 TLV limits Do
230. slope will occur pr down slope period 2186 o 012 45 Disabled SIE tep Restart Disable alo With DIP Switch 3 OFF As Shipped zim wen Dl TO Button ki t 7255 Output Current Pre Flow fem Ron Gas Hold the second trigger Actuate the trigge Actuate the trigger a third Or actuate the trigger a third time pull for more than 1 holding it less than 1 time during down slope to during down slope to immediately second to maintain second to begin immediately end down slope end down slope Hold the third trigger crater current before normal down slope and stop pull to maintain crater current stopping The following two options are available during the normal TONS down slope period 2 PRECISION TIG 275 LINCOLN E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope bo Ola lz ole cic Sla ol o cic Return to Section TOC Return to Master TOC B 12 TIG WELD CYCLE CHART OPERATION CODES BELOW 11000 K1829 1 2 or 4 STEP Trigger 4 STEP Trigger Closed 1 Open LI MAXIMUM OUTPUT SETTING Adjustable 2 Max A Amptrol or Remote PEAK Range MINIMUM OUTPUT VVith PULSE ON No Pulsing During Upslope Time or VVhen Dovvnslope Drops Belovv Background Setting PULSE FREQ Adiustable
231. snnnnnennnnennnnennanennnnsnnnnennnnnennnnen F 61 Elecirital A Section G wA Ur E P404 amp P558 Series PRECISION TIG 275 LINCOLN Return to Master TOC Return to Master TOC O O E 9 i B o an Return to Master TOC A 1 TABLE OF CONTENTS INSTALLATION SECTION Installation PET TENE 2 0 Additional Output Capacity MR b ab Wire and FUSS WRITTEN UU UT LINES FANEN A 3 Temperature A e Eo O OE trnem A 3 VP o MA A A A 4 AAKG EE ECT A 4 UU TIT A 4 TRS T RH A 4 High Frequency Interference A 4 Input Electrical Connections re A 5 Ground COTROC E o o ESOS A 5 Output Cables Connections amp 6 A 6 TIG Toro PA A 7 Auxiliary Power Connections cocina Adi A 8 ROMO o A in A 8 Robotic Interface COMME CHOI seede A 9 PRECISION TIG 275 LINCOLN Return to Section TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS OTL o Of a o lx ole cre Sla ol o cic Return to Section TOC Return to Master TOC Return to Master TOC A 2 INSTALLATION A 2 TECHNICAL SPECIFICATIONS PRECISION TIG 275 Domestic Canadian amp Export RATED INPUT SINGLE PHASE ONLY K Duty Cycle Applications
232. ss panel or harness is defective CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN amp F 16 TROUBLESHOOTING amp REPAIR F 16 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED COURSE OF ACTION SYMPTOMS MISADJUSTMENT S FUNCTION PROBLEMS Return to Section TOC Return to Master TOC 1 Check the AC balance control R2 and associated leads for loose or faulty connections See the Wiring Diagram The wave balance control does 1 The AC wave balance control is not function properly operational only in the TIG mode 2 The control board may be faulty NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced Process panel or harness is defective Return to Section TOC Return to Master TOC Gas pre flow and post flow time is 1 If an advanced control board is too long installed check dip switch set ting on the board see Installation Manual 1 Check plug J3 on the control board Either the jumper plug or the advanced control board must be plugged into J3
233. t may not be accurate for all machines covered by this manual E ad c 039 1A FR A00V 115 in E og 475 m 4 m SUG coo A 58 1 tu 3 Bin D Tz TP3 i RISA 8 a 4 H 222 T as le Ek ek Ele E 2 z tr G 15 AE Pee ene ert nt en de sd et al ME EE AE re AS qax m ma mu mum x vr 16Y UNREG 5 nSHUTDOWN SHT 2 THERMAL YELLOW 12mA gt SHUTDOWN A PT FY PE a nl en Pr ri el JH BA Yn td nd tr ve J ZK SCR3 GATE SORA CATHODE J 6 J 1 SER GATE 150V 0 SCRS 1 amp 2 CATHODES J 9 SCRS 384 AMODES 46 7 gt ls SER GATE 2 16 gt SCR amp GATE SERA CATHODE J amp S10 5 m LAST NO USED GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD I 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS 1 4W UNLESS OTHERWISE SPECIFIED LABELS DIODES 1A 00V UNLESS OTHERWISE SPECIFIEO A SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT N7 COMMON CONNECTION r FRAME CONNECTION EARTH GROUND CONNECTION THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERM
234. ter reads 200 amps 2 Using a DC avg digital test voltmeter with at least 0 5 accuracy at 1 000v measure the DC voltage between pin 2 lead 303 and pin 1 lead 306 at the right side meter plug nearest the trim mer OO O Io Ir CHS OTL o Of a o lx ole cre 512 ol o r l 3 This voltage should match the 200A panel meter reading as 0 200v or 200mv within 1 If not adjust the trimmer so that the panel meter accuracy is corrected See Figure F 1 PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC ech TROUBLESHOOTING amp REPAIR dii Return to Section TOC Return to Master TOC OO O Io P CHS ojeg 1 Ola o lx ole cik 312 ol o cic Return to Section TOC Return to Master TOC O JO e e METER CALIBRATION ADJUSTMENTS continued ope 9 o FIGURE F 2 CONTROL BOARD TRIMMERS go ic olg cizc mi a O O R2 5 3 PM co nnt DZ24 kd 313 HIE SME l reer LIE 77 e ki R62 C34 2251 j i em Lal 2 1 a 8 EE el E ES s R120 D30 C63 R126 i R92 D41 C56 R119 R125 EX Q R134 R167 R175 zl E C70 C79 o o ei m C92 255 m R246 x I R247 at C108 o ES ms N R o AMMETER CALIBRATION PROCEDURE Locate the Ammeter Calibration Trimmer R5 See Figure F 1 Set to TIG mode with DC polarity and LOCAL con trol W
235. the high voltage transformer REPLACEMENT PROCEDURE 1 2 Replace the high voltage transformer Secure the new transformer using the four phillips head mounting screws Refer to Figure F10 for insulator location Replace the 3 8 screw securing the spark gap assembly box Reconnect leads S and F 5 Reconnect high voltage transformer lead to the capacitor Reconnect leads 231D and 231E to single black lead Replace any necessary cable ties Secure the case back using the 3 8 mount ing bolts previously removed Replace the case sides and top PRECISION TIG 275 LINCOLN F 47 LEADS S 4 F ES m YY M K yy 27 SCREVV 3 8 PRECISION TIG 275 LINCOLN amp SPARK GAP ASSEMBLY BOX TROUBLESHOOTING amp REPAIR HIGH VOLTAGE TRANSFORMER REMOVAL AND REPLACEMENT continued Figure F 11 3 8 Screw amp Leads S and F Locations F 47 OOL Je1sey 01 UINISY NOL Je1Se A 01 NOL 491SEVN 01 Ulm ki NOL Je1Se A 0 Winey OOL uonoes oj uinjed OOL uonoes o OOL uonoes o uinjed OOL uonoes o uinjed F 48 NOTES PRECISION TIG 275 LINCOLN je F 48 NOL Je1sey 01 Winey NOL Je1Se A 01 Ulm ki NOL 491SEVN 01 Ulm ki NOL Je1Se A 0 Winey OOL uoroes inl ki OOL uonoes o OOL Uooes o inl ki OOL uonoes o in ki F 49 TROUBLESHOOTING amp RE
236. the machine s output work terminal The other secondary lead X2 is connected to one of the AC connections of the SCR bridge The electrode terminal is connected to the other AC side of the bridge The choke is now PROTECTION METER STICK BOARD TIG SWITCH REMOTE RECEPTACLE REAR GANG WORK POLARITY e SWITCH BYPASS R BOARD C FRONT ELECTRODE HIGH FREQUENCY TRANSFORMER msme REAR Eod ELECTRODE HIGH VOLTAGE TRANSFORMER FEEDBACK THERMOSTAT HEDIS CONTROL BOARD LOCAL REMOTE BALANCE POST SWITCH CONTROL FLOW electrically across the negative and positive SCR bridge connections With the ability of the choke to store energy and the SCRs to turn on at the appropri ate times an AC square wave is developed and applied to the output terminals The bypass board pro tects the internal circuitry from interference FIGURE E 8 DC WELDING CURRENT GENERATION o PRIMARY 10 CHOKE ELECTRODE WORK PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O c o 69 2 D Return to Section TOC Return to Master TOC O O 9 o B o as OUTPUT ANODE 7 GATE E 7 THEORY OF OPERATION E 7 FIGURE E 9 SCR OPERATION CATHODE SCR OPERATION A silicon controlled rectifier SCR is a three terminal device used to control rather large currents to a load An S
237. tiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier LINCOLN v SAFETY iv 6 Eloigner les materiaux inflammables ou les recouvrir afin de prevenir tout risque d incendie d aux etincelles Quand on ne soude pas poser la pince a une endroit isole de la masse Un court circuit accidental peut provoquer un echauffement 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 w
238. tion NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If Return to Section TOC Return to Master TOC the machine functions normally the Advanced Process panel or harness is defective 4 Perform the SCR Bridge Test 5 Check the output controls R1 R4 and associated wiring See Wiring Diagram 6 Check the J4 connection on the control board 7 The control board may be faulty OO O Io Ir CHS ope bo Ola lz ole cre 515 ol o cic 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 275 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope o Of a lz ole cre 515 ol o cic F 6 Observe Safety Guidelines TROUBLESHOOTING amp REPAIR detailed in the beginning of this manual PROBLEMS SYMPTOMS No output from the machine in either Stick or TIG modes The thermal light is on NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced
239. tion 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 Hi Freq 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 Hemove 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 C 1 This setting is ade quate for most applications Where less high frequen cy is desired the setting can be reduced to 0 008 inch es 0 2 mm WARNING Use extreme caution when working with the high frequency circuit The high voltages developed can be lethal Turn the input power off using the dis connect switch or fuse box before working inside the machine This is particularly important when working on the secondary circuit of the high volt age transformer T3 because the output voltage is dangerously high D 3 MAINTENANCE D 3 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 off per above 2 Remove the access panel on the right case s
240. trol K870 included K870 RECOMMENDED EQUIPMENT INTERFACE FOR CODES BELOW 11000 TIG water cooled TIG air cooled Machine PT275 Welding Package K1825 1 PT275 K1826 1 2 K1827 1 Input Cable Clamp Gas Reg Hose Magnum Torch Magnum Parts Work Clamp Lead Foot Amptrol User provided included PTW20 included 15 ft included K870 included Lamm NERS Oe KP510 and K918 2 included User provided LE Harris 3100211 PTA9 or PTA17 KP507 or KP508 K2150 1 Work Lead Assembly K870 or K870 1 PRECISION TIG 275 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir CHS ope 1 Of a lz ole cre 312 ol o cic Return to Section TOC Return to Master TOC CONTROLS AND SETTINGS B 4 OPERATION B 4 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 OG E ooo 1 POWER SWITCH 2 POLARITY SWITCH 3 MODE SWITCH 4 AC BALANCE CONTROL 5 LOCAL REMOTE CURRENT CONTROL SWITCH 6 MAXIMUM OUTPUT CONTROL 7 MINIMUM OUTPUT CONTROL AND DISPLAY SWITCH 7 4 MENU BUTTON AND DISPLAY SWITCH FOR CODES ABOVE 11000 8 DIGITAL METER AND DISPLAY SWITCH 9 POSTFLOW TIME 10 THERMAL SHUTDOWN LIGHT 11 REMOTE
241. ure panels of your machine ELECTRIC PRECISION TIG 275 Go ELECTRICAL DIAGRAMS 5 WIRING DIAGRAM ENTIRE MACHINE CODE 10893 G4031 2 Fir E 7 415 VOLT CONNECTION 55 CONNECT STRAP TO O E CONTROL PANEL VIEWED FROM REAR HIGH H4 AS SHOWN l Ae PRECISION TIG 275 WIRING DIAGRAM NCOMNECTSTRAPTO WOT olo CONNECT STRAP TO LL NE O H1 I r gt MID H3 l c siz 306 gt 1
242. y selectable with Advanced Control Panel installed OPERATION FOR CODES ABOVE 11000 ONLY B 6 TIG Mode Menu with Advanced Control Panel installed Setting Description Selection 4 HS TIG Hot Start of output setting 0 0 Only setting for SS0 above CO CO NIO OT A C N Selection 5 UP Upslope Time None Only setting for SS1 8 552 above 1 0 5 sec 1 0 sec 1 5 sec 2 0 sec 2 5 sec Setting Description Selection 6 HS Stick Hot Start added to output setting 0 Selection 7 AF Stick Arc Force added to output setting Softer arc 1 Crisper arc Default Factory Setting Indicated by blinking decimal point If no Advanced Control Panel the Stick menu displays Any of the following actions will exit the menu display 1 Pressing and holding the Menu Button again for about 5 seconds 2 Allowing the menu display to be unchanged for about 15 seconds 3 Closing the arc start switch TIG Mode or starting the arc Stick Mode Note In Stick Mode the machine output will remain on while in menu display e Re entering the menu displays the last parameter and setting that was displayed when the menu was exited All settings may be reset to the Factory Default Settings above by holding the Menu button pressed while turning on the machine s Power switch The display will show rES to indicate the defaults are reset PREC
243. y 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 E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OO O Io Ir ope 0 Of a lz ole cre 512 ol o r l Return to Section TOC Return to Master TOC 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 S1 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 Ai CAUTION e THE CONTROL BOARDS CONTAIN STATIC SEN SITIVE COMPONENTS To avoid possible damage to these components 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 ON 1234567 DIP SVVITCH S1 STICK WELDING FEATURES The following DIP switch feature

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