PRECISION TIG 275

OPERATOR’S MANUAL

IM702-AJune, 2005

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thoughtfuloperation on your part. DO NOTINSTALL, OPERATE OR REPAIRTHIS EQUIPMENT WITHOUTREADING THIS MANUAL ANDTHE SAFETY PRECAUTIONSCONTAINED THROUGHOUT.And, most importantly, think beforeyou act and be careful.

For use with machines having Code Numbers: 10806; 10807; 10893

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Copyright © 2005 Lincoln Global Inc.

Precision TIG 275 WeldingPackage shown with optionalAdvanced Control Panel

IP21S

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework 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.

____________________________________________________1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stopthe engine and allow it to cool before refuel-ing to prevent spilled fuel from vaporizing oncontact with hot engine parts and igniting. Donot spill fuel when filling tank. If fuel is spilled,wipe it up and do not start engine until fumeshave been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in posi-

tion and in good repair.Keep hands, hair, clothing and toolsaway from V-belts, gears, fans and all other moving partswhen starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from theLincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

For Diesel Engines: Diesel engine exhaust andsome of its constituents are known to the Stateof California to cause cancer, birth defects, andother reproductive harm.

For Gasoline Engines: The engine exhaust fromthis product contains chemicals known to theState of California to cause cancer, birth defects,or other reproductive harm.

CALIFORNIA PROPOSITION 65 WARNINGS

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

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 bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contact cancause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate circuits.This can create fire hazards or overheat lifting chains orcables until they fail.

6.h. Also see item 1.c.

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un plancher met-allique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble desoudage et la machine à souder en bon et sûr état defonc-tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être le totalde la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partie ducorps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié ainsiqu’un verre blanc afin de se protéger les yeux du rayon-nement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peaude soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible dela zone de travail qu’il est pratique de le faire. Si on place lamasse sur la charpente de la construction ou d’autres endroitséloignés de la zone de travail, on augmente le risque de voirpasser le courant de soudage par les chaines de levage,câbles de grue, ou autres circuits. Cela peut provoquer desrisques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voirle code “Code for safety in welding and cutting” CSA StandardW 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

vv

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product •••as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at the timethe shipment is received.

Please record your equipment identification information below for future reference. This information can be foundon your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packetaccompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then“Product Registration”. Please complete the form and submit your registration.

TABLE OF CONTENTSPage.

Installation ..........................................................................................................Section ATechnical Specifications ........................................................................................A-1,A-2Safety Precautions.. ............................................................................................................................................... .A-3

Select Suitable Location........................................................................................A-3Grinding .................................................................................................................A-3Stacking.................................................................................................................A-3Undercarriage Lifting and Moving .........................................................................A-3Tilting .....................................................................................................................A-3Environmental Rating ............................................................................................A-3

Machine Grounding and High FREQUENCY INTERFERENCE PROTECTION ...................A-3,A-4Input and Grounding Connections ..............................................................................A-4Output Cable, Connections and Limitations ................................................................A-5

Work Cable Connection ..................................................................................A-5Stick Electrode Cable Connection ..................................................................A-5TIG Torch Connection .....................................................................................A-6Auxiliary Power Connections ..........................................................................A-7Remote Control (If Used) ................................................................................A-7Robotic Interface Connection ..................................................................A-7, A-8

________________________________________________________________________OPERATION .........................................................................................................................................................Section B-1

Safety Precautions.......................................................................................................B-1Product Description......................................................................................................B-1

Pipe Thawing.........................................................................................................B-1 Duty Cycle: ............................................................................................................B-1Recommended Processes and Equipment ...........................................................B-2Controls and Settings ..........................................................................B-3 THRU B-6Internal Set Up Controls ........................................................................................B-7Sick Welding Features...........................................................................................B-7TIG Welding Features ...........................................................................................B-7

2 Step Trigger Modes......................................................................................B-84 Step Trigger Modes ....................................................................................B-9

TIG Welding Cycle Chart ....................................................................................B-10Setup Guidelines for TIG Welding with an Amptrol.....................................B-10, B11Making a TIG Weld with an Amptrol ....................................................................B-12

________________________________________________________________________Accessories ............................................................................................................................................... .......Section C

Optional Equipment .....................................................................................................C-1________________________________________________________________________Maintenance......................................................................................................................................................Section D

Safety Precautions.......................................................................................................D-1Routine and Periodic Maintenance..............................................................................D-1Overload Protection .....................................................................................................D-1Service Procedures, Component Access,Spark Gap Adjustment ...............................D-2Under-Cooler Service ..................................................................................................D-2

________________________________________________________________________Troubleshooting.............................................................................................................................................Section E

Safety Precautions.......................................................................................................E-1How To Use TroubleShooting Guide............................................................................E-1Troubleshooting.................................................................................................E-2 to E-7

________________________________________________________________________Diagrams ..............................................................................................................................................................Section F

Wiring Diagrams..............................................................................................................................................F-1, F-2Dimension Prints .............................................................................................................................................F-3, F-4

________________________________________________________________________Parts List........................................................................................................................................................................P404

vivi

A-1INSTALLATION

PRECISION TIG 275

A-1

TECHNICAL SPECIFICATIONS-PRECISION TIG 275 (K1825-1 Domestic Package*-60Hz)(K1826-1 Domestic,K1826-2 Canadian-60Hz) (K1827-1 Export-50/60Hz)

Voltage + 10%

208/230/460

460/575

220-230/380-400/415

Max. Amps With Out Power Factor Capacitor

104/94/47124/112/56

86/78/3995/86/43

77/70/3573/66/33

6/5/3

47/3856/45

39/3143/35

35/2833/263/2

300W

95/55/50109/63/58

80/46/4285/49/45

70/41/3765/38/3510/6/5400W

Max. Amps With Power Factor Capacitor

80/72/3695/86/43

64/58/2962/56/28

55/50/2540/36/1836/32/16

35/2843/34

29/2328/23

25/2018/1416/13500W

80/46/4386/50/46

64/37/3467/39/36

52/30/2846/27/2523/13/12

500W

Duty Cycle-Applications

40%AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIG60%

AC/DC Stick / Balance TIGUnbalance (70% Penetration#) AC TIG

100%AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIGIdle Amps

40%AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIG60%

AC/DC Stick / Balance TIGUnbalance (70% Penetration#) AC TIG

100%AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIGIdle AmpsIdle Power

40%AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIG60%

AC/DC Stick / Balance TIGUnbalance (70% Penetration#) AC TIG

100%AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIGIdle AmpsIdle Power

RATED INPUT - SINGLE PHASE ONLYK

Number

K1825-1

K1826-1

K1826-2

K1827-1

RATED OUTPUT - NEMA EW1 Class ll (40) K1825-1,K1826-1,K1826-2Duty Cycle-Applications

40%AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIG60%

AC/DC Stick / Balance TIGUnbalance (70% Penetration#) AC TIG

100%AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIG

Volts at Rated Amperes

31.016.1

29.015.4

28.014.8

Amps

275255

225200

200150

*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.

RATED POWER FACTOR (STICK) K1825-1,K1826-1 & K1826-2 .63 min. .85 min.K1827-1 .65 min. .77 min.

R

R

NRTL/C

NRTL/C

IEC 60974-1

N80

K1826-1, -2K1827-1

K1825-1

A-2INSTALLATION

PRECISION TIG 275

A-2

ADDITIONAL OUTPUT CAPACITYOutput Current

Range

2Amps DCto

340Amps AC-DC*

Type of Output

CC (Constant Current)AC/DC (GTAW)Stick (SMAW)

Maximum Open Circuit Voltage

(STICK AND TIG)AC/DC OCV: 75/68

Auxiliary PowerK1825-1, K1826-1, K1826-2

15Amp Circuit Breaker and NEMA 5-15R DuplexReceptacle for up to:

115VAC 8Amp Auxiliary Power Receptacle115VAC weld Switched Cooler Receptacle load

K1834-15 Amp Circuit Breakerand grounded 220VAC

Euro(Schuko) receptacle

Height Width Depth Weight31.0 in. 22.0 in. 26.0 in. Approx. 397 lbs.787 mm 559 mm 660 mm 180 kgs.

49.7 in. 28.0 in. 41.0 in. Approx.641 lbs.1262 mm 711 mm 1041 mm 291 kgs.

PHYSICAL DIMENSIONS

1 ALSO CALLED ‘INVERSE TIME" OR "THERMAL/MAGNETIC " CIRCUIT BREAKERS; CIRCUIT BREAKERS WHICH HAVE A DELAY IN TRIPPING ACTION THAT DECREASES ASTHE MAGNITUDE OF CURRENT INCREASES.

* 50/60HZ IEC Max. range exceeds 310A.

TEMPERATURE RANGESOPERATING TEMPERATURE RANGE

-20°C to +40°C (-04° to +104°F)

TRANSFORMER INSULATION CLASS 180°C (H)

STORAGE TEMPERATURE RANGE-40°C to +85°C (-40° to +185°F)

For all Stick, DC TIG, and Balanced AC TIG Weldingat 275A/40% Duty Cycle with out Standard Power

Factor Correction CapacitorsBased on the 1999 U.S. National Electrical Code

For Unbalanced AC TIG Welding Above 275 Amps:255A/40% Duty Cycle, Auto-Balance Penetration with

out Standard Power Factor Correction CapacitorsBased on the 1999 U.S. National Electrical Code

RECOMMENDED INPUT WIRE AND FUSE SIZES

Input

Voltage /

phase/

Frequency

208/1/60

230/1/60

460/1/60

575/1/60

220-230/1/50/60

380-400/1/50/60

415/1/50/60

Input

Ampere

Rating

Rating on

Nameplate

104

94

47

38

95

55

50

Input

Ampere

Rating

124

112

56

45

109

63

58

Type 75°C

Copper

Ground Wire in

Conduit AWG

(IEC) Sizes

6 (13.3 mm2)

6 (13.3 mm2)

10 (5.3mm2)

10 (5.3mm2)

6 (13.3 mm2)

8 (8.4mm2)

8 (8.4mm2)

Type 75°C

Copper

Ground Wire in

Conduit AWG

(IEC) Sizes

6 (13.3 mm2)

6 (13.3 mm2)

8 (8.4 mm2)

10 (5.3mm2)

6 (13.3 mm2)

8 (8.4 mm2)

8 (8.4 mm2)

Fuse

(Super Lag)

or Breaker

Size1

125

125

60

50

125

80

80

Fuse

(Super Lag)

or Breaker

Size1

150

150

70

60

150

90

90

Type 75°CCopper Wire inConduit AWG

(IEC) Sizes40°C (104°F)

Ambient

4 (21.2 mm2)

4 (21.2 mm2)

8 (8.4mm2)

10 (5.3mm2)

4 (21.2 mm2)

8 (8.4mm2)

8 (8.4mm2)

Type 75°CCopper Wire inConduit AWG

(IEC) Sizes40°C (104°F)

Ambient

3 (26.7 mm2)

3 (26.7 mm2)

8 (8.4 mm2)

8 (8.4 mm2)

4 (21.2 mm2)

6 (13.3 mm2)

6 (13.3 mm2)

RATED OUTPUT - IEC 60974-1 (K1827-1)Duty Cycle-Applications

40%AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIG60%

AC/DC Stick / Balance TIGUnbalance (70% Penetration#) AC TIG

100%AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIG

Volts at Rated Amperes

31.020.2

29.018.0

28.016.0

Amps

275255

225200

200150

A-3INSTALLATION

PRECISION TIG 275

A-3

SAFETY PRECAUTIONS

SELECT SUITABLE LOCATION

Place the welder where clean cooling air can freely cir-culate in through the top rear vents and out through thebottom rear vents. Dirt, dust or any foreign materialthat can be drawn into the welder should be kept at aminimum. Failure to observe these precautions canresult in excessive operating temperatures and nui-sance trips.

GRINDINGDo not direct grinding particles towards the welder. Anabundance of conductive material can cause mainte-nance problems.

STACKINGThe Precision TIG 275's cannot be stacked .

UNDERCARRIAGE LIFTING AND MOVING

When the Precision TIG 275 is purchased as a weld-ing package, or used with any of the availableUndercarriage optional accessories, proper installationmakes the Precision TIG 275 lift bale nonfunctional.Do not attempt to lift the power source with an under-carriage attached. The undercarriage is designed forhand moving only; mechanized movement can lead topersonal injury and/or damage to the Precision TIG275.

TILTINGEach machine must be placed on a secure, level sur-face, either directly or on a recommended undercar-riage. The machine may topple over if this precautionis not followed.

ENVIRONMENTAL RATING

Precision TIG 275 power sources carry an IP21SEnvironmental rating. They are rated for use in damp,dirty rain-sheltered environments.

MACHINE GROUNDING AND HIGH FRE-QUENCY INTERFERENCE PROTECTION

The frame of the welder must be grounded. A ground screwmarked with the symbol is located on the input connectionpanel (Figure A.1) for this purpose. See your local and nation-al electrical codes for proper grounding methods.

The spark gap oscillator in the high frequency genera-tor, being similar to a radio transmitter, can be blamedfor many radio, TV and electronic equipment interfer-ence problems. These problems may be the result ofradiated interference. Proper grounding methods canreduce or eliminate radiated interference.

The Precision TIG 275 has been field tested under rec-ommended installation conditions and has been foundto comply with F.C.C. allowable radiation limits. Thiswelder has also been found to comply with NEMA stan-dards for high frequency stabilized power sources.

Radiated interference can develop in the following fourways:

• Direct interference radiated from the welder.• Direct interference radiated from the welding leads.• Direct interference radiated from feedback into the

power lines.• Interference from re-radiation of "pickup" by

ungrounded metallic objects.

Keeping these contributing factors in mind, installingthe equipment per the following instructions shouldminimize problems.

1. Keep the welder power supply lines as short as pos-sible and completely enclose them in rigid metallicconduit or equivalent shielding for a minimum dis-tance of 50 feet (15.2 m). There must be good elec-trical contact between this conduit and the welder.Both ends of the conduit must be connected to adriven ground and the entire length must be contin-uous.

2. Keep the work and electrode leads as short as pos-sible and as close together as possible. Lengthsshould not exceed 25 feet (7.6 m). Tape the leadstogether when practical.

Read entire installation section before startinginstallation.

ELECTRIC SHOCK can kill.• Only qualified personnel should

perform this installation.

• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

• Do not touch electrically hot parts.

• Always connect the Precision TIG 275 grounding screw (behindthe reconnect panel cover located near the back of the left caseside) to a good electrical earth ground.

• Always connect the Precision TIG 275 to a power supplygrounded in accordance with the National Electrical Code andall local codes.

WARNING

INPUT and GROUNDING CONNECTIONS

Be sure the voltage, phase, and frequency of the inputpower is as specified on the rating plate, located on therear of the machine.

Fuse the input circuit with the recommended super lagfuses or delay type1 circuit breakers. Choose an inputand grounding wire size according to local or nationalcodes or use Section A-2. Using fuses or circuit break-ers smaller than recommended may result in "nui-sance" tripping from welder inrush currents even if notwelding at high currents.

Unbalanced AC TIG welding draws higher input cur-rents than those for Stick, DC TIG, or Balanced AC TIGwelding. The welder is designed for these higher inputcurrents. However, where unbalanced AC TIG weldingabove 185 amps is planned, the higher input currentsrequire larger input wire sizes and fuses per Section A-2:

Remove the reconnect panel cover located near theback of the left case side to reveal the reconnect panel.Welder supply line entry provision is in the case rearpanel. Entry is through a 1.75 inch (44 mm) diameterhole in the case back. Appropriate supply line strainrelief clamp is provided by installer. (See Figure A.1)

All connections should be made in accordancewith all local codes and national electrical codes.Installation by a qualified electrician is recom-mended.

A-4INSTALLATION

PRECISION TIG 275

A-4

3. Be sure the torch and work cable rubber coveringsare 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 syntheticrubber insulated cables.

4. Keep the torch in good repair and all connectionstight to reduce high frequency leakage.

5. The work terminal must be connected to a groundwithin ten feet of the welder, using one of the fol-lowing methods:

• A metal underground water pipe in direct contactwith the earth for ten feet or more.

• A 3/4" (19 mm) galvanized pipe or a 5/8" (16 mm)solid galvanized iron, steel or copper rod driven atleast eight feet into the ground.

The ground should be securely made and the ground-ing cable should be as short as possible using cable ofthe same size as the work cable, or larger. Groundingto the building frame electrical conduit or a long pipesystem can result in re-radiation, effectively makingthese members radiating antennas. (This is not rec-ommended).

6. Keep all access panels and covers securely inplace.

7. All electrical conductors within 50 feet (15.2 m) ofthe welder should be enclosed in grounded rigidmetallic conduit or equivalent shielding. Flexiblehelically-wrapped metallic conduit is generally notsuitable.

8. When the welder is enclosed in a metal building,several good earth driven electrical grounds (as in 5above) around the periphery of the building are rec-ommended.

Failure to observe these recommended installationprocedures can cause radio or TV interference prob-lems and result in unsatisfactory welding performanceresulting from lost high frequency power.

WARNINGELECTRIC SHOCK can kill.

• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on thisequipment.

FIGURE A.1

CONNECT INPUTPOWER LEADS

CONNECT INPUTVOLTAGE LEVEL

CONNECT INPUTGROUND LEAD

A-5INSTALLATION

PRECISION TIG 275

A-5

Recommended Cable Sizes for Combined Lengths ofCopper Work and Electrode Cables using 75o C Wire:

Machine Rating 0 to 100 Ft. 101 to 200 Ft 201 to 250 Ft

275A/40% #1 (42.4 mm2) 1/0 (53.5 mm2) 2/0 (67.4 mm2)

WORK CABLE CONNECTION

A 15’ (2/0) weld cable with clamp is available (K2150-1), orincluded with the Precision TIG Welding Package model.Otherwise, it is user provided.

With power source off, connect a separate work cableto the 1/2-13 threaded "WORK" stud of the welder, andsecure a tight connection with the flange nut provided.The work cable should be routed through the cablestrain relief hole provided in the base directly below thewelding output terminal.Note: If the Precision TIG is equipped with an Under-Cooler or Under-Storage unit, the coiled work cableand 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 sourceoff, connect a stick electrode cable to the 1/2-13threaded "STICK Electrode" stud of the welder, andsecure a tight connection with the flange nut provided.The electrode cable should be routed through thecable strain relief hole provided in the base directlybelow the welding output terminal.

DISCONNECT STICK ELECTRODE WELDINGCABLE WHEN TIG WELDING.

EVEN THOUGH HI-FREQ IS NOT APPLIED TO THEPRECISION TIG STICK TERMINAL, IT WILL BEELECTRICALLY "HOT" TO WORK WHEN TIGWELDING.------------------------------------------------------------------------

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 singlephase line or one phase of a two or three phase line.

3. On multiple input voltage welders, be sure thereconnect panel is connected for the voltage beingsupplied to the welder.

Failure to follow these instructions can causeimmediate failure of components within the welder.------------------------------------------------------------------------

Welders are shipped connected for the highest inputvoltage as listed on the rating plate. To change thisconnection, designations on the reconnect panel LOW,MID, and HIGH correspond to the name plated inputvoltages of a triple voltage welder. Dual voltagewelders use only LOW and HIGH.

EXAMPLE: On a 208/230/460 volt welder, LOW is208V, MID is 230V, and HIGH is 460V.Note: Export model has a voltage range for LOW and

MID connections: LOW is 220-230V, MID is380-400V and High is 415V.

Reconnect the jumper strap to the terminal stud corre-sponding to the input voltage level used. Make sure allconnections are tight.

OUTPUT CABLES, CONNECTIONS ANDLIMITATIONS

• To avoid being startled by a high frequencyshock, keep the TIG torch and cables in goodcondition

• Turn the power switch of the power source OFFbefore installing adapters on cable or when con-necting or disconnecting adapter plugs to powersource.

-----------------------------------------------------------------------

Refer to Figure A.2 for the location of the WORK andSTICK terminals, as well as the TIG Torch connectionpanel.

WARNING

WARNING

CAUTION

A-6INSTALLATION

PRECISION TIG 275

A-6

TIG TORCH CONNECTION

The Precision TIG torch connection box, located on theright side of the machine, provides all the input andoutput 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 TorchReel and Holster for handy and safe storage of con-nected torch when not welding, and excess torch cablelength while welding.

Combination connectors (Power/Water andPower/Gas) are electrically "hot" while welding inSTICK or TIG modes.

If using an Air-Cooled Torch be sure coolant isshut off and/or Cooler is unplugged from thePrecision TIG Water Cooler Receptacle on thetorch side of the upper case back.

Observe the safety precautions necessary for han-dling and using compressed gas containers.Contact your supplier for specifics.

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 cylinder away from live electrical cir-

cuits.• Maximum inlet pressure 150 psi.-----------------------------------------------------------------The Precision TIG machines do not have Hi-Freq.available at the Stick electrode stud, therefore studconnection adapters (such as LECO. S19257-series)cannot be used for torch connection.

Single-piece cable air-cooled torches with a 3/8-24 RHconnector 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 asthe Magnum PTA-26, or LA-26) require the availableK2166-1 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” StudConnector (S20403-3) with with a 7/8-14 LH male fitting.

Magnum PTW-18/-20 (or LW-) water-cooled Torchesrequire no adapter for Precision TIG connection.

WARNING

WORKSTICK WORKSTICK

STICKELECTRODE

STUD

WORK

STUD

TIG TORCHCONNECTION

P ANEL

FIGURE A(Shown without hinged stud cover)

REMOTE

CONTROLRECEPTACLE

CABLESTRAIN

RELIEF HOLES

FIGURE A.2

A-7INSTALLATION

PRECISION TIG 275

A-7

AUXILIARY POWER CONNECTIONS

The Precision TIG machines provide a standard NEMA5-15R duplex receptacle, located on the upper caseback on the torch side of the machine:

• The bottom outlet of this duplex receptacle providesswitched 115VAC power for the Under-Cooler, orWater Solenoid accessory. This Cooler receptacleturns on when the arc starts and remains on for about8 minutes after the arc goes out (with the Fan-As-Needed machine cooling fan, see MaintenanceSection), so the Cooler’s fan and water pump will notrun continuously in idle, but will run while welding.

• The top outlet of this duplex receptacle provides atleast 8 amps at 115VAC, whenever the Precision TIGPower switch is ON. This auxiliary circuit is intendedfor running 115VAC accessories or small power tools.Note: Some types of equipment, especially pumpsand large motors, have starting currents which aresignificantly higher than their running current. Thesehigher starting currents may cause the circuit breakerto open. (See next paragraph)

• Both the receptacle circuits are protected from shortsand overloads by a 15 amp circuit breaker, locatedabove the receptacle. if the breaker trips its buttonpops out exposing a red ring. When the circuit break-er cools the button can be reset by pressing it backin.Note: When the breaker trips not only will the auxil-iary and cooler power be interrupted, but so will thepower to the shielding gas solenoid and machinecooling fan.

The Precision TIG Export models also provide agrounded 220vac Euro type Schuko receptacle and a5 amp circuit breaker, located on the upper case backon the reconnect side of the machine, intended for usewith a 220vac water cooler.

REMOTE CONTROL (If Used)

The Foot Amptrol (included with the Precision TIGWelding Package), or other Remote accessory, isinstalled by routing the plug of its control cable upthrough the left cable strain relief hole provided in thebase (see Figure A.2), then connecting the 6-pin plugto the mating Remote receptacle behind the stud panelcover. (See Operation Section B-2 for mating plugwiring.)Note: If the Precision TIG is equipped with an Under-Cooler or Under-Storage unit, the Foot Pedal (or otherremote control accessory) and coiled control cable, orexcess cable length, may be conveniently stored in thedrawer while remaining connected.

FIGURE A.3

For Gas Supply hosewith 5/8-18RH male(Provided with WeldPackage model)

For Coolant SupplyHoseswith 5/8-18LH male(Provided with WeldPackage modelorUnder-Cooler Cart)

A-8INSTALLATION

PRECISION TIG 275

A-8

ROBOTIC INTERFACE CONNECTION

Robotic interface can be made at the RemoteReceptacle (See Operation Section B-2). The machineis shipped with the remote receptacle circuit internallyconnected to receptacle J5 of the Control board forstandard Amptrol operation. In order to enable theremote receptacle for robotic interface its connectionplug must be moved from J5 to J5A on the Controlboard. (Refer to the machine Wiring Diagram.)

The robotic interface functions with the Precision TIGset to either TIG or STICK mode, but must be inREMOTE switch position for the Preset Control inter-face to function. When in the REMOTE position withrobotic interface neither the MAXIMUM OUTPUT northe MINIMUM OUTPUT panel controls limit the inter-face control setting over the rated output range of themachine.

The diagram in Figure A.4 below shows the remotereceptacle plug connections and signals for roboticinterface:

+VCC = 70Vdc max.

R = VCC / 5ma

5ma

Robotic Common

A

BC

D

EF

REMOTE RECEPTACLE(Front View)

For 18-12P Plug(LECO S12020-27)

ARC STARTINPUT FROM ROBOT(18Vac,10ma switch)

*

+PRESET CONTROL

INPUT FROM ROBOT(0 -10Vdc = Rated Output Range)

ARC ESTABLISHEDOUTPUT TO ROBOT(High = Not Welding)

(Low = Welding)

* Precision TIG Control Common.

Note: The Interface connectioncable may pick up noiseinterference. Additionalbypass/filtering circuits may beneeded for the external circuits.

FIGURE A.4

B-1OPERATIONB-1

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-StartTM Technology,Presettable Min. and Max. Output controls, and built-inhigh frequency stabilization for continuous AC TIG andDC TIG starting. It also has AC/DC Stick (SMAW)capability, with adjustable Arc Force availability. A TIGPulse Panel, Power Factor Capacitors and a WaterSolenoid are available as field installed optional kits.Also, a new Undercarriage (with double gas bottlerack) is available for field installation, as well as a newUnder-Cooler Cart, which is also included in an avail-able efficiently integrated entire TIG Welding Packagewith convenient built-in storage provisions for weldingequipment and components.

The Precision TIG 275 includes advanced featuressuch as a Digital Meter, Presettable control, AutoBalanceTM, 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 adjustableDownslope Time control are included with an availablefield installed kit. It also features a Stick stud panel anda universal TIG torch connection box for simultaneous,but separated, electrode outputs.

PIPE THAWING

The Precision TIG 275 is not recommended for pipethawing.

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 6minutes idling. If the rated duty cycle is significantlyexceeded, the thermostatic protection will shut off theoutput until the machine cools to a normal operatingtemperature. (Refer to Specification Section A-1)

PRECISION TIG 275

ELECTRIC SHOCK can kill.• Only qualified personnel should

perform this installation.• Turn the input power OFF at the

disconnect switch or fuse box. • Do not touch electrically live parts

or electrode with skin or wet cloth-ing.

• Insulate yourself from work andground.

• Always wear dry insulating gloves.• Read and follow “Electric Shock

Warnings” in the Safety section if weld-ing must be performed under electrical-ly hazardous conditions such as weld-ing in wet areas or on or in the work-piece.

FUMES AND GASEScan be dangerous.• Keep your head out of fumes.• Use ventilation or exhaust to

remove fumes from breathingzone.

WELDING SPARKScan cause fire orexplosion• Keep flammable material away.• Do not weld on containers that

have held combustibles.

ARC RAYScan burn.

• Wear eye, ear and bodyprotection.

SAFETY PRECAUTIONS

Read and understand this entire section before operat-ing the machine.

Observe additional Safety Guidelines detailed inthe beginning of this manual.

WARNING

B-2OPERATIONB-2

RECOMMENDED PROCESSES ANDEQUIPMENT

RECOMMENDED PROCESSESThe Precision TIG 275 is recommended for the TIG(GTAW) and Stick (SMAW) welding processes withinits output capacity range of 2 amps DC, or 5 amps AC,to 340 amps AC/DC. It is compatible with mostMagnum TIG accessories (refer EquipmentLimitations), as well as many industry standard items,such as TIG torches, hoses, and water coolers.

PROCESS LIMITATIONSPrecision TIG machines are not recommended for arcgouging due to it's limited output capacity, and are alsonot recommended for pipe thawing.

EQUIPMENT LIMITATIONSThe Precision TIG machines are protected from over-loads beyond the electrical ratings and duty cycles, perthe Specifications Section A-1, A-2, with Thermostatprotection of the primary and secondary transformercoils.

The Precision TIG machines do not have Hi-Freq.available at the Stick electrode stud, therefore studconnection adapters (such as LECO. S19257-series)cannot be used for torch connection.

PRECISION TIG 275

RECOMMENDED EQUIPMENT/INTERFACE

TIG (water cooled) TIG (air cooled)Machine: PT275 Welding Package (K1825-1) PT275(K1826-1, -2, K1827-1)Input Cable/Clamp: User provided User providedGas Reg./Hose: (included) LE/Harris 3100211Magnum Torch: (PTW20 included) PTA9 or PTA17Magnum Parts: (KP510 and K918-2 included) KP507 or KP508 Work Clamp/Lead: (15 ft. included) K2150-1 Work Lead AssemblyFoot Amptrol: (K870 included) K870 or K870-1

B-3OPERATIONB-3

1. POWER SWITCH - Input line switch turns inputpower ON or OFF, as indicated by the on or off sta-tus of the front panel displays.

2. POLARITY SWITCH – The 3-position rotary powerswitch 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 weldingmodes. The selected mode is indicated by a lit col-ored panel light which permits viewing the machinesetting from a distance:3.a STICK mode (Top position) –Red panel light

ELECTRIC SHOCK can kill.• When the Power Source is ON in

STICK mode the Electrode circuits ofboth the Stick and TIG torch cablesare electrically HOT to Work.

------------------------------------------------------------------------

• The CC Stick mode may be used for general pur-pose stick welding (SMAW ) within the capacity ofthe machine. The capacity is too limited for arc aircarbon (AAC) gouging.

• In this mode; the output terminals are activatedelectrically HOT, gas flow is not activated and HOTSTART and ARC FORCE levels are fixed, orAdvanced Panel selectable (See Section B-7 ), withno front panel adjustment.

3.b TIG mode (Bottom position) – No panel light.

• When the Polarity Switch is set to AC, the TIGmode provides continuous high frequency to stabi-lize the arc for AC TIG welding.

Hi-Freq. turns on after preflow time with the arcstart switch closure, and turns off when the arcgoes out* after the arc start switch opens.

* Arc voltage and current are sensed to determine ifthe arc is established or out.

PRECISION TIG 275

CONTROLS AND SETTINGS

The Front Control Panel contains the knobs and switches necessary for adjusting the operation of the PrecisionTIG 275, with function indicator lights and an electronic display for volts and amps. The components aredescribed below:

FIGURE B.1 - CONTROL PANEL

WARNING

1. POWER SWITCH 2. POLARITY SWITCH3. MODE SWITCH4. AC BALANCE CONTROL5. LOCAL/REMOTE CURRENT CONTROL

SWITCH6. MAXIMUM OUTPUT CONTROL7. MINIMUM OUTPUT CONTROL AND

DISPLAY SWITCH8. DIGITAL METER AND DISPLAY

SWITCH9. POSTFLOW TIME10. THERMAL SHUTDOWN LIGHT11. REMOTE RECEPTACLE12. TRIGGER SWITCH13. PULSE MODE SWITCH14. PULSE FREQUENCY CONTROL15. PULSE % ON TIME CONTROL16. PULSE BACKGROUND CURRENT

CONTROL17. DOWNSLOPE TIME

B-4OPERATIONB-4

• When the Polarity Switch is set to DC (- or +), theTIG mode provides high frequency only for starting.

Hi-Freq. turns on after pre-flow time with the arcstart switch closure, and turns off when the arc isestablished*

• Also functions for DC+ polarity to permit "balling" oftungsten for AC TIG welding.

4. AC BALANCE CONTROL – The potentiometercontrol permits AC wave balance adjustment fromMax. Penetration (~85% negative wave) with thecontrol at Max. full CW position, to Max. Cleaning(~65% positive wave) with the control set near min-imum CCW position.

• Full minimum CCW position is the Auto Balanceposition which is indicated by the Green panel lightturning on. This feature automatically provides theproper amount of cleaning and penetration for nor-mal AC TIG welding

• The mid position is the Balanced position (~50%positive and negative waves).

• The Balance control is only functional if the machineis set to AC polarity and TIG mode.

5. LOCAL/REMOTE CURRENT CONTROL SWITCH – A2-position switch selects how the welding output iscontrolled for both Stick and TIG Modes:

• LOCAL (Top position) selects output control only bythe machine panel Output Control. (See Item 6)

• REMOTE (Bottom position) selects output control toalso be by an Amptrol (See Item 6), or other remote(10K pot) control connected to the Remote recepta-cle (See Item 11) This switch selection is indicted bythe Green panel light turning on.

In either position the arc start switch functions whenconnected to the Remote receptacle (See Item 11).

6. MAXIMUM OUTPUT CONTROL – The large knobis used to set the output welding current over therated output range of the machine.

• With the Current Control switch to LOCAL position,this knob sets the welding output level.

• With the Current Control switch to REMOTE posi-tion, this knob sets the maximum welding level thatthe Peak output can be set with the remote Amptrol.

• The new MicroStartTM Technology minimum currentcircuit provides for low end welding (down to 2amps) previously unobtainable on an SCR platformTIG machine.

7. MINIMUM OUTPUT CONTROL AND DISPLAY SWITCH–A smaller knob is used to preset the minimum cur-rent level only for TIG mode. Pressing the Display(momentary) switch toggle left to Minimum Set posi-tion displays the Minimum control level setting on theDigital meter. (See Item 8)

• This knob sets the Start output level. When the arclights (using a new built-in TIG start pulse) this levelupslopes quickly (0.5 sec.w/ Advanced Panel, zerow/o) and smoothly to the weld output level. The set-ting range for this Start control is the 2 amp mini-mum range of the machine up to about 50 amps, butno more than the level set by the Maximum Outputcontrol knob (See Item 6), but otherwise is indepen-dent of the Maximum setting.

• This setting also serves as the Crater-fill level, butwith a Precision TIG Advanced Panel it can beselected (see Section B-7) to be either the MinimumOutput control setting (same as Start setting) asshipped, or the minimum rating of the machine (2amps).

• The Remote Amptrol range of control is betweenthis Minimum setting and the Maximum Output con-trol knob setting, so these knobs can set the resolu-tion of the Amptrol. Also, the Minimum settingserves as both the minimum Amptrol start levelwhen the arc start switch is closed, as well as theminimum Amptrol crater-fill level before the arc startswitch is opened to help prevent premature arc outand Hi-Freq re-initiation.

.• In STICK mode the Start control is not functional

since Hot Start level is fixed, or internal AdvancedPanel adjustable (see Section B-7). Pressing theDisplay (momentary) switch toggle left to MinimumOutput position displays minimum amps rating ofthe machine.

PRECISION TIG 275

B-5OPERATIONB-5

8. DIGITAL METER AND DISPLAY SWITCH– A 3-digit LED meter is used to monitor the preset andactual welding procedure based on the Display(momentary) switch position:

• Before welding with Display switch in center (nor-mal) position, the digital meter displays the presetwelding amps set by Maximum Output control knob(See Item 6). If in Stick mode using REMOTE (SeeItem 5.), the digital meter displays the preset weld-ing amps set by the Remote control. (See Item 11)

• While welding with Display switch in center (normal)position, the digital meter displays the actual weld-ing amps with one amp resolution (XXX) and accu-racy within 4%+/-2A of reading.

• Any time in TIG mode and while pressing theDisplay switch to left, the digital meter displays theamps preset by the Minimum Output control knob(See Item 7).

• Any time in Stick mode and while pressing theDisplay switch to left, the digital meter displays theminimum amps rating of the machine (See Item 7).

• Any time, in either mode, while pressing the Displayswitch right to Volts position, the digital meter dis-plays actual output volts. Volts is displayed with 0.1volt resolution (XX.X) and accuracy within 3%+/-1Vof reading.

9. POSTFLOW TIME – This knob is used to set theTIG mode shielding gas postflow time over therange of about 2 to 60 seconds after the arc is shutoff. The postflow on time status is indicated by theGreen panel light.

• Gas preflow time for TIG mode is fixed at 0.5 sec-ond, with no panel control.

• Both time ranges are x2 extendable, if needed, byinternal control box selection. (See Section B-7)

10. THERMAL SHUTDOWN LIGHT – This yellow LEDpanel light turns on if the machine output is shut-down because internal overheating has occurred,and turns off when the thermostat resets.

11. REMOTE RECEPTACLE – A 6-socket receptacleis provided for the connection of an Amptrol, orother, remote control: (See Figure B.2)

• When the Current Control Switch, (See Item 5), isin the REMOTE position the Amptrol, or otherremote (10K pot), connected to the Remote recep-tacle controls the TIG or Stick mode output withinthe range preset by the Maximum and MinimumOutput controls. (See Item 6 and Item 7, also 8 formeter display)

• When the Current Control Switch is in either LOCALor REMOTE positions the arc start switch functionswhen connected to the Remote receptacle.

ADVANCED PANEL CONTROLSThe following controls are included only if the PrecisionTIG 275 has the Advanced Control Panel (K1829-1)option installed: (Refer to Section B-10 Tig Weld CycleChart for graphic illustration of these TIG welding func-tions.)

12. TRIGGER SWITCH – This 2-position switchselects how the arc start switch ( connected to theabove Remote receptacle) functions; in 2-Step or 4-Step mode:

• DO NOT USE 4-STEP IF USING AN AMPTROLREMOTE.

• Neither the arc start switch nor the output con-trol in the amptrol will function normally to shutoff or control the out put. ONLY USE 2-STEP.

------------------------------------------------------------------------• In 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 ramptime setting (See Item 17), from Weld set-ting to Crater-fill level (See Item 7), whichthen stops the arc and initiates Postflowtime (See Item 9).

Note: See Section B-7 for 2-Step operation duringDownslope with Restart feature selected to be dis-abled, instead of enabled (as shipped).

PRECISION TIG 275

A

BC

D

EF

Max

10K ohmMin

REMOTE RECEPTACLE*(Front View)

REMOTE OUTPUTCONTROL

ARC STARTSWITCH

*For 18-12P Plug(LECO S12020-27)

CAUTION

FIGURE B.2

B-6OPERATIONB-6

• In 4-Step position allows welding without continu-ously holding the start switch trigger. The arc startswitch functions in the following manner:

1. Closing switch starts preflow, then arc startsat Minimum (Start) setting level (See Item7). If the trigger is maintained closed afterpreflow time the output remains at the Startlevel until it is released.

2. Opening switch initiates fixed (0.5 sec.)ramp time from Start setting level to Weldsetting.

3. Reclosing switch initiates Downslope ramptime setting (See item 17) from Weld settingdown to the Crater-fill level (See Item 7) ofthe machine.

4. Reopening switch after Downslope timeholds Crater-fill level until switch opens,then stops the arc and initiates the PostflowTime (See Item 9). Or, reopening switchduring Downslope time immediately stopsthe arc and initiates the Postflow.

Note: See Section B-7 for 4-Step operation duringDownslope with Restart feature selected to beenabled, instead of disabled (as shipped).

13. PULSE MODE SWITCH – Turns on the PulseMode as indicated by the Green panel light turning on.

• Pulsing provides a Peak current level set byREMOTE and/or LOCAL control of the output cur-rent (See Item5), for a time determined by the PulseFrequency Control setting (See Item 14) and the %ON Time (See Item 15). The balance of the cycletime is at the Background Current level (See Item16).

• Pulsing begins after upslope when the output cur-rent rises above the Background Current level andends when the output current drops below this level.

14. PULSE FREQUENCY CONTROL – This knob isused to set the Pulse Frequency over the peak pulserange of about 0.1 pps to 20 pps. (One pulse cycletime = 1/pps = 10 to .05 sec. range.)

15. PULSE % ON TIME CONTROL – This knob con-trols the duration of the peak current as a percentage(5% to 95%) of one pulse cycle. The balance of thecycle time will be at the Background Current setting.(See Item 16)

16. PULSE BACKGROUND CURRENT CONTROL –This knob controls the level of the Background Currentas a percentage (MIN.-100%) of the Peak (REMOTEand/or LOCAL) output level (See Item 6) down to theMinimum Output setting (See Item 7).

17. DOWNSLOPE TIME– This knob is used to set thetime, over the range of zero to about 10 seconds, toramp down from weld setting to Crater-fill level (SeeItem 7).

• If the arc goes out after the Downslope time is initi-ated, the Downslope time is interrupted and thePostflow time is initiated. This prevents Hi-Freq re-initiation during ramp down crater fill

• When using an Amptrol remote control, where thedownslope is controlled by the operator down to thecrater-fill level, the Downslope time should be set tozero so as not to have the Downslope time delaywhen the arc start switch is opened.

PRECISION TIG 275

B-7OPERATIONB-7

INTERNAL SET UP CONTROLS

Precision TIG 275 models which have an AdvancedPanel (K1829-1) option installed* have the followingadditional control features which are set up using theDIP Switch (S1) provided on the internal panel of thisoption.

Access to this internal panel is obtained by removingthe two screws securing the top corners of thePrecision 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:

• THE CONTROL BOARDS CONTAIN STATIC SEN-SITIVE COMPONENTS

• To avoid possible damage to these componentsbe sure to ground yourself by touching themachine’s sheet metal while handling or makingsettings on the internal control box components.

------------------------------------------------------------------------PRECISION TIG ADVANCED PANEL

(Internal Panel)

DIP SWITCH POSITIONS (FACTORY SETTINGS)

STICK WELDING FEATURES

The following DIP switch feature selections functiononly when the Precision TIG is set to Stick mode. (SeeItem 3):

• Switch #6 Hot Start Level – Provides an extra out-put "boost" pulse at the arc strike to enhance arcstarting. This is factory set for a level (about 50%extra) which is usually good for most stick weldingapplications

ON – Hot Start level is used (as shipped).OFF – No Hot Start.

• Switch #7 Arc Force Level – Prevents "stubbing"of the electrode by providing extra output current ifthe arc voltage drops below the level required tosustain the welding arc. High (+65%) and Low(+12%) factory set levels are selectable which aregood for most stick welding applications.

ON – Higher for a "crisper" arc, often desired for 6010type electrodes.

OFF – Lower Arc Force (as shipped) for a "softer" arcwith 7018 or general type electrodes.

• Switch #8 (NOT CURRENTLY FUNCTIONAL)

TIG WELDING FEATURES

The following DIP switch feature selections functiononly when the Precision TIG is set to TIG mode (SeeItem 3):

• Switch #1 Preflow/Postflow Time Extension*(See Item 9)

ON – Doubles the time ranges.OFF – Standard time ranges (as shipped).

• Switch #2 2-Step Trigger Restart Feature (SeeFigure B.3)

ON – Restart Enabled (as shipped).OFF – Restart Disabled.

• Switch #3 4-Step Trigger Restart Feature (SeeFigure B.4)

ON – Restart Enabled.OFF – Restart Disabled (as shipped)

• Switch #4 (NOT CURRENTLY FUNCTIONAL)

• Switch #5 Crater-Fill Level (See Item 7)

ON - Level is minimum rating of the machine (2A)OFF – Level (as shipped) is Minimum Output setting

(same as Start level).

* The Preflow/Postflow Time doubling feature can also be selectedon Precision TIG 275 models without the Advanced Panel byaccessing the Control board in the control box per above instruc-tions, then disconnecting the jumper terminals attached to thejumper plug connected to receptacle J3 of the Control board.(Refer to Machine Wiring Diagram.)

PRECISION TIG 275

CAUTION

HOT STARTARC FORCE

^ ON

1 2 3 4 5 6 7

DIP SWITCH (S1)

S F

ON

OFF

1 2 3 4 5 6 7 8

B-8OPERATIONB-8

PRECISION TIG 275

(With DIP Switch #2 ON, As Shipped)

(With DIP Switch #2 OFF)

FIGURE B.3

B-9OPERATIONB-9

PRECISION TIG 275

FIGURE B.4

(With DIP Switch #3 OFF, As Shipped)

(With DIP Switch #3 ON)

B-10OPERATIONB-10

SETUP GUIDELINES FOR TIG WELDINGWITH AN AMPTROL

Both the Hand and Foot Amptrols work in a similarmanner. They are meant to be used for remote currentcontrol for TIG welding using the machine’s 2-Steptrigger mode (See Item 12).

The Amptrol is capable of controlling the output of thePrecision TIG over the range between the level presetby the Minimum Output control when the Amptrol is atits inactivated state, and the level preset by theMaximum Output control when the Amptrol is at fully-activated state.

It is important to note that even with the Precision TIG’snew MicroStartTM Technology, some tungstens may bedifficult to start at the low (2 amps) minimum rating ofthe machine. Rather than guessing where to depressthe Amptrol to start the arc reliably, the MinimumOutput control allows presetting the exact level, soreliable starts, as well as minimum crater-fill levels, canbe consistently obtained at the minimum Amptrol (inac-tivated ) state. FIGURE B.6 shows Precision TIG setupfor TIG welding with an Amptrol.

USING THE START PEDAL FOOT AMPTROL (K870-1)

To further enhance reliability of consistently obtainingthis minimum level just after the Amptrol’s start switchis closed, or just before it opens for crater-fill, the newK870-1 Start Pedal Foot Amptrol is available. Itsindependent start pedal on control pedal provides two-stage foot action to easily feel start switch closure atminimum output level for precise arc start and cratercontrol. Also, an adjustable heel stop helps assurecomfortable foot location.(See Figure B.5)

Currently available TIG foot pedal controls combine thearc start switch actuation in the same pedal action withthe output control variable resistance. This techniqueprovides no independent tactile feel of where the arcstart switch actuates, and at what control level, for con-sistent TIG starting. Nor does it provide a way for con-sistent crater-fill control to feel at what decreasing con-trol pedal position the arc start switch will re-opencausing arc out.

PRECISION TIG 275

PREFLOWFixed 0.5 sec

or x2

START TIMEManual

in 4-Step

UPSLOPEFixed<0.5 secw/o Amptrol

MINIMUM OUTPUT(Start) SETTINGAdjustable 2-50A

MAXIMUM OUTPUTSETTING

Adjustable 2-Max.A

Amptrol or Remote(PEAK) Range

2 or 4-STEPTriggerClosed

4-STEPTrigger

1ST Open

4-STEP Trigger Re-closed or

2-STEP TriggerOpened

4-STEP Trigger Re-opened

afterDownslope Time

DOWNSLOPEAdjust 0 —10 secw/ Advan. Panel(Fixed 0 sec w/o)

POSTFLOWAdjust 2-60 sec

or x2

CRATER-FILLLEVEL

AdvancedPanel Select:

Mach. Min.or

MIN. Setting(as w/o Panel)

With PULSE ONNo Pulsing

During Upslope Timeor

When DownslopeDrops Below

Background Setting

% ON TIMEAdjustable

5-95%

PULSE FREQ.Adjustable0.1-20 pps

BACKGROUNDAdjustable

MIN.Setting -100% Peak

CRATER-FILL TIMEManual in 2/4-Stepw/ Restart Disabled

TIG WELD CYCLE CHART

SEE ITEM 12 SEE ITEM 12SEE ITEM 12 SEE ITEM 12

SEE ITEM 7

SEE ITEM 9SEE ITEM 17

SEE ITEM 16

SEE ITEM 15SEE ITEM 14

SEE ITEM 7

SEE ITEM 12

SEE ITEM 9

SEE ITEM 7

SEE ITEM 6

SEE ITEM 6 & 7

SEE ITEM 12 & TIGWelding Features

B-11OPERATIONB-11

PRECISION TIG 275

Max. to Min.Amptrol

Min. to Max.Amptrol

Setup for TIG Amptrol Welding

Advanced Panel

(If used)

Standard Controls

Power Switch

ON

Polarity Switch

AC or DC-

Mode Switch

TIG

AC Balance

AUTOor

Set:

More + for alum.oxide "Cleaning" w/o "Spitting" or "wetting" loss.

Balanced for equal + and - current.More - for higher "Penetration".

Local/Remote

Switch

REMOTE

Trigger Switch

2-STEP

Pulse Switch

ON or OFF

Pulse Frequency

4-6 pps is a typical initial setting.Set for bead shape and travel speed:

Higher for thinner plate and faster travel.Lower for thicker plate and slower travel.

% On Time

40-60% is a typical initial setting.Set for total heat of Peak current:

Lower reduces distortion and burn-thru.

Background Current

40-60% is a typical initial setting.Set as low as will maintain a pulse arc

(Will not drop below Min.Output setting.)

Downslope

ZEROFor no arc-out delay.

Minimum OutputPress Display switch

and Set to desired min.Amptrol (Start/Crater)

output level.

PostflowSet as low as required.

Higher for largertungsten and current.

Maximum OutputSet to desired max.

Amptrol output level.

FIGURE B.6

Controls

The new foot pedal provides such independent actiondistinction of precisely where the arc start switch actu-ates without over-riding minimum control pedal posi-tion, and precisely where the control pedal has beenreturned to minimum position without inadvertently de-actuating the arc start switch. The result is repeatableconsistency in TIG weld starting and crater-fill for man-ual process control.

Using this new foot pedal with the Precision TIG’s newpresettable Minimum Output level, in addition to thepresettable Maximum Output level, further enhancesthe starting and crater level consistency as well as thecontrol resolution of the manually controlled foot pedal.

ToePressureSwitch

FootRock

Control

Adjustableor

RemovableHeel Stop

Fully PressedControl Pedal

Maximum OutputMachine Setting

Minimum OutputMachine Setting

At-RestControl Pedal

PressedSwitch Pedal

At-RestSwitch Pedal

Off Time

FIGURE B.5

B-12OPERATIONB-12

PRECISION TIG 275

RECOMMENDED ELECTRODE AMPERAGE RANGES - PRECISION TIG 275

SMAW ProcessELECTRODE POLARITY 3/32" 1/8" 5/32"

Fleetweld 5P, Fleetweld 5P+ DC+ 40 - 70 75 - 130 90 - 175Fleetweld 180 DC+ 40 - 80 55 - 110 105 - 135Fleetweld 37 DC+ 70 - 95 100 - 135 145 - 180Fleetweld 47 DC- 75 - 95 100 - 145 135 - 200Jet-LH MR DC+ 85 - 110 110 - 160 130 - 220Blue Max Stainless DC+ 40 - 80 75 - 110 95 - 110Red Baron Stainless DC+ 40 - 70 60 - 100 90 - 140Mild steel procedures are based on recommended procedures listed in C2.10 8/94 and the maximum rating of the PRECISION TIG 275Excaliber 7018 procedures are based on Jet-LH 78 MRBlue Max procedures are based on C6.1 6/95Red Baron Procedure are based on ES-503 10/93

GTAW ProcessElectrode Polarity DC- AC* Approximate Argon

Electrode Tip Preparation Sharpened Balled Gas Flow Rate

Electrode Type EWZr C.F.H. (l/min.)EWTh-1, EWCe-2 EWTh-1, EWTh-2EWTh-2, EWLa-1 EWP EWCe-2, EWLa-1 Stainless

Electrode Size (in.) EWG EWG Aluminum Steel.010 Up to 15 A. Up to 15 A. Up to 15 A. 3-8 (2-4) 3-8 (2-4).020 Up to 15 A. 10 to 15 A. 5 to 20 A. 5-10 (3-5) 5-10 (3-5).040 Up to 80 A. 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 120 A. 5-10 (3-5) 9-13 (4-6)3/32 Up to MAX. A. 60 to 130 A. 100 to 180 A. 13-17 (6-8) 11-15 (5-7)1/8 X 100 to 180 A. 160 to 250 A. 15-23 (7-11) 11-15 (5-7)

Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure .........................................EWP...........green

+1% Thoria ..............................EWTh-1......yellow

+2% Thoria ..............................EWTh-2......red

+2% Ceria................................EWCe-2 .....orange

+1.5% Lanthana ......................EWLa-1......black

+0.15 to 0.40% Zirconia ..........EWZr..........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.

MAKING A TIG WELD WITH AN AMPTROL

1. Install welding equipment per Section A-5.

2. Setup controls per Section B-10.

3. Turn on the shielding gas supply, and torch coolantinput supply (if used).

Note: The Precision TIG Under-Cooler (or WaterSolenoid connected to the Cooler receptacle) runs withthe Fan-As-Needed machine cooling fan (SeeMaintenance Section D), so the cooler fan and waterpump will also not run continuously in idle, but will runwhile welding.

4. With the torch held safely away from everything,close the Arc Start Switch of the Amptrol and set thegas flow meter. Then open the switch. The welderis now ready for welding.

5. Position the tungsten electrode at the start of theweld at a 65° to 75° angle with the horizontal, in thedirection of pushing travel, so that the electrode isapproximately 1/8" (4 mm) above the work piece.

Close the arc start switch. This opens the gas valveto 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 becomesavailable to strike the arc. When the arc strikes thetorch coolant (if used) starts to flow. Also, if weldingDC- TIG, the high frequency shuts off just after thearc strikes.

6. Hold the arc start switch closed at minimum AmptrolStart level (See Section B-10) until an arc is estab-lished, then increase the output to the desired weld-ing level and push the torch in the direction of trav-el.

7. At the end of the weld, decrease the Amptrol outputto the crater-fill level before releasing the arc startswitch to start the Postflow time. Hold the torch gasshielding over the solidifying weld crater while post-flow time expires and the gas valve reopens. Thetorch coolant (if used) continues to flow for up to 8minutes after the arc goes out (with the Fan-As-Needed feature) to assure torch cooling.• Repeat steps 5 through 7 to make another weld.

*

C-1ACCESSORIESC-1

OPTIONAL EQUIPMENT

FACTORY INSTALLED OPTIONS

The basic Precision TIG 275 machine is factoryequipped 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 theDomestic model (K1826-1) to make up the DomesticWelding Package (K1825-1) include:

• K1828-1 Under-Cooler Cart • 3100211 Harris Argon Flow Regulator with 10’

hose.• K870 Foot Amptrol • K1784-4 25’ PTW-20 water-cooled TIG Torch• K918-2 Zippered Torch Cover• KP510 Parts Kit for Torch• K2150-1 Work Lead Assembly

See below for more detailed descriptions.

FIELD INSTALLED OPTIONS

The following Options/Accessories are available for thePrecision TIG 275 and are installed per instructions inthis manual and / or provided in the package:

• K1829-1 Precision TIG Advanced Control PanelProvides 2/4-step trigger with adjustable Pulser con-trols and Down slope timer for TIG welding. Alsoincludes adjustable Hot Start and Arc Force internalpanel controls for Stick welding, and other userselectable features.

• K1828-1 Under-Cooler Cart Includes a "cooler-in-a-drawer" with hoses and alockable storage drawer on a dual bottle undercar-riage (see below).

• K1869-1 UndercarriageIncludes a dual bottle rack with chain and an under-carriage with 5" front casters,10" rear wheels and ahandle.

• K1830-1 Water Solenoid KitProvides for stopping flow of external water supply.Connects to coolant inlet and cooler receptacle ofPrecision TIG.(Can not be used with a water cooler.)

• K870 Foot AmptrolSingle pedal foot activation of arc start switch andoutput control, with 25’ plug cable.

• K870-1 Start Pedal Foot AmptrolIndependent start pedal on control pedal providestwo-stage foot action to easily feel start switch clo-sure at minimum output level for enhanced arc startand crater-fill control. Provided with adjustable, orremovable, heel stop and 25’ plug cable.(Refer toFigure B.5)

• K963-3 Hand AmptrolFastens to torch for convenient thumb activation ofarc start switch and output control, with 25’ plugcable:

• K814 Arc Start SwitchNeeded for TIG welding without an Amptrol. Includes25’ plug cable, and attaches to torch for convenientfinger control.

• K1831-1 Power Factor Capacitor KitUsed when welding at higher output currents toreduce input current and help keep electricity coststo a minimum.

• Magnum® PTA and PTW Series TorchesAll Air Cooled or Water-Cooled Magnum® TIGTorches may be used with the PRECISION TIG 275.Connection adapters are only required for Air-CooledTorches (Refer to Diagrams on A-7):

K2166-1 7/8” Torch Connector for PTA-26 (onepiece)

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 PrecisionTIG models.)

• 3100211 Harris Argon Flow Regulator (Includes 10’hose.)

• K2150-1 Work Lead Assembly15ft. 2/0 cable with 1/2" stud lug and work clamp.

PRECISION TIG 275

D-1MAINTENANCED-1

PRECISION TIG 275

ELECTRIC SHOCK can kill.

• Only qualified personnel shouldperform this maintenance.

• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on thisequipment.

• Do not touch electrically hot parts.

To avoid receiving a high frequency shock, keep theTIG torch and cables in good condition.

Very little routine maintenance is necessary to keepyour Precision TIG 275 running in top condition. Nospecific schedule can be set for performing the follow-ing items; factors such as hours of usage and machineenvironment should be considered when establishinga 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 maintainthe recommended spacing. See the ServiceProcedures (See Service Procedures in thisSection) for complete information on spark gap set-tings.

• The fan motor has sealed ball bearings whichrequire no maintenance.Overload Protection

SAFETY PRECAUTIONS

ROUTINE AND PERIODIC MAINTENANCE

WARNING

WARNING

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 whilewelding; then for about 8 minutes after welding hasstopped to assure proper machine cooling. This helpsreduce the amount of dust and dirt drawn into themachine with the cooling air. The cooling fan will oper-ate briefly when the machine power is initially turnedon, and continuously while the yellow ThermalShutdown Light is lit (see Thermostatic Protection).

THERMOSTATIC PROTECTION

This welder has thermostatic protection from excessiveduty cycles, overloads, loss of cooling, and excessiveambient temperatures. When the welder is subjectedto an overload, or inadequate cooling, the primary coilthermostat and/or secondary coil thermostat will open.This condition will be indicated by the illumination ofthe yellow Thermal Shutdown Light on the front panel(see Item 10 in Section B). The fan will continue to runto cool the power source. Postflow occurs when TIGwelding is shut down, but no welding is possible untilthe machine is allowed to cool and the yellow ThermalShutdown 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 resistorfrom overheating with F.A.N. cooling off, as well as toconserve on gas waste.

AUXILIARY POWER CIRCUIT BREAKER

The 115vac auxiliary circuits and rear receptacle (seeSection A Auxiliary Power Connections) are protectedfrom overloads by a 15 amp circuit breaker, locatedabove the receptacle. If the breaker trips its buttonpops out exposing a red ring. When the circuit breakercools 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 sowill the power to the shielding gas solenoid andmachine cooling fan.

The Export models also include a 5 amp circuit break-er, located on the opposite side of the upper case back,for protection of the 220vac Schuko type cooler recep-tacle.

D-2MAINTENANCED-2

SERVICE PROCEDURES

Operation of the Precision TIG should be trouble-freefor the life of the machine. Should a malfunction occur,however, the following procedures will be useful totrained service personnel with experience in repairingarc welding equipment:

COMPONENT ACCESSThe following components are accessible for routineset up and periodic service without requiring removalof the case sides or roof:

• Input Reconnect Panel (refer Section A) is locatedbehind a removable panel on the rear of the left caseside. Remove the two screws (with a screwdriver ora 3/8"/ 9.5mm hex driver) on the bottom corners ofthis panel to remove it.

• Control Box components and PC Boards (referSection B-6) are located behind the front controlpanel. Remove the two screws (with a screwdriver ora 3/8"/ 9.5mm hex driver) on the top corners of thispanel to swing it down.

• Hi-Freq. Spark Gap assembly (refer Spark GapAdjustment) is located behind a removable panel onthe rear of the right case side, under the torch box.Remove the screw (with a screwdriver or a 3/8"/9.5mm hex driver) on the bottom center of this panelto remove it.

SPARK GAP ADJUSTMENT

The spark gap is set at the factory to a gap of 0.015inches (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).

Use extreme caution when working with circuit ofthe high frequency. The high voltages developedcan be lethal. Turn the input power off using thedisconnect switch or fuse box before workinginside the machine. This is particularly importantwhen working on the secondary circuit of the highvoltage transformer (T3) because the output volt-age is dangerously high.------------------------------------------------------------------------

Note: In highly dirty environments where there is anabundance of conductive contaminants, use a lowpressure air stream or a firm piece of paper to cleanout 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 side

(See Component Access).3. Check the spark gap spacing with a feeler gauge.

If adjustment is required:1. Adjust the gap by loosening the Allen head screw

on one of the aluminum blocks, reset the gap andtighten 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 forthe Under-Cooler are provided in the operator’s manu-al (IM723) provided with the Under-Cooler Cart.

PRECISION TIG 275

.015 Spark Gap

FIGURE C.1 SPARK GAP

WARNING

DO NOT use a volt-ohm meter to measure output voltages in TIG mode. TheHigh Frequency Arc Starter voltage can damage the meter.

CAUTION

E-1TROUBLESHOOTINGE-1

PRECISION TIG 275

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing that bestdescribes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contribute tothe machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician and machineoperator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, pleaseobserve all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING

E-2TROUBLESHOOTINGE-2

PRECISION TIG 275

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

OUTPUT PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE

RECOMMENDEDCOURSE OF ACTION

Thermal light comes on

Meter doesn’t light up

Has output in No gas & no hi-freqStick mode but no output in Tig mode

Gas & hi-freq are o.k.

No output in both Stick and Tigmodes

1. Thermal shut down. Dirt and dustmay have clogged the coolingchannels inside machine; airintake and exhaust louvers maybe blocked; welding applicationmay exceed recommended dutycycle. Wait until machine cooldown and thermal light goes out.Blow out machine with clean, drylow pressure air; check air intakeand louvers; stay within recom-mended duty cycle.

2. Bad thermostat or its connections

1. Losing AC supply to Control PCboard

2. Loosing input to machine

3. Faulty Control PC board

1. Faulty trigger or hand/foot Amptrolor connections.

2. Faulty Protection PC board orbad connection to Control PCboard

3. Losing trigger supply to ControlPC board

1. Faulty Control PC board

1. Bad connection at P4 of ControlPC board

2. Faulty Control PC board

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

E-3TROUBLESHOOTINGE-3

PRECISION TIG 275

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

METER PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE

RECOMMENDEDCOURSE OF ACTION

Meter does not light up

Meter does not display V (Volt) orMin A (Minimum current)

No gas

No control on post flow time

Pre flow & Post flow time too long

1. Bad meter or its connection

2. Bad connection at P8 of ControlPC board

3. Faulty Control PC board

1. Bad Display switch or its connec-tion

2. Bad connection at P9 of ControlPC board

1. Circuit breaker CB1 open. PressCB1 in to reset

2. Bad connection at P12 of ControlPC board

3. Faulty gas solenoid valve SV1 orits connection

4. Faulty Control PC board

1. Faulty potentiometer R3 or itsconnection

2. Bad connection at P9 of ControlPC board

1. If an Advanced Control PC boardwas installed, check setting ofDIP switch on that board

2. Missing plug P3 on Control boardor bad connection at P3 when anAdvanced Control PC board is notpresent

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

GAS PROBLEMS

E-4TROUBLESHOOTINGE-4

PRECISION TIG 275

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

HI-FREQ PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE

RECOMMENDEDCOURSE OF ACTION

No hi-freq

Hi-freq intensity too weak

Hi-freq on continuously in DC Tig

Hi-freq shuts off after starting in ACTig

1. Circuit breaker CB1 open

2. Bad connection at P12 of ControlPC board

3. Spark gaps shorted

4. Faulty Control PC board

1. Dirty spark gap or improper gapsetting

2. Faulty Arc Starter assembly

1. Bad connection at P11 of ControlPC board

2. Micro-switch S2A is not engaged &disengaged properly when switch-ing between DC & AC polarity.(S2A locates on the Polarityswitch)

3. Faulty Control PC board

1. Micro-switch S2A is not engaged &disengaged properly when switch-ing between DC & AC polarity.(S2A locates on the Polarityswitch)

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

E-5TROUBLESHOOTINGE-5

PRECISION TIG 275

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

PRESET & OUTPUT CONTROL PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE

RECOMMENDEDCOURSE OF ACTION

Meter does not display preset

High output current in both DC & ACpolarities regardless of preset

High output current in DC polarityregardless of preset, o.k. in AC polar-ity

In 2-step Tig, output stays on formore than downslope time after trig-ger open (machine with AdvancedControl panel only)

Output stays on after releasinghand/foot Amptrol (machine withAdvanced Control panel only)

1. Faulty potentiometer R1 or its con-nection

2. Bad connection at P9 of ControlPC board

3. Faulty Advanced Control PC board( if present ) or its connection tothe main Control PC board

4. Missing plug P3 on Control boardor bad connection at P3 when anAdvanced Control PC board is notpresent

1. Bad connection at P6 of ControlPC board

2. Bad shunt connection

3. Faulty Control PC board

4. Faulty SCR bridge

1. Shorted free wheeling diode D1

1. Bad 2/4 step switch or its connec-tion

2. Bad connection at P1 of AdvancedControl PC board

1. Downslope is not set at min.

2. Bad Downslope potentiometerR12 or its connection

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

E-6TROUBLESHOOTINGE-6

PRECISION TIG 275

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

STICK WELDING PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE

RECOMMENDEDCOURSE OF ACTION

Stick electrode "blast off" when arcis struck

Stick electrode "sticks" in the weldpuddle

Poor starting in DC polarity

Arc "flutters" in DC polarity, o.k. inAC polarity

Arc "flutters" in both DC & AC polari-ties

1. Current may be set too high forelectrode size

2. (Machine with Advanced ControlPC board only) Hot Start level settoo high

1. Current may be set too low forelectrode size

2. (Machine with Advanced ControlPC board only) Arc Force level settoo low

1. Input line may be too low

2. Bad connection at P11 of ControlPC board

3. Bad Background rectifier, back-ground resistor R7, or backgrounddiode D2

1. Tungsten not "sharp"

2. Bad free wheeling diode D1 or itsconnection

1. Tungsten electrode may be toolarge in diameter for the currentsetting

2. Gas shielding may be insufficient.

3. Contaminated gas or leaks in thegas line, torch, or connections

4. Helium blend is used as a shield-ing gas

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

TIG WELDING PROBLEMS

E-7TROUBLESHOOTINGE-7

PRECISION TIG 275

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

TIG PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE

RECOMMENDEDCOURSE OF ACTION

Arc "pulsates" in AC polarity, DCpolarity is o.k.

Black area along weld bead

Output quits momentarily; gas flowand hi-freq are also interrupted

1.Micro switch S2A on polarity switchdoes not open in AC polarity

1. Oily or organic contamination fromwork piece

2. Tungsten electrode may be conta-minated

3. Leaks in gas line, torch, or con-nections

1. May be caused by hi-freq interfer-ence. Check that machine isgrounded properly. Surroundingmachines that generate hi-freqalso should be properly grounded.

2. Ground connection of ProtectionPC board may has become loose

3. Ground connection ofBypass/Stabilizer PC board mayhas become loose.

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

F-1WIRING DIAGRAMF-1

PRECISION TIG 275

RE

CE

PTA

CLE

CAB

B

CO

NTR

OL

PC B

OAR

D

10K

A-B

FEDC

AT

MIN

IMU

M

D F

RE

MO

TETM

AM

PTR

OL

OP

TIO

NA

L

A

E

RE

MO

TE

A B C D E F

+-

GR

GY

54321

(STI

CK)

(AU

TO B

AL)

(REM

OTE

)(P

. FLO

W)

(TH

ERM

AL)

8

4 1 2 3 6 56

BW

+-

BW

+-

BW

+-

BW

+-

G

331

654321 2 3 4 5 71

54321 66

301

303

304B

306

302

ME

TER

(VIE

WE

D F

RO

M R

EA

R)

87 654321

J23

J22

301

302

303

304

304A

306

304B

321

322

313

314

315

316

317

318

319

320

311

312

J8 J9

5983721 6 4

331

10

411

W403

404

405

406

407

408

409

410

401

402

TIG OPTION PCB(OPTIONAL)

87654321

220

G1

217

21W

221

R 2

22

11310226

927

027

122

0B

65 4321

233A

235

16815714413512691

J11

L8

J10

J1

J5

J12J4J6

N.A

.

862 3 4 5 71

J5A

N.B

.

260

236

521 3

J7

PR

OTE

CTI

ON

PC

B

R12

R11

R10

G

R9

FRE

QO

N T

IME

DO

WN

SLO

PE

BA

CK

GR

OU

ND

401D

402403

405406

408409410

401B

(PU

LSE

ON

) +-

AD

VA

NC

ED

CO

NTR

OL

PA

NEL

(OP

TIO

NA

L)

401C

401D

W

B

VIE

W O

F C

ON

NE

CTO

R O

N P

C B

OA

RD

ELE

CTR

ICAL

SY

MB

OLS

PE

R E

1537

.

OH

MS

/WA

TTS

CO

MP

ON

EN

T VA

LUE

UN

ITS

:R

ES

ISTO

RS:

MFD

/VO

LTS

CA

PA

CIT

OR

S: 8LA

TCH0F

CO

NN

EC

TOR

J5

EXA

MP

LE: T

HIS

IS P

IN 7

32

LEA

D C

OLO

RIN

G C

OD

E:

B-B

LAC

K 21 8

G-G

RE

EN

O-O

RA

NG

ER

-RE

D

CO

NN

EC

TOR

PIN

NU

MB

ERS:

7 14

U-B

LUE

Y-Y

ELLO

WW

-WH

ITE

1

3 J5

460

VO

LT C

ON

NE

CTIO

NC

ON

NE

CT

STR

AP

TOH

IGH

(H4)

(A

S S

HO

WN

)

232

H4

(460

V)

F

W20

9

18V

AC

X7

R21

0

201

X8FS

X5 X2

X1

T1

78VA

C

S

204

115V

AC

X9 X10

20V

AC

X3H

3 (2

30V

)H

2 (2

08V

) X

6

262

263

63.5

VA

C26

7

268

CR

4

231A

231

115V

AC

X4

CB

115

A232

231

FSFS

FS

CR

4

233B 234

48

26

233

01

233A

C8

C9

214

213

R8

267

233A

231A

268

269

220B

271

270

220A

262

263

201

204

W20

9R

210

115V

AC

AR

C S

TAR

TER

AS

’BLY

R5

SV1

GA

S V

ALV

E

L3

C6

T2

C7

T3G

AP

SP

AR

K

L2

237

S F

R6BY

PASS

/ST

ABIL

IZER

PC B

OAR

D

FAN

260

235

233A

239238

284

285

236B

236

231D

231E

231A

231E

233A

PO

S

D

FRO

NT

GA

NG

NEGPO

LAR

ITY

SW

ITC

H

MIC

RO

SW

ITC

H

PO

LAR

ITY

S2

NO

(RE

AR

VIE

W, S

HO

WN

X2

NC

MIC

RO

-SW

ITC

H

CLO

SE

DC

LOS

ED

OP

EN

TO G

RO

UN

D P

ER

C

A-C

, D-E

, B-F

B-D

, C-E

, A-F

, G-H

G

DC

+ RE

AR

GA

NG

DC

-

266A

S2A

265A

HA

L1A

C

SW

ITC

H

E

F

ELE

CTR

ICAL

CO

DE

NA

TIO

NA

L

253

PO

S

B-D

, A-E

, C-F

, G-H

IN A

C P

OSI

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N)

D2

B

252

R7

286

W221R222

271A

BA

CK

GR

OU

ND

RE

CTI

FIE

R

265

266

G4

G3

G2

213

214

201

204

W20

9R

210

262

263

265

266

252

253

G1

G2

217

216 22

0

G3

220A

G4

218

SCR

4D

1

X1 NEG

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1

SCR

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(-)

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G40

31B

PR

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N T

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75 W

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G D

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RA

M F

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: 10

806

L9L10

L7

L6

L5

L12

L4

L13

L11

J3

N.D.

N.C

.

L1 (U

)

L2 (V

)

C1

RE

CO

NN

EC

T P

AN

EL

H4

H2

H1

H3

250

S1P

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SW

ITC

H

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C5

C4

CAP

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S(O

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NAL

)

PO

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FA

CTO

R

C2

A

GR

OU

ND

HIG

H

MID

LOW

CO

M

251

21

34

56

89

107

21

34

56

89

107

J2J3

21

34

56

89

107

OR

N.C.

230

VO

LT C

ON

NE

CTIO

NC

ON

NE

CT

STR

AP

TOM

ID (H

3)

208

VO

LT C

ON

NE

CTIO

NC

ON

NE

CT

STR

AP

TOLO

W (H

2)

407

L1 (U

)

L2 (V

)

FRO

NT

ELE

CTR

OD

E

RE

AR

ELE

CTR

OD

E

WO

RK

TRAN

SFO

RM

ER

PR

IMA

RY

THER

MO

STA

TTR

ANS

FOR

ME

RS

EC

ON

DA

RYTH

ERM

OST

AT

PU

LSE

2-ST

EP

401

404

ON

OFF

411

401A

4-ST

EP

TRIG

GE

R

401B

R4

R1

R2

BA

LAN

CE

MIN

IMU

MO

UTP

UT

MA

XIM

UMO

UTP

UT

MO

DE

RE

MO

TE

R3

PO

ST F

LOW

319

322

316C

313C

316B315

316317

311312

313318

313B

TIG

STI

CK

321DIS

PLA

Y

314320

LOC

AL

311A

316A

316C

311A

316A316B

F

C

S

E

N.E

.

CO

NTR

OL

PAN

EL (

VIEW

ED F

RO

M R

EAR

)

332

333

BW

334

335

BW

332

BW

333

BW

334

BW

335

BW

1211109865431 2 7

1211109865431 2 7

64

10921

621

8

C1,

C2

POW

ER F

ACTO

R C

APAC

ITO

RS,

50/

460

(OPT

ION

AL)

C4,

C5

BY-P

ASS

CAP

AC

ITO

RS,

.004

7C

6H

IGH

VO

LTAG

E C

APAC

ITO

R, .

0015

/12k

VC

7PH

ASE

SH

IFT

CAP

AC

ITO

R,

15uF

/250

VAC

C8,

C9

HIG

H F

REQ

PR

OTE

CTI

ON

CAP

AC

ITO

RS,

.22/

400

CB

1C

IRC

UIT

BR

EAKE

R, 1

5 AM

PC

R4

12V

DC

RE

LAY

CO

ILD

1FR

EE W

HEE

LIN

G D

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ED

2BA

CKG

RO

UN

D D

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TPU

T IN

DU

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FR

EQ IN

DU

CTO

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L4 -L

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F TO

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R1

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TPU

T C

ON

TRO

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MET

ER, 1

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2BA

LAN

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CO

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NTI

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UT

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ASE

SH

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00/1

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ING

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7R

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R9

FREQ

CO

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10O

N T

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CO

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OL

POTE

NTI

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11BA

CKG

RO

UN

D P

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NTI

OM

ETER

, 10K

R12

DO

WN

SLO

PE P

OTE

NTI

OM

ETE

R, 1

0KS1

INPU

T PO

WER

SW

ITC

HS2

POLA

RIT

Y SW

ITC

HS2

AM

ICR

OS

WIT

CH

ON

PO

LAR

ITY

SWIT

CH

SCR

1,2,

3,4

MAI

N P

OW

ER S

CR

’SSV

1G

AS S

OLE

NO

ID V

ALVE

, 115

VAC

SV2

WAT

ER S

OLE

NO

ID V

ALVE

, 115

VAC

(OPT

ION

AL)

T1M

AIN

TR

ANSF

OR

ME

RT2

HIG

H V

OLT

AGE

TRAN

SFO

RM

ER

T3H

IGH

FR

EQ T

RAN

SFO

RM

ER

N.A

. CO

NNE

CTI

ON

IS P

IN T

O P

IN B

ETW

EEN

J23

AND

J5.

N.B

. RO

BOTI

C IN

TER

FACE

CO

NNE

CTI

ON.

N.C

. REM

OVE

JU

MPE

R PL

UG

IN J

3 W

HEN

INST

ALLI

NG

TIG

OPT

ION

PC B

OAR

D.

N.D

. DIS

CON

NEC

T JU

MPE

R LE

AD B

ETW

EEN

PIN

1 AN

D

P

IN 2

IN J

3 TO

DO

UBL

E PR

EFLO

W &

PO

STFL

OW T

IMES

.N

.E.

DIS

PLAY

TO

GG

LE S

HOW

N IN

MIN

AM

P PO

SITI

ON.

N.F

. PL

UG

S IN

TO L

OW

ER S

WIT

CHED

REC

EPTA

CLE.

SV

2W

AT

ER

VAL

VE

(OP

TIO

NA

L)N.F

.

313A

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

onl

y.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hine

s co

vere

d b

y th

is m

anua

l. T

he s

pec

ific

dia

gra

m f

or

a p

artic

ular

co

de

is p

aste

din

sid

e th

e m

achi

ne o

n o

ne o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

the

Ser

vice

Dep

artm

ent

for

a re

pla

cem

ent.

G

ive

the

equi

pm

ent

cod

e nu

mb

er..

F-2WIRING DIAGRAMF-2

PRECISION TIG 275

RE

CE

PTA

CLE

CAB

B

CO

NTR

OL

PC

BO

AR

D

10K

A-B

FEDC

AT

MIN

IMU

M

D F

RE

MO

TETM

AM

PTR

OL

OP

TIO

NA

L

A

E

RE

MO

TE

A B C D E F

+-

GR

GY

54321

(STI

CK)

(AU

TO B

AL)

(REM

OTE

)(P

. FLO

W)

(TH

ERM

AL)

8

4 1 2 3 6 56

BW

+-

BW

+-

BW

+-

BW

+-

G

331

654321 2 3 4 5 71

54321 66

301

303

304B

306

302

ME

TER

(VIE

WE

D F

RO

M R

EA

R)

87 654321

J23

J22

301

302

303

304

304A

306

304B32

132

2

313

314

315

316

317

318

319

320

311

312

J8 J9

5983721 6 4

331

10

411

W403

404

405

406

407

408

409

410

401

402

TIG OPTION PCB(OPTIONAL)

87654321

220

G1

217

21W

221

R 2

22

11310226

927

027

122

0B

65 4321

233A

235

16815714413512691

J11

L8

J10

J1

J5

J12J4J6

N.A

.

862 3 4 5 71

J5A

N.B

.

260

236

521 3

J7

PR

OTE

CTI

ON

PC

B

R12

R11

R10

R9

FRE

QO

N T

IME

DO

WN

SLO

PE

BA

CK

GR

OU

ND

401D

402403

405406

408409410

401B

AD

VA

NC

ED

CO

NTR

OL

PA

NEL

(OP

TIO

NA

L)

401C

401D

VIE

W O

F C

ON

NE

CTO

R O

N P

C B

OA

RD

ELE

CTR

ICAL

SY

MB

OLS

PE

R E

1537

.

OH

MS

/WA

TTS

CO

MP

ON

EN

T VA

LUE

UN

ITS

:R

ES

ISTO

RS:

MFD

/VO

LTS

CA

PA

CIT

OR

S: 8LA

TCH0F

CO

NN

EC

TOR

J5

EXA

MP

LE: T

HIS

IS P

IN 7

32

LEA

D C

OLO

RIN

G C

OD

E:

B-B

LAC

K 21 8

G-G

RE

EN

O-O

RA

NG

ER

-RE

D

CO

NN

EC

TOR

PIN

NU

MB

ERS:

7 14

U-B

LUE

Y-Y

ELLO

WW

-WH

ITE

1

3 J5

575

VO

LT C

ON

NE

CTIO

NC

ON

NE

CT

STR

AP

TOH

IGH

(H4)

(A

S S

HO

WN

)

232

H4

(575

V)

F

W20

9

18V

AC

X7

R21

0

201

X8FS

X5 X2

X1

T1

78VA

C

S

204

115V

AC

X9 X10

20V

AC

X3

H2

(460

V)

X6

262

263

63.5

VA

C26

7

268

CR

4

231A

231

115V

AC

X4

CB

115

A232

231

FSFS

FS

CR

4

233B 234

48

26

233

01

233A

C8

C9

214

213

R8

267

233A

231A

268

269

220B

271

270

220A

262

263

201

204

W20

9R

210

115V

AC

AR

C S

TAR

TER

AS

’BLY

R5

SV

1G

AS

VA

LVE

L3

C6

T2

C7

T3G

AP

SP

AR

K

L2

237

S F

R6BY

PASS

/ST

ABIL

IZER

PC B

OAR

D

FAN

260

235

233A

239238

284

285

236B

236

231D

231E

231A

231E

233A

PO

S

D

FRO

NT

GA

NG

NEGPO

LAR

ITY

SW

ITC

H

MIC

RO

SW

ITC

H

PO

LAR

ITY

S2

NO

(RE

AR

VIE

W, S

HO

WN

X2

NC

MIC

RO

-SW

ITC

H

CLO

SE

DC

LOS

ED

OP

EN

TO G

RO

UN

D P

ER

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1G

AS

SO

LEN

OID

VA

LVE

, 115

VA

CS

V2

WA

TER

SO

LEN

OID

VA

LVE

, 115

VA

C (O

PTI

ON

AL)

T1M

AIN

TR

AN

SFO

RM

ER

T2H

IGH

VO

LTA

GE

TR

AN

SFO

RM

ER

T3H

IGH

FR

EQ

TR

AN

SFO

RM

ER

220V

AC

N.F

.

H3

(380

V)

250

A

250

G

(PU

LSE

ON

) +-

W

B

L1 (U

)

L2 (V

)

L1A

L2A

BY

PAS

SP

C B

OA

RD

TO G

RO

UN

D P

ER

NA

TIO

NA

LE

LEC

TRIC

CO

DE

GND

-H2

GND

-HG

ND4

GND

5G

ND

1R

ECO

NNE

CT P

ANEL

SU

PPO

RT

T1TR

AN

S.

FO

OT

CA

SE

BA

CK

CA

SE

FRO

NT

CO

NTR

OL

PA

NE

L11

5 V

AC

RE

CE

PT.

GA

SV

ALV

E

GN

D6

PR

OTE

CTI

VE

BO

ND

ING

CIR

CU

IT22

0 V

AC

RE

CE

PT.

313A

F-4DIMENSION PRINTF-4

PRECISION TIG 275

49.6

7

27.1

6

27.9

7

40.9

6

3.47

L11

799XA

45.3

1

6.84

18.6

75.86

13.4

5

43.2

0

K18

25-1

DO

ME

ST

IC P

AC

KA

GE

F-5DIMENSION PRINTF-5

PRECISION TIG 275

L11

660

XB

-UF

** L

OCA

TIO

N O

F (4

) O

.284

BAS

E M

OUN

TING

HO

LES.

12.7

7

31.0

0

26.0

0

1.00

24.0

0**

.28

3.47

20.5

0**

22.0

0

.30

.75

3.44

TORC

H HO

LSTE

R

2.11

TORC

H BO

X

11.0

0

2.98

K18

26-1

DO

ME

ST

IC,

K18

26-2

CA

NA

DA

AN

D K

1827

-1 E

XP

OR

T

NOTES

PRECISION TIG 275

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TOBE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

l Do not touch electrically live parts orelectrode with skin or wet clothing.

l Insulate yourself from work andground.

l No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

l Aislese del trabajo y de la tierra.

l Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

l Isolez-vous du travail et de la terre.

l Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

l Isolieren Sie sich von denElektroden und dem Erdboden!

l Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

l Isole-se da peça e terra.

l Keep flammable materials away.

l Mantenga el material combustiblefuera del área de trabajo.

l Gardez à l’écart de tout matérielinflammable.

l Entfernen Sie brennbarres Material!

l Mantenha inflamáveis bem guarda-dos.

l Wear eye, ear and body protection.

l Protéjase los ojos, los oídos y elcuerpo.

l Protégez vos yeux, vos oreilles etvotre corps.

l Tragen Sie Augen-, Ohren- und Kör-perschutz!

l Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

l Keep your head out of fumes.l Use ventilation or exhaust to

remove fumes from breathing zone.

l Los humos fuera de la zona de res-piración.

l Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

l Gardez la tête à l’écart des fumées.l Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

l Vermeiden Sie das Einatmen vonSchweibrauch!

l Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

l Mantenha seu rosto da fumaça.l Use ventilação e exhaustão para

remover fumo da zona respiratória.

l Turn power off before servicing.

l Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

l Débranchez le courant avant l’entre-tien.

l Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

l Não opere com as tampas removidas.l Desligue a corrente antes de fazer

serviço.l Não toque as partes elétricas nuas.

l Do not operate with panel open orguards off.

l No operar con panel abierto oguardas quitadas.

l N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

l Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

l Mantenha-se afastado das partesmoventes.

l Não opere com os paineis abertosou guardas removidas.

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