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Lincoln Electric IM702-A manual

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Table of contents for the manual

  • Page 1

    PRECISION TIG 275 OPERA T OR’S MANUAL IM702-A June, 2005 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING TH[...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _______________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

  • Page 4

    FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical[...]

  • Page 5

    iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits [...]

  • Page 6

    v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to 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 it handy for quick reference. Pay[...]

  • Page 7

    T ABLE OF CONTENTS Page . Installation ..........................................................................................................Section A T echnical Specifications ........................................................................................A-1,A-2 Safety Precautions .. ...................................................[...]

  • Page 8

    A-1 INST ALLA TION PRECISION TIG 275 A-1 TECHNICAL SPECIFICA TIONS- PRECISION TIG 275 (K1825-1 Domestic Package*-60Hz) (K1826-1 Domestic,K1826-2 Canadian-60Hz) (K1827-1 Export-50/60Hz) V oltage + 10% 208/230/460 460/575 220-230/ 380-400/415 Max. Amps W ith Out Power Factor Capacitor 104/94/47 124/1 12/56 86/78/39 95/86/43 77/70/35 73/66/33 6/5/3 47[...]

  • Page 9

    K1826-1, -2 K1827-1 K1825-1 A-2 INST ALLA TION PRECISION TIG 275 A-2 ADDITIONAL OUTPUT CAP ACITY Output Current Range 2Amps DC to 340Amps AC-DC * T ype of Output CC (Constant Current) AC/DC (GT AW) Stick (SMA W) Maximum Open Circuit V oltage (STICK AND TIG) AC/DC OCV : 75/68 Auxiliary Power K1825-1, K1826-1, K1826-2 15Amp Circuit Breaker and NEMA 5[...]

  • Page 10

    A-3 INST ALLA TION PRECISION TIG 275 A-3 SAFETY PRECAUTIONS SELECT SUIT ABLE LOCA TION Place the welder where clean cooling air can freely cir- culate in through the top rear vents and out through the bottom rear vents. Dirt, dust or any foreign material that can be drawn into the welder should be kept at a minimum. Failure to observe these precaut[...]

  • Page 11

    INPUT and GROUNDING CONNECTIONS Be sure the voltage, phase, and frequency of the input power is as specified on the rating plate, located on the rear of the machine. Fuse the input circuit with the recommended super lag fuses or delay type1 circuit breakers. Choose an input and grounding wire size according to local or national codes or use Section[...]

  • Page 12

    A-5 INST ALLA TION PRECISION TIG 275 A-5 Recommended Cable Sizes for Combined Lengths of Copper Work and Electrode Cables using 75 o C Wire: Machine Rating 0 to 100 Ft . 101 to 200 Ft 201 to 250 Ft 275A/40% #1 (42.4 mm 2 ) 1/0 (53.5 mm 2 ) 2/0 (67.4 mm 2 ) WORK CABLE CONNECTION A1 5 ’ (2/0) weld cable with clamp is available (K2150-1), or include[...]

  • Page 13

    A-6 INST ALLA TION PRECISION TIG 275 A-6 TIG TORCH CONNECTION The Precision TIG torch connection box, located on the right side of the machine, provides all the input and output connections for the installation of both air- cooled and water-cooled TIG torches with fittings con- forming to Compressed Gas Association (CGA) stan- dards: Note: The Prec[...]

  • Page 14

    A-7 INST ALLA TION PRECISION TIG 275 A-7 AUXILIAR Y POWER CONNECTIONS The Precision TIG machines provide a standard NEMA 5-15R duplex receptacle, located on the upper case back on the torch side of the machine: • The bottom outlet of this duplex receptacle provides switched 1 15V AC power for the Under-Cooler , or W ater Solenoid accessory . This[...]

  • Page 15

    A-8 INST ALLA TION PRECISION TIG 275 A-8 ROBOTIC INTERF ACE CONNECTION Robotic interface can be made at the Remote Receptacle (See Operation Section B-2). The machine is shipped with the remote receptacle circuit internally connected to receptacle J5 of the Control board for standard Amptrol operation. In order to enable the remote receptacle for r[...]

  • Page 16

    B-1 OPERA TION B-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 (GT A W) with new patented (pending) Micro-Start TM T echnology , Presettable Min. and Max. Output controls, and built-in high frequency stabilization for con[...]

  • Page 17

    B-2 OPERA TION B-2 RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Precision TIG 275 is recommended for the TIG (GT AW) and Stick (SMA W) welding processes within its output capacity range of 2 amps DC, or 5 amps AC, to 340 amps AC/DC. It is compatible with most Magnum TIG accessories (refer Equipment Limitations), as well as many ind[...]

  • Page 18

    B-3 OPERA TION B-3 1. POWER SWITCH - Input line switch turns input power ON or OFF , as indicated by the on or off sta- tus of the front panel displays. 2. POLARITY SWITCH – The 3-position rotary power switch has detente positions for DC-, AC and DC+ selections for the Electrode output welding polarity . 3. MODE SWITCH – The mode switch allows [...]

  • Page 19

    B-4 OPERA TION B-4 • When the Polarity Switch is set to DC (- or +), the TIG mode provides high frequency only for starting. Hi-Freq. turns on after pre-flow time with the arc start switch closure, and turns off when the arc is established* • Also functions for DC+ polarity to permit "balling" of tungsten for AC TIG welding. 4. AC BAL[...]

  • Page 20

    B-5 OPERA TION B-5 8. DIGIT AL METER AND DISPLA Y SWITCH – A3 - digit LED meter is used to monitor the preset and actual welding procedure based on the Display (momentary) switch position: • Before welding with Display switch in center (nor- mal) position, the digital meter displays the preset welding amps set by Maximum Output control knob (Se[...]

  • Page 21

    B-6 OPERA TION B-6 • In 4-Step position allows welding without continu- ously holding the start switch trigger . The arc start switch functions in the following manner: 1. Closing switch starts preflow , then arc starts at Minimum (Start) setting level (See Item 7). If the trigger is maintained closed after preflow time the output remains at the [...]

  • Page 22

    B-7 OPERA TION B-7 INTERNAL SET UP CONTROLS Precision TIG 275 models which have an Advanced Panel (K1829-1) option installed* have the following additional control features which are set up using the DIP Switch (S1) provided on the internal panel of this option. Access to this internal panel is obtained by removing the two screws securing the top c[...]

  • Page 23

    B-8 OPERA TION B-8 PRECISION TIG 275 ( With DIP Switch #2 ON , As Shi pp ed ) ( With DIP Switch #2 OFF ) FIGURE B.3[...]

  • Page 24

    B-9 OPERA TION B-9 PRECISION TIG 275 FIGURE B.4 ( With DIP Switch #3 OFF , As Shi pp ed ) ( With DIP Switch #3 ON )[...]

  • Page 25

    B-10 OPERA TION B-10 SETUP GUIDELINES FOR TIG WELDING WITH AN AMPTROL Both the Hand and Foot Amptrols work in a similar manner . They are meant to be used for remote current control for TIG welding using the machine ’ s 2-Step trigger mode (See Item 12). The Amptrol is capable of controlling the output of the Precision TIG over the range between [...]

  • Page 26

    B-11 OPERA TION B-11 PRECISION TIG 275 Max. to Min. Amptrol Min. to Max. Amptrol Setup for TIG Ampt rol Weld ing Advanced P anel (If used) Standard C ontrols Power Switch ON Polarity Switch AC or DC - Mode Switch TIG AC Balance AUTO or Set: More + for a lum.oxid e " Cleaning " w/o "S pitti ng " o r " wettin g " loss. B[...]

  • Page 27

    B-12 OPERA TION B-12 PRECISION TIG 275 RECOMMENDED ELECTRODE AMPERAGE RANGES - PRECISION TIG 275 SMA W Process ELECTRODE POLARITY 3/32" 1/8" 5/32" Fleetweld 5P , Fleetweld 5P+ DC+ 40 - 70 75 - 130 90 - 175 Fleetweld 180 DC+ 40 - 80 55 - 1 10 105 - 135 Fleetweld 37 DC+ 70 - 95 100 - 135 145 - 180 Fleetweld 47 DC- 75 - 95 100 - 145 135[...]

  • Page 28

    C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED OPTIONS The basic Precision TIG 275 machine is factory equipped with: • A 3/8" Adapter (S20403-4) for air cooled torch con- nection of a PT A-9 or PT A-17. Accessories that are factory installed with the Domestic model (K1826-1) to make up the Domestic Welding Package (K1825-1) incl[...]

  • Page 29

    D-1 MAINTENANCE D-1 PRECISION TIG 275 ELECTRIC SHOCK can kill. • Only qualified personnel should perform this maintenance. • T urn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. T o avoid receiving a high frequency shock, keep the TIG torch and cables in good c[...]

  • Page 30

    D-2 MAINTENANCE D-2 SERVICE PROCEDURES Operation of the Precision TIG should be trouble-free for the life of the machine. Should a malfunction occur , however , the following procedures will be useful to trained service personnel with experience in repairing arc welding equipment: COMPONENT ACCESS The following components are accessible for routine[...]

  • Page 31

    DO NOT use a volt-ohm meter to measure output voltages in TIG mode. The High Frequency Arc Starter voltage can damage the meter . CAUTION E-1 TROUBLESHOOTING E-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 Local Lincoln Authorized Field Service Facili[...]

  • Page 32

    E-2 TROUBLESHOOTING E-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 Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION OUTP[...]

  • Page 33

    E-3 TROUBLESHOOTING E-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 Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION METE[...]

  • Page 34

    E-4 TROUBLESHOOTING E-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 Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION HI-F[...]

  • Page 35

    E-5 TROUBLESHOOTING E-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 Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRES[...]

  • Page 36

    E-6 TROUBLESHOOTING E-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 Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION STIC[...]

  • Page 37

    E-7 TROUBLESHOOTING E-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 Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION TIG [...]

  • Page 38

    F-1 WIRING DIAGRAM F-1 PRECISION TIG 275 RECEPTACLE C A B B CONTROL PC BOARD 10K A-B F E D C AT MINIMUM D F REMOTE TM AMPTROL OPTIONAL A E REMOTE A B C D E F + - G R G Y 5 4 3 2 1 (STICK) (AUTO BAL) (REMOTE) (P. FLOW) (THERMAL) 8 4 1 2 3 6 5 6 B W + - B W + - B W + - B W + - G 331 6 5 4 3 2 1 2 3 4 5 7 1 5 4 3 2 1 6 6 301 303 304B 306 302 METER (VI[...]

  • Page 39

    F-2 WIRING DIAGRAM F-2 PRECISION TIG 275 RECEPTACLE C A B B CONTROL PC BOARD 10K A-B F E D C AT MINIMUM D F REMOTE TM AMPTROL OPTIONAL A E REMOTE A B C D E F + - G R G Y 5 4 3 2 1 (STICK) (AUTO BAL) (REMOTE) (P. FLOW) (THERMAL) 8 4 1 2 3 6 5 6 B W + - B W + - B W + - B W + - G 331 6 5 4 3 2 1 2 3 4 5 7 1 5 4 3 2 1 6 6 301 303 304B 306 302 METER (VI[...]

  • Page 40

    F-3 WIRING DIAGRAM F-3 PRECISION TIG 275 NOTE: This diagram is for refer ence only . It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a r eplacement. Give the equipme[...]

  • Page 41

    F-4 DIMENSION PRINT F-4 PRECISION TIG 275 49.67 27.16 27.97 40.96 3.47 L11799 XA 45.31 6.84 18.67 5.86 13.45 43.20 K1825-1 DOMESTIC P ACKAGE[...]

  • Page 42

    F-5 DIMENSION PRINT F-5 PRECISION TIG 275 L11660 XB-UF ** L OC ATIO N OF (4) O .28 4 BASE MOUNTING HOLES. 12.77 31.00 26.00 1.00 24.00 ** .28 3.47 20.50 * * 22.00 .30 .75 3.4 4 TORCH HOLSTER 2.11 TORCH BOX 11.00 2.98 K1826-1 DOMESTIC, K1826-2 CANADA AND K1827-1 EXPORT[...]

  • Page 43

    NOTES PRECISION TIG 275[...]

  • Page 44

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA E[...]

  • Page 45

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. l Keep your head out of fumes. l Use ventilation or exhaust to remove fumes from [...]

  • Page 46

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com • World's Leader in W elding and Cutting Products •[...]