Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii; ELECTRIC SHOCK can kill.
ii SAFETY ii 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...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
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 seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
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...
Page 7 - TABLE OF CONTENTS; Page
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications .................................................................................A-1, A-2Select Suitable Location .........
Page 8 - INSTALLATION; For AC/DC Stick, DC TIG and Balanced AC TIG; INPUT - SINGLE PHASE ONLY; Power; PHYSICAL DIMENSIONS
A-1 INSTALLATION SQUARE WAVE TIG 275 A-1 TECHNICAL SPECIFICATIONS - Square Wave TIG 275 (K1617-1, and -2) For AC/DC Stick, DC TIG and Balanced AC TIG Welding at 275A 40% Duty Cycle w/o Optional K1620-1 Power Factor Capacitors Based on the 1996 U.S. National Electrical Code For Unbalanced AC TIG Weld...
Page 10 - should be lifted with a hoist.; Do not attempt to lift
A-3 INSTALLATION SQUARE WAVE TIG 275 A-3 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 Square Wave TIG ...
Page 11 - SUPPLY CONNECTIONS
A-4 INSTALLATION SQUARE WAVE TIG 275 A-4 2. Keep the work and electrode leads as short as pos- sible and as close together as possible. Lengthsshould not exceed 25 ft (7.6m). Tape the leadstogether when practical. 3. Be sure the torch and work cable rubber coverings are free of cuts and cracks that ...
Page 12 - circuit breakers. Choose an input; page at; Technical Specifications; page at the beginning of; INPUT RECONNECT PROCEDURE; Remove the right case side to reveal the reconnect; CAUTION
A-5 INSTALLATION SQUARE WAVE TIG 275 A-5 Fuse the input circuit with the recommended super lagfuses or delay type 1 circuit breakers. Choose an input and grounding wire size according to local or nationalcodes or refer to the Technical Specifications page at the beginning of this section. Using fuse...
Page 13 - Reconnect Panel Instructions for 460/575 Canadian Model
A-6 INSTALLATION SQUARE WAVE TIG 275 A-6 5 7 5 V 4 6 0 V W A R N I N G : P o w e r e d b y h i g h v o l t a g e w h i c h c a n k i l l . T u r n o f f a l l i n p u t C o n n e c t t h e i n p u t p o w e r l e a d s t o t h e i n p u t t e r m i n a l s , L 1 ( U ) a n d L 2 ( V ) , a t t h e r i...
Page 14 - OUTPUT CONNECTIONS; Cable Sizes for Combined Lengths of Copper
A-7 INSTALLATION SQUARE WAVE TIG 275 A-7 Designations on the reconnect panel LOW, MID, andHIGH correspond to the nameplated input voltages ofa triple voltage welder. Dual voltage welders use onlyLOW and HIGH. EXAMPLE: On a 208/230/460 volt welder, LOW is208V, MID is 230V, and HIGH is 460V. 3. Make s...
Page 15 - TIG TORCH CONNECTION; • Air-Cooled TIG Torch connections refer to TWIST-; ACCESSORIES; Use the; •Keep cylinder upright and chained
A-8 INSTALLATION SQUARE WAVE TIG 275 A-8 TIG TORCH CONNECTION The Twist-Mate connection allows fast and reliable TIGtorch attachment to the electrode terminal of theSquare Wave TIG 275 welding power supply. Twist-Mate TIG adapters are made of brass, combining highelectrical conductivity with mechani...
Page 17 - Hold the TIG adapter, with cables and hoses; STICK ELECTRODE CABLE CONNECTION; K559-2 Magnum Cooler Mounting Bracket
A-10 INSTALLATION SQUARE WAVE TIG 275 A-10 4. Hold the TIG adapter, with cables and hoses installed, firmly in place by securing it into the Twist-Mate receptacle on the power source or into apadded vise. Apply a thin film of lubricant to theboot’s lead in chamfer area. Also apply lubricant tothe le...
Page 18 - OPERATION; SAFETY PRECAUTIONS
B-1 OPERATION B-1 SQUARE WAVE TIG 275 ELECTRIC SHOCKcan kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. • Read and follow “Electric Shock Warnings” in the Safety section if welding mus...
Page 19 - GRAPHIC SYMBOLS THAT APPEAR ON
B-2 OPERATION B-2 SQUARE WAVE TIG 275 2 A GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL & & POWER SWITCH SYMBOL MEANING ON OUTPUT CONTROL SYMBOL MEANING CURRENT CONTROL (OUTPUT) OFF INPUT POWER OVER TEMPERATURE AC WAVE BALANCE CONTROL SYMBOL MEANING AC WAVE BALANCE CLEAN (INC...
Page 21 - GENERAL DESCRIPTION
B-4 OPERATION B-4 GENERAL DESCRIPTION The Square Wave TIG 275 is a constant current, singlerange square wave AC/DC TIG (GTAW) arc weldingpower source with built-in high frequency stabilization.It also has stick (SMAW) capability. A TIG Pulser Kit,Power Factor Capacitor Kit, and a Water Solenoid Kita...
Page 22 - LIMITATIONS
B-5 OPERATION B-5 • DC+/AC/DC- Polarity Switch allows the welder to change polarity without reconnecting leads. • Provides excellent arc starting and stability through- out the machines wide current range (5 to 315 Amps)to handle the vast majority of TIG welding applica-tions. • Simple output curren...
Page 23 - Current Control -; CONTROLS AND SETTINGS
B-6 OPERATION B-6 1. Current Control - This knob is used to set the welding current from 5 to 315 amps. Read thecomplete Operating Instructions section for moreinformation on Local and Remote setting of current. 2. AC Wave Balance Control - This knob is active in the AC TIG mode only. It is used to ...
Page 24 - Trimmer Potentiometers -; WELDING OPERATION; TIG WELDING
B-7 OPERATION B-7 6. Trimmer Potentiometers - Allows the meters to be calibrated in the field. 7. Digital Ammeter - The ammeter displays actual welding current during a weld cycle and displaysthe peak current for approximately 5 seconds afterwelding is complete. Otherwise the machine’s setcurrent is...
Page 25 - TABLE B.1 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES; Connect the Twist Mate plug to the receptacle locat-; RECOMMENDED POLARITY
B-8 OPERATION B-8 SQUARE WAVE TIG 275 (1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gasses. (2) Tungsten electrodes are classified as follows by the American Welding Society (AWS): Pure . . . . . . . . . . . . . . . EWP1% Thor...
Page 27 - HAND AND FOOT AMPTROL OPERATION; ADVANCED TIG WELDING FEATURES; AC WAVE BALANCE AND AUTO BALANCE
B-10 OPERATION B-10 10. With the torch held safely away from everything, press the Arc Start Switch and set the gas flowmeter. Release the switch. The welder is now readyfor welding. 11. Position the tungsten electrode at the start of the weld at a 65˚ to 75˚ angle with the horizontal so thatthe ele...
Page 28 - STICK WELDING; will illuminate when the power is on.; AUXILIARY POWER; 0 HERTZ DOMESTIC MACHINES; 0/60 HERTZ EUROPEAN MACHINES; If this situation occurs, the user
B-11 OPERATION B-11 STICK WELDING 1. Turn the welder “ON”. The digital ammeter/voltmeter will illuminate when the power is on. 2. Set the Mode Switch to “STICK”. Set the output cur- rent displayed on the digital ammeter with theOutput Control Knob. No other functions or adjust-ments operate in the S...
Page 29 - OPTIONAL ACCESSORIES
C-1 ACCESSORIES C-1 ACCESSORIES INCLUDED WITHMACHINE K852-50 - Twist Mate Cable Plug for #2 to #1 WorkLead. K1622-1 - Twist Mate Adapter Kit for LA9 and LA17Torches. K1622-2 - Twist Mate Adapter Kit for LW18 and LW20Torches. OPTIONAL ACCESSORIES K963-1, -2 - Hand Amptrol K870 - Foot Amptrol K814 - A...
Page 30 - MAINTENANCE; ROUTINE AND PERIODIC MAINTENANCE; THERMOSTATIC PROTECTION; SERVICE PROCEDURES
D-1 MAINTENANCE D-1 SQUARE WAVE 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,...
Page 31 - COMPONENT LOCATION AND ACCESS; The Case side can be removed while roof is in; High Voltage; SPARK GAP ADJUSTMENT; RIGHT SIDE VIEW OF MACHINE
D-2 MAINTENANCE D-2 COMPONENT LOCATION AND ACCESS Control PC Board: Remove the left case side. Use a 3/8" Nut Driver orother suitable tool. Note: The Case side can be removed while roof is in place, as long as the three screws which secure theroof to the case side are removed. The PC Board ismou...
Page 32 - TROUBLESHOOTING; Local; Step 3. RECOMMENDED COURSE OF; HOW TO USE TROUBLESHOOTING GUIDE; DO NOT
E-1 TROUBLESHOOTING E-1 SQUARE WAVE 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 Facility for technical troubleshooting assistance before you proceed. CAUTION This Troublesho...
Page 33 - GENERAL MACHINE TROUBLE; Local Lincoln Authorized
E-2 TROUBLESHOOTING E-2 SQUARE WAVE 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 troubles...
Page 36 - TIG WELDING TROUBLE
E-5 TROUBLESHOOTING E-5 SQUARE WAVE 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 troubles...
Page 38 - for technical troubleshooting assistance before you proceed.; INPUT - BYPASS PC BOARD; CONTROL PC BOARD
E-7 TROUBLESHOOTING E-7 SQUARE WAVE 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 Facility for technical troubleshooting assistance before you proceed. CAUTION PC BOARD TROUBL...
Page 39 - WIRING DIAGRAM
F-1 WIRING DIAGRAM F-1 SQUARE WAVE TIG 275 B 232 R 222 (U) (V) L1 255 254 L1 L2 C1 RECEPTACLE G1 G2 SCR4 246 2 STEP TIG BRASS 115VAC 251 TERMINAL 243 248 H4 POS D FRONT GANG ELECTRICAL SYMBOLS PER E1537. 276 A F J6 C C E J7A ARC STARTER AS'BLY 253 N.A. CONNECTION IS PIN TO PIN BETWEEN 248 A B B R5 2...
Page 42 - DIMENSION PRINT
DIMENSION PRINT SQUARE WAVE TIG 275 20.00 40.65 4.00 24.06 3.57 .71 15.37 28.00 3.57 17.50 A M19118 9.57 19.15 22.89 33.40 27.65 F-4 F-4
Page 43 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. This printing will go fast so don ’ t delay. Place your order now using ...
Page 44 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O 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 I...
Page 46 - World's Leader in Welding and Cutting Products
• 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 •