Lincoln Electric Welding System TIG 275 User Manual

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IM908  
October, 2006  
PRECISION TIG 275  
For use with machines having Code Numbers:  
11370  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However, your  
overall safety can be increased by  
proper installation ... and thoughtful  
operation on your part. DO NOT  
INSTALL, OPERATE OR REPAIR  
THIS EQUIPMENT WITHOUT  
READING THIS MANUAL AND  
THE SAFETY PRECAUTIONS  
CONTAINED  
THROUGHOUT.  
And, most importantly, think before  
you act and be careful.  
Precision TIG 275 shown with  
optional Advanced Control  
Panel and Under Cooler Cart  
IP21S  
OPERATOR’S MANUAL  
Copyright © 2006 Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
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 and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
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 and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5. b. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of the  
equipment, maintenance of the equipment and the specific  
welding procedure and application involved. Worker expo-  
sure level should be checked upon installation and periodi-  
cally thereafter to be certain it is within applicable OSHA PEL  
and ACGIH TLV limits.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.d. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
5.e. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
AUG 06  
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SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
the welding sparks from starting a fire.  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
Away from areas where they may be struck or subjected to  
physical damage.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact can  
cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate circuits.  
This can create fire hazards or overheat lifting chains or  
cables until they fail.  
8.a. Turn 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.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
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SAFETY  
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:  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
8. S’assurer que la masse est connectée le plus prés possible de  
la zone de travail qu’il est pratique de le faire. Si on place la  
masse sur la charpente de la construction ou d’autres endroits  
éloignés de la zone de travail, on augmente le risque de voir  
passer le courant de soudage par les chaines de levage,  
câbles de grue, ou autres circuits. Cela peut provoquer des  
risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher met-  
allique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état defonc-  
tionnement.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le total  
de la tension à vide des deux machines.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie du  
corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
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 ainsi  
qu’un verre blanc afin de se protéger les yeux du rayon-  
nement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
b. Porter des vêtements convenables afin de protéger la peau  
de soudeur et des aides contre le rayonnement de l‘arc.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
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.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Mar. ‘93  
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SAFETY  
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SAFETY  
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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!  
Thank You  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the time  
the shipment is received.  
Please record your equipment identification information below for future reference. This information can be found  
on 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 you  
have recorded above. The code number is especially important when identifying the correct replacement parts.  
On-Line Product Registration  
- Register your machine with Lincoln Electric either via fax or over the Internet.  
• For faxing: Complete the form on the back of the warranty statement included in the literature packet  
accompanying this machine and fax the form per the instructions printed on it.  
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then  
“Product Registration”. Please complete the form and submit your registration.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or  
loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to  
this equipment.  
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TABLE OF CONTENTS  
Page.  
Installation ..........................................................................................................Section A  
Technical Specifications ........................................................................................A-1,A-2  
Safety Precautions.. ............................................................................................................................................... .A-3  
Select Suitable Location........................................................................................A-3  
Grinding .................................................................................................................A-3  
Stacking.................................................................................................................A-3  
Undercarriage Lifting and Moving .........................................................................A-3  
Tilting .....................................................................................................................A-3  
Environmental Rating ............................................................................................A-3  
Machine Grounding and High FREQUENCY INTERFERENCE PROTECTION ...................A-3,A-4  
Input and Grounding Connections..............................................................................A-4  
Output Cable, Connections and Limitations ................................................................A-5  
Work Cable Connection ..................................................................................A-5  
Stick Electrode Cable Connection ..................................................................A-5  
TIG Torch Connection .....................................................................................A-6  
Auxiliary Power Connections ..........................................................................A-7  
Remote Control (If Used)................................................................................A-7  
Robotic Interface Connection ..................................................................A-7, A-8  
________________________________________________________________________  
OPERATION .........................................................................................................................................................Section B-1  
Safety Precautions.......................................................................................................B-1  
Product Description......................................................................................................B-1  
Pipe Thawing.........................................................................................................B-1  
Duty Cycle: ............................................................................................................B-1  
Recommended Processes and Equipment...........................................................B-2  
Controls and Settings ..........................................................................B-3 THRU B-6  
Internal Set Up Controls........................................................................................B-7  
Sick Welding Features...........................................................................................B-7  
TIG Welding Features ...........................................................................................B-7  
2 Step Trigger Modes......................................................................................B-8  
4 Step Trigger Modes ....................................................................................B-9  
TIG Welding Cycle Chart ....................................................................................B-10  
Setup Guidelines for TIG Welding with an Amptrol.....................................B-10, B11  
Making a TIG Weld with an Amptrol....................................................................B-12  
________________________________________________________________________  
Accessories ............................................................................................................................................... .......Section C  
Optional Equipment .....................................................................................................C-1  
________________________________________________________________________  
Maintenance......................................................................................................................................................Section D  
Safety Precautions.......................................................................................................D-1  
Routine and Periodic Maintenance..............................................................................D-1  
Overload Protection.....................................................................................................D-1  
Service Procedures, Component Access,Spark Gap Adjustment...............................D-2  
Under-Cooler Service ..................................................................................................D-2  
________________________________________________________________________  
Troubleshooting.............................................................................................................................................Section E  
Safety Precautions.......................................................................................................E-1  
How To Use TroubleShooting Guide............................................................................E-1  
Troubleshooting.................................................................................................E-2 to E-7  
________________________________________________________________________  
Diagrams..............................................................................................................................................................Section F  
Wiring Diagrams..............................................................................................................................................F-1, F-2  
Dimension Prints.............................................................................................................................................F-3, F-4  
________________________________________________________________________  
Parts List......................................................................................................................................................................P-543  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS-PRECISION TIG 275 (K1827-2 Export-50/60Hz)  
RATED INPUT - SINGLE PHASE ONLY  
Duty Cycle-Applications  
Voltage + 10%  
Max. Amps With Out  
Max. Amps With  
K
Power Factor Capacitor Power Factor Capacitor  
Number  
40%  
AC/DC Stick / Balance TIG  
Unbalance (70% Penetration#) AC TIG  
60%  
AC/DC Stick / Balance TIG  
Unbalance (70% Penetration#) AC TIG  
100%  
80/46/43  
86/50/46  
95/55/50  
109/63/58  
K1827-2  
220-230/  
380-400/415  
64/37/34  
67/39/36  
80/46/42  
85/49/45  
N80  
AC/DC Stick / Balance TIG  
Unbalance (70% Penetration#) AC TIG  
Idle Amps  
52/30/28  
46/27/25  
23/13/12  
500W  
70/41/37  
65/38/35  
10/6/5  
IEC 60974-1  
Idle Power  
400W  
RATED POWER FACTOR (STICK)  
K1827-2  
.65 min.  
.77 min.  
*Shown on Front of this IM manual with Advanced Control Panel (Refer to Optional Equipment)  
#Exceeds NEMA Unbalanced Load Specification comparable for Auto-Balance.  
PRECISION TIG 275  
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A-2  
A-2  
INSTALLATION  
RATED OUTPUT - IEC 60974-1 (K1827-2)  
Duty Cycle-Applications  
Volts at Rated Amperes  
Amps  
40%  
AC/DC Stick / Balance TIG  
Unbalance (70% Penetration ) AC TIG  
60%  
31.0  
20.2  
275  
255  
#
AC/DC Stick / Balance TIG  
Unbalance (70% Penetration ) AC TIG  
29.0  
18.0  
225  
200  
#
100%  
AC/DC Stick / Balance TIG  
Unbalance (70% Penetration ) AC TIG  
28.0  
16.0  
200  
150  
#
ADDITIONAL OUTPUT CAPACITY  
Output Current  
Range  
Maximum Open  
Type of Output  
Auxiliary Power  
Circuit Voltage  
15Amp Circuit Breaker and NEMA 5-15R Duplex  
Receptacle for up to:  
2Amps DC  
to  
340Amps AC-DC*  
115VAC 8Amp Auxiliary Power Receptacle  
115VAC weld Switched Cooler Receptacle load  
(STICK AND TIG)  
AC/DC OCV: 75/68  
CC (Constant Current)  
AC/DC (GTAW)  
Stick (SMAW)  
5 Amp Circuit Breaker  
and grounded 220VAC  
Euro(Schuko) receptacle  
RECOMMENDED INPUT WIRE AND FUSE SIZES  
For all Stick, DC TIG, and Balanced AC TIG Welding  
For Unbalanced AC TIG Welding Above 275 Amps:  
255A/40% Duty Cycle, Auto-Balance Penetration with  
out Standard Power Factor Correction Capacitors  
Based on the 1999 U.S. National Electrical Code  
at 275A/40% Duty Cycle with out Standard Power  
Factor Correction Capacitors  
Based on the 1999 U.S. National Electrical Code  
Input  
Ampere  
(Super Lag) Rating  
or Breaker Rating on  
Type 75°C  
Copper  
Ground Wire in (Super Lag) Ampere  
Conduit AWG or Breaker  
(IEC) Sizes  
Type 75°C  
Copper Wire in  
Conduit AWG  
(IEC) Sizes  
40°C (104°F)  
Ambient  
Type 75°C  
Copper Wire in  
Conduit AWG  
(IEC) Sizes  
40°C (104°F)  
Ambient  
Type 75°C  
Copper  
Ground Wire in  
Conduit AWG  
(IEC) Sizes  
Input  
Voltage /  
phase/  
Input  
Fuse  
Fuse  
Rating  
Size1  
125  
80  
Nameplate  
Size1  
150  
90  
Frequency  
2
2
2
2
220-230/1/50/60  
380-400/1/50/60  
415/1/50/60  
95  
55  
50  
6 (13.3 mm )  
109  
63  
4 (21.2 mm )  
4 (21.2 mm )  
6 (13.3 mm )  
2)  
2)  
2)  
2)  
8 (8.4mm  
6 (13.3 mm  
8 (8.4mm  
8 (8.4 mm  
2)  
2)  
2)  
2)  
90  
58  
80  
8 (8.4mm  
6 (13.3 mm  
8 (8.4mm  
8 (8.4 mm  
PHYSICAL DIMENSIONS  
Height  
Width  
Depth  
26.0 in.  
660 mm  
Weight  
Approx. 397 lbs.  
180 kgs.  
31.0 in.  
22.0 in.  
559 mm  
K1827-2  
787 mm  
TEMPERATURE RANGES  
OPERATING TEMPERATURE RANGE  
STORAGE TEMPERATURE RANGE  
-40°C to +85°C (-40° to +185°F)  
-20°C to +40°C (-04° to +104°F)  
TRANSFORMER INSULATION CLASS 180°C (H)  
1 ALSO CALLED INVERSE TIME" OR "THERMAL/MAGNETIC " CIRCUIT BREAKERS; CIRCUIT BREAKERS WHICH HAVE A DELAY IN TRIPPING ACTION THAT DECREASES AS  
THE MAGNITUDE OF CURRENT INCREASES.  
*
50/60HZ IEC Max. range exceeds 310A.  
PRECISION TIG 275  
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A-3  
A-3  
INSTALLATION  
ENVIRONMENTAL RATING  
SAFETY PRECAUTIONS  
Read entire installation section before starting  
installation.  
Precision TIG 275 power sources carry an IP21S  
Environmental rating. They are rated for use in damp,  
dirty rain-sheltered environments.  
WARNING  
MACHINE GROUNDING AND HIGH FRE-  
QUENCY INTERFERENCE PROTECTION  
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.  
The frame of the welder must be grounded. A ground screw  
marked with the symbol is located on the input connection  
panel (Figure A.1) for this purpose. See your local and nation-  
al electrical codes for proper grounding methods.  
• Do not touch electrically hot  
parts.  
The spark gap oscillator in the high frequency genera-  
tor, being similar to a radio transmitter, can be blamed  
for many radio, TV and electronic equipment interfer-  
ence problems. These problems may be the result of  
radiated interference. Proper grounding methods can  
reduce or eliminate radiated interference.  
• Always connect the Precision TIG 275 grounding screw (behind  
the reconnect panel cover located near the back of the left case  
side) to a good electrical earth ground.  
• Always connect the Precision TIG 275 to a power supply  
grounded in accordance with the National Electrical Code and  
all local codes.  
SELECT SUITABLE LOCATION  
The Precision TIG 275 has been field tested under rec-  
ommended installation conditions and has been found  
to comply with F.C.C. allowable radiation limits. This  
welder has also been found to comply with NEMA stan-  
dards for high frequency stabilized power sources.  
Place the welder where clean cooling air can freely cir-  
culate in through the top rear vents and out through the  
bottom rear vents. Dirt, dust or any foreign material  
that can be drawn into the welder should be kept at a  
minimum. Failure to observe these precautions can  
result in excessive operating temperatures and nui-  
sance trips.  
Radiated interference can develop in the following four  
ways:  
Direct interference radiated from the welder.  
Direct interference radiated from the welding leads.  
Direct interference radiated from feedback into the  
power lines.  
Interference from re-radiation of "pickup" by  
ungrounded metallic objects.  
GRINDING  
Do not direct grinding particles towards the welder. An  
abundance of conductive material can cause mainte-  
nance problems.  
STACKING  
The Precision TIG 275's cannot be stacked .  
Keeping these contributing factors in mind, installing  
the equipment per the following instructions should  
minimize problems.  
UNDERCARRIAGE LIFTING AND MOVING  
1. Keep the welder power supply lines as short as  
possible. Input leads within 50 feet (15.2 m) of the  
welder should be enclosed in rigid metallic conduit  
or equivalent shielding. There must be good electri-  
cal contact between this conduit and the welder.  
Both ends of the conduit must be connected to a  
driven ground and the entire length must be contin-  
uous.  
When the Precision TIG 275 is purchased as a weld-  
ing package, or used with any of the available  
Undercarriage optional accessories, proper installation  
makes the Precision TIG 275 lift bale nonfunctional.  
Do not attempt to lift the power source with an under-  
carriage attached. The undercarriage is designed for  
hand moving only; mechanized movement can lead to  
personal injury and/or damage to the Precision TIG  
275.  
2. Keep the work and electrode leads as short as pos-  
sible and as close together as possible. Lengths  
should not exceed 25 feet (7.6 m). Tape the leads  
together when practical.  
TILTING  
Each machine must be placed on a secure, level sur-  
face, either directly or on a recommended undercar-  
riage. The machine may topple over if this precaution  
is not followed.  
PRECISION TIG 275  
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A-4  
A-4  
INPUT and GROUNDING CONNECTIONS  
INSTALLATION  
3. Be sure the torch and work cable rubber coverings  
are free of cuts and cracks that allow high frequen-  
cy leakage. Cables with high natural rubber content,  
such as Lincoln Stable-Arc® better resist high fre-  
quency leakage than neoprene and other synthetic  
rubber insulated cables.  
WARNING  
ELECTRIC SHOCK can kill.  
• Turn the input power OFF at the  
disconnect switch or fuse box  
before working on this  
equipment.  
4. Keep the torch in good repair and all connections  
tight to reduce high frequency leakage.  
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.  
5. The work terminal must be connected to a ground  
within ten feet of the welder, using one of the fol-  
lowing methods:  
Fuse the input circuit with the recommended super lag  
fuses or delay type1 circuit breakers. Choose an input  
and grounding wire size according to local or national  
codes or use Section A-2. Using fuses or circuit break-  
ers smaller than recommended may result in "nui-  
sance" tripping from welder inrush currents even if not  
welding at high currents.  
A metal underground water pipe in direct contact  
with 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 at  
least eight feet into the ground.  
The ground should be securely made and the ground-  
ing cable should be as short as possible using cable of  
the same size as the work cable, or larger. Grounding  
to the building frame electrical conduit or a long pipe  
system can result in re-radiation, effectively making  
these members radiating antennas. (This is not rec-  
ommended).  
Unbalanced AC TIG welding draws higher input cur-  
rents than those for Stick, DC TIG, or Balanced AC TIG  
welding. The welder is designed for these higher input  
currents. However, where unbalanced AC TIG welding  
above 185 amps is planned, the higher input currents  
require larger input wire sizes and fuses per Section A-2:  
Remove the reconnect panel cover located near the  
back of the left case side to reveal the reconnect panel.  
Welder supply line entry provision is in the case rear  
panel. Entry is through a 1.75 inch (44 mm) diameter  
hole in the case back. Appropriate supply line strain  
relief clamp is provided by installer. (See Figure A.1)  
6. Keep all access panels and covers securely in  
place.  
7. All electrical conductors within 50 feet (15.2 m) of  
the welder should be enclosed in grounded rigid  
metallic conduit or equivalent shielding. Flexible  
helically-wrapped metallic conduit is generally not  
suitable.  
FIGURE A.1  
8. When the welder is enclosed in a metal building,  
several good earth driven electrical grounds (as in 5  
above) around the periphery of the building are rec-  
ommended.  
CONNECT INPUT  
POWER LEADS  
CONNECT INPUT  
CONNECT INPUT  
GROUND LEAD  
VOLTAGE LEVEL  
Failure to observe these recommended installation  
procedures can cause radio or TV interference prob-  
lems and result in unsatisfactory welding performance  
resulting from lost high frequency power.  
All connections should be made in accordance  
with all local codes and national electrical codes.  
Installation by a qualified electrician is recom-  
mended.  
PRECISION TIG 275  
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A-5  
A-5  
INSTALLATION  
1. Connect the terminal marked  
nect panel) to an earth ground.  
(below the recon-  
Recommended Cable Sizes for Combined Lengths of  
Copper Work and Electrode Cables using 75 C Wire:  
o
Machine Rating  
0 to 100 Ft.  
101 to 200 Ft  
201 to 250 Ft  
2. Connect the input leads to terminals marked L1 (U)  
and L2 (V) on the reconnect panel. Use a single  
phase line or one phase of a two or three phase line.  
2
2
2
275A/40%  
#1 (42.4 mm ) 1/0 (53.5 mm ) 2/0 (67.4 mm )  
WORK CABLE CONNECTION  
3. On multiple input voltage welders, be sure the  
reconnect panel is connected for the voltage being  
supplied to the welder.  
A 15(2/0) weld cable with clamp is available (K2150-1), or  
included with the Precision TIG Welding Package model.  
Otherwise, it is user provided.  
CAUTION  
Failure to follow these instructions can cause  
immediate failure of components within the welder.  
------------------------------------------------------------------------  
With power source off, connect a separate work cable  
to the 1/2-13 threaded "WORK" stud of the welder, and  
secure a tight connection with the flange nut provided.  
The work cable should be routed through the cable  
strain relief hole provided in the base directly below the  
welding output terminal.  
Note: If the Precision TIG is equipped with an Under-  
Cooler or Under-Storage unit, the coiled work cable  
and clamp, or excess work cable length, may be con-  
veniently stored in the drawer while remaining con-  
nected.  
Welders are shipped connected for the highest input  
voltage as listed on the rating plate. To change this  
connection, designations on the reconnect panel LOW,  
MID, and HIGH correspond to the name plated input  
voltages of a triple voltage welder. Dual voltage  
welders use only LOW and HIGH.  
STICK ELECTRODE CABLE CONNECTION  
EXAMPLE: On a 208/230/460 volt welder, LOW is  
208V, MID is 230V, and HIGH is 460V.  
Note: Export model has a voltage range for LOW and  
MID connections: LOW is 220-230V, MID is  
380-400V and High is 415V.  
If manual stick welding is desired, with power source  
off, connect a stick electrode cable to the 1/2-13  
threaded "STICK Electrode" stud of the welder, and  
secure a tight connection with the flange nut provided.  
The electrode cable should be routed through the  
cable strain relief hole provided in the base directly  
below the welding output terminal.  
Reconnect the jumper strap to the terminal stud corre-  
sponding to the input voltage level used. Make sure all  
connections are tight.  
OUTPUT CABLES, CONNECTIONS AND  
LIMITATIONS  
WARNING  
DISCONNECT STICK ELECTRODE WELDING  
CABLE WHEN TIG WELDING.  
WARNING  
EVEN THOUGH HI-FREQ IS NOT APPLIED TO THE  
PRECISION TIG STICK TERMINAL, IT WILL BE  
ELECTRICALLY "HOT" TO WORK WHEN TIG  
WELDING.  
• To avoid being startled by a high frequency  
shock, keep the TIG torch and cables in good  
condition  
• Turn the power switch of the power source OFF  
before installing adapters on cable or when con-  
necting or disconnecting adapter plugs to power  
source.  
------------------------------------------------------------------------  
-----------------------------------------------------------------------  
Refer to Figure A.2 for the location of the WORK and  
STICK terminals, as well as the TIG Torch connection  
panel.  
PRECISION TIG 275  
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A-6  
A-6  
INSTALLATION  
FIGURE A.2  
TIG TORCH  
CONNECTION  
PANEL  
REMOTE  
CONTROL  
RECEPTACLE  
STICK  
WORK  
WORK  
STICK  
ELECTRODE  
STUD  
STUD  
(Shown without hinged stud cover)  
FIGURE A  
CABLE  
STRAIN  
RELIEF HOLES  
TIG TORCH CONNECTION  
CYLINDER could explode  
if damaged.  
The Precision TIG torch connection box, located on the  
right side of the machine, provides all the input and  
output connections for the installation of both air-  
cooled and water-cooled TIG torches with fittings con-  
forming to Compressed Gas Association (CGA) stan-  
dards:  
Note: The Precision TIG provides an insulated Torch  
Reel and Holster for handy and safe storage of con-  
nected torch when not welding, and excess torch cable  
length while welding.  
• 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 stud  
connection adapters (such as LECO. S19257-series)  
cannot be used for torch connection.  
WARNING  
Combination connectors (Power/Water and  
Power/Gas) are electrically "hot" while welding in  
STICK or TIG modes.  
Single-piece cable air-cooled torches with a 3/8-24 RH  
connector fitting (such as the Magnum PTA-9/-17, or LA-  
9/-17) require the provided S20403-4 Torch Connector,  
while those with a 7/8-14 RH connector fitting (such as  
the Magnum PTA-26, or LA-26) require the available  
K2166-1 Torch Connector. (See Figure A.3)  
If using an Air-Cooled Torch be sure coolant is  
shut off and/or Cooler is unplugged from the  
Precision TIG Water Cooler Receptacle on the  
torch side of the upper case back.  
Two-piece cable air-cooled torches (such as PTA-, or LA-  
torches) can be used with the available 1/2Stud  
Connector (S20403-3) with with a 7/8-14 LH male fitting.  
Observe the safety precautions necessary for han-  
dling and using compressed gas containers.  
Contact your supplier for specifics.  
Magnum PTW-18/-20 (or LW-) water-cooled Torches  
require no adapter for Precision TIG connection.  
PRECISION TIG 275  
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A-7  
A-7  
INSTALLATION  
FIGURE A.3  
For Gas Supply hose  
with 5/8-18RH male  
(Provided with Weld  
Package model)  
For Coolant Supply  
Hoses  
with 5/8-18LH male  
(Provided with Weld  
Package model  
or  
Under-Cooler Cart)  
The Precision TIG Export models also provide a  
grounded 220vac Euro type Schuko receptacle and a  
5 amp circuit breaker, located on the upper case back  
on the reconnect side of the machine, intended for use  
with a 220vac water cooler.  
AUXILIARY POWER CONNECTIONS  
The Precision TIG machines provide a standard NEMA  
5-15R duplex receptacle, located on the upper case  
back on the torch side of the machine:  
The bottom outlet of this duplex receptacle provides  
switched 115VAC power for the Under-Cooler, or  
Water Solenoid accessory. This Cooler receptacle  
turns on when the arc starts and remains on for about  
8 minutes after the arc goes out (with the Fan-As-  
Needed machine cooling fan, see Maintenance  
Section), so the Coolers fan and water pump will not  
run continuously in idle, but will run while welding.  
REMOTE CONTROL (If Used)  
The Foot Amptrol (included with the Precision TIG  
Welding Package), or other Remote accessory, is  
installed by routing the plug of its control cable up  
through the left cable strain relief hole provided in the  
base (see Figure A.2), then connecting the 6-pin plug  
to the mating Remote receptacle behind the stud panel  
cover. (See Operation Section B-2 for mating plug  
wiring.)  
Note: If the Precision TIG is equipped with an Under-  
Cooler or Under-Storage unit, the Foot Pedal (or other  
remote control accessory) and coiled control cable, or  
excess cable length, may be conveniently stored in the  
drawer while remaining connected.  
The top outlet of this duplex receptacle provides at  
least 8 amps at 115VAC, whenever the Precision TIG  
Power switch is ON. This auxiliary circuit is intended  
for running 115VAC accessories or small power tools.  
Note: Some types of equipment, especially pumps  
and large motors, have starting currents which are  
significantly higher than their running current. These  
higher starting currents may cause the circuit breaker  
to open. (See next paragraph)  
Both the receptacle circuits are protected from shorts  
and overloads by a 15 amp circuit breaker, located  
above the receptacle. if the breaker trips its button  
pops out exposing a red ring. When the circuit break-  
er cools the button can be reset by pressing it back  
in.  
Note: When the breaker trips not only will the auxil-  
iary and cooler power be interrupted, but so will the  
power to the shielding gas solenoid and machine  
cooling fan.  
PRECISION TIG 275  
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A-8  
A-8  
INSTALLATION  
ROBOTIC INTERFACE CONNECTION  
Robotic interface can be made at the Remote  
Receptacle (See Operation Section B-2). The machine  
is shipped with the remote receptacle circuit internally  
connected to receptacle J5 of the Control board for  
standard Amptrol operation. In order to enable the  
remote receptacle for robotic interface its connection  
plug must be moved from J5 to J5A on the Control  
board. (Refer to the machine Wiring Diagram.)  
The robotic interface functions with the Precision TIG  
set to either TIG or STICK mode, but must be in  
REMOTE switch position for the Preset Control inter-  
face to function. When in the REMOTE position with  
robotic interface neither the MAXIMUM OUTPUT nor  
the MINIMUM OUTPUT panel controls limit the inter-  
face control setting over the rated output range of the  
machine.  
The diagram in Figure A.4 below shows the remote  
receptacle plug connections and signals for robotic  
interface:  
REMOTE RECEPTACLE  
FIGURE A.4  
(Front View)  
For 18-12P Plug  
(LECO S12020-27)  
PRESET CONTROL  
INPUT FROM ROBOT  
(0 -10Vdc = Rated Output Range)  
+
C
Note: The Interface connection  
cable may pick up noise  
+VCC = 70Vdc max.  
B
A
D
E
ARC START  
INPUT FROM ROBOT  
(18Vac,10ma switch)  
*
interference. Additional  
bypass/filtering circuits may be  
needed for the external circuits.  
R = VCC / 5ma  
5ma  
F
ARC ESTABLISHED  
OUTPUT TO ROBOT  
(High = Not Welding)  
(Low = Welding)  
Robotic  
Common  
*
Precision TIG Control Common.  
PRECISION TIG 275  
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B-1  
B-1  
OPERATION  
SAFETY PRECAUTIONS  
PRODUCT DESCRIPTION  
Read and understand this entire section before operat-  
ing the machine.  
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)  
TM  
with new patented (pending) Micro-Start Technology,  
WARNING  
Presettable Min. and Max. Output controls, and built-in  
high frequency stabilization for continuous AC TIG and  
DC TIG starting. It also has AC/DC Stick (SMAW)  
capability, with adjustable Arc Force availability. A TIG  
Pulse Panel, Power Factor Capacitors and a Water  
Solenoid are available as field installed optional kits.  
Also, a new Undercarriage (with double gas bottle  
rack) is available for field installation, as well as a new  
Under-Cooler Cart, which is also included in an avail-  
able efficiently integrated entire TIG Welding Package  
with convenient built-in storage provisions for welding  
equipment and components.  
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 and  
ground.  
• 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.  
The Precision TIG 275 includes advanced features  
such as a Digital Meter, Presettable control, Auto  
TM  
Balance , Fan As Needed (F.A.N.) fixed Preflow, vari-  
able Postflow shielding gas and Timers. In addition, 2-  
Step/4-Step and Pulse TIG operation with adjustable  
Downslope Time control are included with an available  
field installed kit. It also features a Stick stud panel and  
a universal TIG torch connection box for simultaneous,  
but separated, electrode outputs.  
FUMES AND GASES  
can be dangerous.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to  
remove fumes from breathing  
zone.  
PIPE THAWING  
The Precision TIG 275 is not recommended for pipe  
thawing.  
WELDING SPARKS  
can cause fire or  
explosion  
Duty Cycle  
• Keep flammable material away.  
• Do not weld on containers that  
have held combustibles.  
The duty cycle is based upon a 10-minute time period;  
i.e., for 40% duty cycle, it is 4 minutes welding and 6  
minutes idling. If the rated duty cycle is significantly  
exceeded, the thermostatic protection will shut off the  
output until the machine cools to a normal operating  
temperature. (Refer to Specification Section A-1)  
ARC RAYS  
can burn.  
• Wear eye, ear and body  
protection.  
Observe additional Safety Guidelines detailed in  
the beginning of this manual.  
PRECISION TIG 275  
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B-2  
B-2  
OPERATION  
EQUIPMENT LIMITATIONS  
RECOMMENDED PROCESSES AND  
EQUIPMENT  
The Precision TIG machines are protected from over-  
loads beyond the electrical ratings and duty cycles, per  
the Specifications Section A-1, A-2, with Thermostat  
protection of the primary and secondary transformer  
coils.  
RECOMMENDED PROCESSES  
The Precision TIG 275 is recommended for the TIG  
(GTAW) and Stick (SMAW) welding processes within  
its output capacity range of 2 amps DC, or 5 amps AC,  
to 340 amps AC/DC. It is compatible with most  
Magnum TIG accessories (refer Equipment  
Limitations), as well as many industry standard items,  
such as TIG torches, hoses, and water coolers.  
The Precision TIG machines do not have Hi-Freq.  
available at the Stick electrode stud, therefore stud  
connection adapters (such as LECO. S19257-series)  
cannot be used for torch connection.  
PROCESS LIMITATIONS  
Precision TIG machines are not recommended for arc  
gouging due to it's limited output capacity, and are also  
not recommended for pipe thawing.  
RECOMMENDED EQUIPMENT/INTERFACE  
TIG (air cooled)  
Machine:  
PT275 K1827-2)  
User provided  
LE/Harris 3100211  
PTA9 or PTA17  
KP507 or KP508  
K2150-1 Work Lead Assembly  
K870 or K870-1  
Input Cable/Clamp:  
Gas Reg./Hose:  
Magnum Torch:  
Magnum Parts:  
Work Clamp/Lead:  
Foot Amptrol:  
PRECISION TIG 275  
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B-3  
B-3  
OPERATION  
CONTROLS AND SETTINGS  
The Front Control Panel contains the knobs and switches necessary for adjusting the operation of the Precision  
TIG 275, with function indicator lights and an electronic display for volts and amps. The components are  
described below:  
FIGURE B.1 - CONTROL PANEL  
1. POWER SWITCH  
2. POLARITY SWITCH  
3. MODE SWITCH  
4. AC BALANCE CONTROL  
5. LOCAL/REMOTE CURRENT CONTROL  
SWITCH  
6. MAXIMUM OUTPUT CONTROL  
7. MINIMUM OUTPUT CONTROL AND  
DISPLAY SWITCH  
8. DIGITAL METER AND DISPLAY  
SWITCH  
9. POSTFLOW TIME  
10. THERMAL SHUTDOWN LIGHT  
11. REMOTE RECEPTACLE  
12. TRIGGER SWITCH  
13. PULSE MODE SWITCH  
14. PULSE FREQUENCY CONTROL  
15. PULSE % ON TIME CONTROL  
16. PULSE BACKGROUND CURRENT  
CONTROL  
17. DOWNSLOPE TIME  
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.  
The CC Stick mode may be used for general pur-  
pose stick welding (SMAW ) within the capacity of  
the machine. The capacity is too limited for arc air  
carbon (AAC) gouging.  
2. POLARITY SWITCH – The 3-position rotary power  
switch has detente positions for DC-, AC and DC+  
selections for the Electrode output welding polarity.  
In this mode; the output terminals are activated  
electrically HOT, gas flow is not activated and HOT  
START and ARC FORCE levels are fixed, or  
Advanced Panel selectable (See Section B-7 ), with  
no front panel adjustment.  
3. MODE SWITCH – The mode switch allows vertical-  
ly positioned selection of the two machine welding  
modes. The selected mode is indicated by a lit col-  
ored panel light which permits viewing the machine  
setting from a distance:  
3.b TIG mode (Bottom position) No panel light.  
When the Polarity Switch is set to AC, the TIG  
mode provides continuous high frequency to stabi-  
lize the arc for AC TIG welding.  
3.a STICK mode (Top position) Red panel light  
WARNING  
Hi-Freq. turns on after preflow time with the arc  
start switch closure, and turns off when the arc  
goes out* after the arc start switch opens.  
ELECTRIC SHOCK can kill.  
When the Power Source is ON in  
STICK mode the Electrode circuits of  
both the Stick and TIG torch cables  
* Arc voltage and current are sensed to determine if  
the arc is established or out.  
are electrically HOT to Work.  
------------------------------------------------------------------------  
PRECISION TIG 275  
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B-4  
B-4  
OPERATION  
When the Polarity Switch is set to DC (- or +), the  
TIG mode provides high frequency only for starting.  
With the Current Control switch to REMOTE posi-  
tion, this knob sets the maximum welding level that  
the Peak output can be set with the remote Amptrol.  
Hi-Freq. turns on after pre-flow time with the arc  
start switch closure, and turns off when the arc is  
established*  
TM  
The new MicroStart Technology minimum current  
circuit provides for low end welding (down to 2  
amps) previously unobtainable on an SCR platform  
TIG machine.  
Also functions for DC+ polarity to permit "balling" of  
tungsten for AC TIG welding.  
7. MINIMUM OUTPUT CONTROL AND DISPLAY SWITCH  
4. AC BALANCE CONTROL The potentiometer  
control permits AC wave balance adjustment from  
Max. Penetration (~85% negative wave) with the  
control at Max. full CW position, to Max. Cleaning  
(~65% positive wave) with the control set near min-  
imum CCW position.  
A smaller knob is used to preset the minimum cur-  
rent level only for TIG mode. Pressing the Display  
(momentary) switch toggle left to Minimum Set posi-  
tion displays the Minimum control level setting on the  
Digital meter. (See Item 8)  
This knob sets the Start output level. When the arc  
lights (using a new built-in TIG start pulse) this level  
upslopes quickly (0.5 sec.w/ Advanced Panel, zero  
w/o) and smoothly to the weld output level. The set-  
ting range for this Start control is the 2 amp mini-  
mum range of the machine up to about 50 amps, but  
no more than the level set by the Maximum Output  
control knob (See Item 6), but otherwise is indepen-  
dent of the Maximum setting.  
Full minimum CCW position is the Auto Balance  
position which is indicated by the Green panel light  
turning on. This feature automatically provides the  
proper amount of cleaning and penetration for nor-  
mal AC TIG welding  
The mid position is the Balanced position (~50%  
positive and negative waves).  
The Balance control is only functional if the machine  
is set to AC polarity and TIG mode.  
This setting also serves as the Crater-fill level, but  
with a Precision TIG Advanced Panel it can be  
selected (see Section B-7) to be either the Minimum  
Output control setting (same as Start setting) as  
shipped, or the minimum rating of the machine (2  
amps).  
5. LOCAL/REMOTE CURRENT CONTROL SWITCH A  
2-position switch selects how the welding output is  
controlled for both Stick and TIG Modes:  
LOCAL (Top position) selects output control only by  
the machine panel Output Control. (See Item 6)  
The Remote Amptrol range of control is between  
this Minimum setting and the Maximum Output con-  
trol knob setting, so these knobs can set the resolu-  
tion of the Amptrol. Also, the Minimum setting  
serves as both the minimum Amptrol start level  
when the arc start switch is closed, as well as the  
minimum Amptrol crater-fill level before the arc start  
switch is opened to help prevent premature arc out  
and Hi-Freq re-initiation.  
REMOTE (Bottom position) selects output control to  
also be by an Amptrol (See Item 6), or other remote  
(10K pot) control connected to the Remote recepta-  
cle (See Item 11) This switch selection is indicted by  
the Green panel light turning on.  
In either position the arc start switch functions when  
connected to the Remote receptacle (See Item 11).  
.
In STICK mode the Start control is not functional  
since Hot Start level is fixed, or internal Advanced  
Panel adjustable (see Section B-7). Pressing the  
Display (momentary) switch toggle left to Minimum  
Output position displays minimum amps rating of  
the machine.  
6. MAXIMUM OUTPUT CONTROL The large knob  
is used to set the output welding current over the  
rated output range of the machine.  
With the Current Control switch to LOCAL position,  
this knob sets the welding output level.  
PRECISION TIG 275  
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B-5  
B-5  
OPERATION  
8. DIGITAL METER AND DISPLAY SWITCHA 3-  
digit LED meter is used to monitor the preset and  
actual welding procedure based on the Display  
(momentary) switch position:  
When the Current Control Switch is in either LOCAL  
or REMOTE positions the arc start switch functions  
when connected to the Remote receptacle.  
FIGURE B.2  
Before welding with Display switch in center (nor-  
mal) position, the digital meter displays the preset  
welding amps set by Maximum Output control knob  
(See Item 6). If in Stick mode using REMOTE (See  
Item 5.), the digital meter displays the preset weld-  
ing amps set by the Remote control. (See Item 11)  
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 the  
Display switch to left, the digital meter displays the  
amps preset by the Minimum Output control knob  
(See Item 7).  
Any time in Stick mode and while pressing the  
Display switch to left, the digital meter displays the  
minimum amps rating of the machine (See Item 7).  
Any time, in either mode, while pressing the Display  
switch right to Volts position, the digital meter dis-  
plays actual output volts. Volts is displayed with 0.1  
volt resolution (XX.X) and accuracy within 3%+/-1V  
of reading.  
REMOTE RECEPTACLE*  
(Front View)  
ARC START  
SWITCH  
REMOTE OUTPUT  
CONTROL  
C
F
Max  
B
A
D
E
10K ohm  
Min  
*For 18-12P Plug  
(LECO S12020-27)  
ADVANCED PANEL CONTROLS  
The following controls are included only if the Precision  
TIG 275 has the Advanced Control Panel (K1829-1)  
option installed: (Refer to Section B-10 Tig Weld Cycle  
Chart for graphic illustration of these TIG welding func-  
tions.)  
12. TRIGGER SWITCH This 2-position switch  
selects how the arc start switch ( connected to the  
above Remote receptacle) functions; in 2-Step or 4-  
Step mode:  
CAUTION  
• DO NOT USE 4-STEP IF USING AN AMPTROL  
REMOTE.  
• Neither the arc start switch nor the output con-  
trol in the amptrol will function normally to shut  
off or control the out put. ONLY USE 2-STEP.  
------------------------------------------------------------------------  
In 2-Step position the arc start switch functions the  
same as without the Advanced Panel:  
9. POSTFLOW TIME This knob is used to set the  
TIG mode shielding gas postflow time over the  
range of about 2 to 60 seconds after the arc is shut  
off. The postflow on time status is indicated by the  
Green panel light.  
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, by  
internal control box selection. (See Section B-7)  
1. Closing switch starts preflow, then a fixed  
(0.5 sec.) ramp time from Minimum (Start)  
setting level (See Item 7) to Weld setting.  
10. THERMAL SHUTDOWN LIGHT This yellow LED  
panel light turns on if the machine output is shut-  
down because internal overheating has occurred,  
and turns off when the thermostat resets.  
2. Opening switch initiates Downslope ramp  
time setting (See Item 17), from Weld set-  
ting to Crater-fill level (See Item 7), which  
then stops the arc and initiates Postflow  
time (See Item 9).  
11. REMOTE RECEPTACLE A 6-socket receptacle  
is provided for the connection of an Amptrol, or  
other, remote control: (See Figure B.2)  
Note: See Section B-7 for 2-Step operation during  
Downslope with Restart feature selected to be dis-  
abled, instead of enabled (as shipped).  
When the Current Control Switch, (See Item 5), is  
in the REMOTE position the Amptrol, or other  
remote (10K pot), connected to the Remote recep-  
tacle controls the TIG or Stick mode output within  
the range preset by the Maximum and Minimum  
Output controls. (See Item 6 and Item 7, also 8 for  
meter display)  
PRECISION TIG 275  
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B-6  
B-6  
OPERATION  
In 4-Step position allows welding without continu-  
ously holding the start switch trigger. The arc start  
switch functions in the following manner:  
16. PULSE BACKGROUND CURRENT CONTROL –  
This knob controls the level of the Background Current  
as a percentage (MIN.-100%) of the Peak (REMOTE  
and/or LOCAL) output level (See Item 6) down to the  
Minimum Output setting (See Item 7).  
1. Closing switch starts preflow, then arc starts  
at Minimum (Start) setting level (See Item  
7). If the trigger is maintained closed after  
preflow time the output remains at the Start  
level until it is released.  
17. DOWNSLOPE TIMEThis knob is used to set the  
time, over the range of zero to about 10 seconds, to  
ramp down from weld setting to Crater-fill level (See  
Item 7).  
2. Opening switch initiates fixed (0.5 sec.)  
ramp time from Start setting level to Weld  
setting.  
If the arc goes out after the Downslope time is initi-  
ated, the Downslope time is interrupted and the  
Postflow time is initiated. This prevents Hi-Freq re-  
initiation during ramp down crater fill  
3. Reclosing switch initiates Downslope ramp  
time setting (See item 17) from Weld setting  
down to the Crater-fill level (See Item 7) of  
the machine.  
When using an Amptrol remote control, where the  
downslope is controlled by the operator down to the  
crater-fill level, the Downslope time should be set to  
zero so as not to have the Downslope time delay  
when the arc start switch is opened.  
4. Reopening switch after Downslope time  
holds Crater-fill level until switch opens,  
then stops the arc and initiates the Postflow  
Time (See Item 9). Or, reopening switch  
during Downslope time immediately stops  
the arc and initiates the Postflow.  
Note: See Section B-7 for 4-Step operation during  
Downslope with Restart feature selected to be  
enabled, instead of disabled (as shipped).  
13. PULSE MODE SWITCH Turns on the Pulse  
Mode as indicated by the Green panel light turning on.  
Pulsing provides a Peak current level set by  
REMOTE and/or LOCAL control of the output cur-  
rent (See Item5), for a time determined by the Pulse  
Frequency Control setting (See Item 14) and the %  
ON Time (See Item 15). The balance of the cycle  
time is at the Background Current level (See Item  
16).  
Pulsing begins after upslope when the output cur-  
rent rises above the Background Current level and  
ends when the output current drops below this level.  
14. PULSE FREQUENCY CONTROL This knob is  
used to set the Pulse Frequency over the peak pulse  
range of about 0.1 pps to 20 pps. (One pulse cycle  
time = 1/pps = 10 to .05 sec. range.)  
15. PULSE % ON TIME CONTROL This knob con-  
trols the duration of the peak current as a percentage  
(5% to 95%) of one pulse cycle. The balance of the  
cycle time will be at the Background Current setting.  
(See Item 16)  
PRECISION TIG 275  
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B-7  
B-7  
OPERATION  
• Switch #7 Arc Force Level Prevents "stubbing"  
of the electrode by providing extra output current if  
the arc voltage drops below the level required to  
sustain the welding arc. High (+65%) and Low  
(+12%) factory set levels are selectable which are  
good for most stick welding applications.  
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.  
ON Higher for a "crisper" arc, often desired for 6010  
type electrodes.  
OFF Lower Arc Force (as shipped) for a "softer" arc  
with 7018 or general type electrodes.  
Access to this internal panel is obtained by removing  
the two screws securing the top corners of the  
Precision TIG front control panel and swinging the con-  
trol panel down to reveal the panel mounted on the sur-  
face of the Precision TIG Control board:  
• Switch #8 (NOT CURRENTLY FUNCTIONAL)  
TIG WELDING FEATURES  
CAUTION  
• THE CONTROL BOARDS CONTAIN STATIC SEN-  
SITIVE COMPONENTS  
The following DIP switch feature selections function  
only when the Precision TIG is set to TIG mode (See  
Item 3):  
• To avoid possible damage to these components  
be sure to ground yourself by touching the  
machine’s sheet metal while handling or making  
settings on the internal control box components.  
------------------------------------------------------------------------  
PRECISION TIG ADVANCED PANEL  
• Switch #1 Preflow/Postflow Time Extension*  
(See Item 9)  
ON Doubles the time ranges.  
OFF Standard time ranges (as shipped).  
(Internal Panel)  
• Switch #2 2-Step Trigger Restart Feature (See  
Figure B.3)  
^ ON  
1 2 3 4 5 6 7  
DIP SWITCH (S1)  
ON Restart Enabled (as shipped).  
OFF Restart Disabled.  
• Switch #3 4-Step Trigger Restart Feature (See  
Figure B.4)  
S
F
ON Restart Enabled.  
OFF Restart Disabled (as shipped)  
ON  
• Switch #4 (NOT CURRENTLY FUNCTIONAL)  
1
2
3
4
5
6
7
8
OFF  
• Switch #5 Crater-Fill Level (See Item 7)  
DIP SWITCH POSITIONS (FACTORY SETTINGS)  
ON - Level is minimum rating of the machine (2A)  
OFF Level (as shipped) is Minimum Output setting  
(same as Start level).  
STICK WELDING FEATURES  
The following DIP switch feature selections function  
only when the Precision TIG is set to Stick mode. (See  
Item 3):  
* The Preflow/Postflow Time doubling feature can also be selected  
on Precision TIG 275 models without the Advanced Panel by  
accessing the Control board in the control box per above instruc-  
tions, then disconnecting the jumper terminals attached to the  
jumper plug connected to receptacle J3 of the Control board.  
(Refer to Machine Wiring Diagram.)  
• Switch #6 Hot Start Level Provides an extra out-  
put "boost" pulse at the arc strike to enhance arc  
starting. This is factory set for a level (about 50%  
extra) which is usually good for most stick welding  
applications  
ON Hot Start level is used (as shipped).  
OFF No Hot Start.  
PRECISION TIG 275  
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B-8  
B-8  
OPERATION  
FIGURE B.3  
(With DIP Switch #2 OFF)  
(With DIP Switch #2 ON, As Shipped)  
PRECISION TIG 275  
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B-9  
B-9  
OPERATION  
FIGURE B.4  
(With DIP Switch #3 ON)  
(With DIP Switch #3 OFF, As Shipped)  
PRECISION TIG 275  
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B-10  
B-10  
OPERATION  
TIG WELD CYCLE CHART  
With PULSE ON  
No Pulsing  
2 or 4-STEP  
Trigger  
4-STEP  
Trigger  
1ST Open  
SEE ITEM 12  
4-STEP Trigger  
Re-closed or  
2-STEP Trigger  
Opened  
4-STEP Trigger  
Re-opened  
During Upslope Time  
or  
Closed  
after  
Downslope Time  
SEE ITEM 12  
SEE ITEM 12  
SEE ITEM 12  
When Downslope  
Drops Below  
Background Setting  
MAXIMUM OUTPUT  
SETTING  
Adjustable 2-Max.A  
SEE ITEM 6  
CRATER-FILL  
LEVEL  
Advanced  
Panel Select:  
Amptrol or Remote  
(PEAK) Range  
SEE ITEM 6 & 7  
Mach. Min.  
or  
MIN. Setting  
(as w/o Panel)  
PULSE FREQ.  
Adjustable  
0.1-20 pps  
SEE ITEM 14  
% ON TIME  
Adjustable  
5-95%  
MINIMUM OUTPUT  
(Start) SETTING  
Adjustable 2-50A  
SEE ITEM 7  
SEE ITEM 7  
SEE ITEM 15  
BACKGROUND  
Adjustable  
MIN.Setting -100% Peak  
SEE ITEM 16  
POSTFLOW  
PREFLOW  
Fixed 0.5 sec  
or x2  
UPSLOPE  
Fixed<0.5 sec  
w/o Amptrol  
SEE ITEM 7  
DOWNSLOPE  
Adjust 0 —10 sec  
w/ Advan. Panel  
(Fixed 0 sec w/o)  
SEE ITEM 17  
Adjust 2-60 sec  
or x2  
SEE ITEM 9  
SEE ITEM 9  
START TIME  
CRATER-FILL TIME  
Manual  
in 4-Step  
Manual in 2/4-Step  
w/ Restart Disabled  
SEE ITEM 12 & TIG  
Welding Features  
SEE ITEM 12  
USING THE START PEDAL FOOT AMPTROL (K870-1)  
SETUP GUIDELINES FOR TIG WELDING  
WITH AN AMPTROL  
To further enhance reliability of consistently obtaining  
this minimum level just after the Amptrols start switch  
is closed, or just before it opens for crater-fill, the new  
K870-1 Start Pedal Foot Amptrol is available. Its  
independent start pedal on control pedal provides two-  
stage foot action to easily feel start switch closure at  
minimum output level for precise arc start and crater  
control. Also, an adjustable heel stop helps assure  
comfortable foot location.(See Figure B.5)  
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 machines 2-Step  
trigger mode (See Item 12).  
The Amptrol is capable of controlling the output of the  
Precision TIG over the range between the level preset  
by the Minimum Output control when the Amptrol is at  
its inactivated state, and the level preset by the  
Maximum Output control when the Amptrol is at fully-  
activated state.  
Currently available TIG foot pedal controls combine the  
arc start switch actuation in the same pedal action with  
the output control variable resistance. This technique  
provides no independent tactile feel of where the arc  
start switch actuates, and at what control level, for con-  
sistent TIG starting. Nor does it provide a way for con-  
sistent crater-fill control to feel at what decreasing con-  
trol pedal position the arc start switch will re-open  
causing arc out.  
It is important to note that even with the Precision TIGs  
new MicroStartTM Technology, some tungstens may be  
difficult to start at the low (2 amps) minimum rating of  
the machine. Rather than guessing where to depress  
the Amptrol to start the arc reliably, the Minimum  
Output control allows presetting the exact level, so  
reliable starts, as well as minimum crater-fill levels, can  
be consistently obtained at the minimum Amptrol (inac-  
tivated ) state. FIGURE B.6 shows Precision TIG setup  
for TIG welding with an Amptrol.  
PRECISION TIG 275  
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B-11  
B-11  
OPERATION  
The new foot pedal provides such independent action  
distinction of precisely where the arc start switch actu-  
ates without over-riding minimum control pedal posi-  
tion, and precisely where the control pedal has been  
returned to minimum position without inadvertently de-  
actuating the arc start switch. The result is repeatable  
consistency in TIG weld starting and crater-fill for man-  
ual process control.  
FIGURE B.5  
Foot  
Rock  
Control  
Toe  
Pressure  
Switch  
Adjustable  
or  
Removable  
Heel Stop  
Using this new foot pedal with the Precision TIGs new  
presettable Minimum Output level, in addition to the  
presettable Maximum Output level, further enhances  
the starting and crater level consistency as well as the  
control resolution of the manually controlled foot pedal.  
Maximum Output  
Machine Setting  
Fully Pressed  
Control Pedal  
Minimum Output  
Machine Setting  
At-Rest  
Control Pedal  
Off  
Time  
Pressed  
Switch Pedal  
At-Rest  
Switch Pedal  
Standard Controls  
Setup for TIG Amptrol Welding  
FIGURE B.6  
Power Switch  
ON  
Mode Switch  
TIG  
Polarity Switch  
AC Balance  
AUTO  
or  
AC or DC-  
Set:  
More +  
for alum.oxide "Cleaning"  
w/o"Spitting" o r"wetting"loss.  
+
-
Balanced for equal and current.  
More - for higher "Penetration".  
Local/Remote  
Switch  
REMOTE  
Maximum Output  
Set to desired max.  
Amptrol output level.  
Minimum Output  
Press Display switch  
and Set to desired min.  
Amptrol (Start/Crater)  
output level.  
Min. to Max.  
Amptrol  
Max. to Min.  
Amptrol  
Postflow  
Set as low as required.  
Higher for larger  
tungsten and current.  
Advanced Panel  
Controls  
Trigger Switch  
2-STEP  
Pulse Frequency  
Pulse Switch  
or  
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  
OFF  
% On Time  
40-60% is a typical initial setting.  
Set for total heat of Peak current:  
Lower reduces distortion and burn-thru.  
Background Current  
40-60% is a typical initial setting.  
Downslope  
ZERO  
For no arc-out delay.  
Set as low as will maintain a pulse arc  
Min.Output  
(Will not drop below  
setting.)  
PRECISION TIG 275  
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B-12  
B-12  
OPERATION  
Close the arc start switch. This opens the gas valve  
to automatically purge air from the hose and torch,  
then shields the arc strike area. After the 0.5 sec-  
ond preflow time, the high frequency becomes  
available to strike the arc. When the arc strikes the  
torch coolant (if used) starts to flow. Also, if welding  
DC- TIG, the high frequency shuts off just after the  
arc strikes.  
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 coolant  
input supply (if used).  
Note: The Precision TIG Under-Cooler (or Water  
Solenoid connected to the Cooler receptacle) runs with  
the Fan-As-Needed machine cooling fan (See  
Maintenance Section D), so the cooler fan and water  
pump will also not run continuously in idle, but will run  
while welding.  
6. Hold the arc start switch closed at minimum Amptrol  
Start level (See Section B-10) until an arc is estab-  
lished, then increase the output to the desired weld-  
ing level and push the torch in the direction of trav-  
el.  
7. At the end of the weld, decrease the Amptrol output  
to the crater-fill level before releasing the arc start  
switch to start the Postflow time. Hold the torch gas  
shielding over the solidifying weld crater while post-  
flow time expires and the gas valve reopens. The  
torch coolant (if used) continues to flow for up to 8  
minutes after the arc goes out (with the Fan-As-  
Needed feature) to assure torch cooling.  
4. With the torch held safely away from everything,  
close the Arc Start Switch of the Amptrol and set the  
gas flow meter. Then open the switch. The welder  
is now ready for welding.  
5. Position the tungsten electrode at the start of the  
weld at a 65° to 75° angle with the horizontal, in the  
direction of pushing travel, so that the electrode is  
approximately 1/8" (4 mm) above the work piece.  
Repeat steps 5 through 7 to make another weld.  
RECOMMENDED ELECTRODE AMPERAGE RANGES - PRECISION TIG 275  
SMAW Process  
ELECTRODE  
Fleetweld 5P, Fleetweld 5P+  
Fleetweld 180  
Fleetweld 37  
Fleetweld 47  
Jet-LH MR  
Blue Max Stainless  
Red Baron Stainless  
POLARITY  
DC+  
3/32"  
40 - 70  
40 - 80  
70 - 95  
75 - 95  
85 - 110  
40 - 80  
40 - 70  
1/8"  
5/32"  
75 - 130  
55 - 110  
100 - 135  
100 - 145  
110 - 160  
75 - 110  
60 - 100  
90 - 175  
105 - 135  
145 - 180  
135 - 200  
130 - 220  
95 - 110  
90 - 140  
DC+  
DC+  
DC-  
DC+  
DC+  
DC+  
Mild steel procedures are based on recommended procedures listed in C2.10 8/94 and the maximum rating of the PRECISION TIG 275  
Excaliber 7018 procedures are based on Jet-LH 78 MR  
Blue Max procedures are based on C6.1 6/95  
Red Baron Procedure are based on ES-503 10/93  
GTAW Process  
Electrode Polarity  
Electrode Tip Preparation  
DC-  
Sharpened  
AC*  
Balled  
Approximate Argon  
Gas Flow Rate  
C.F.H. (l/min.)  
EWZr  
Electrode Type  
EWTh-1, EWCe-2  
EWTh-2, EWLa-1  
EWG  
Up to 15 A.  
Up to 15 A.  
Up to 80 A.  
Up to 150 A.  
Up to MAX. A.  
X
EWTh-1, EWTh-2  
EWCe-2, EWLa-1  
EWG  
EWP  
Stainless  
Steel  
(2-4) 3-8 (2-4)  
Electrode Size (in.)  
Aluminum  
3-8  
.010  
.020  
.040  
1/16  
3/32  
1/8  
Up to 15 A.  
10 to 15 A.  
20 to 30 A.  
30 to 80 A.  
60 to 130 A.  
100 to 180 A.  
Up to 15 A.  
5 to 20 A.  
20 to 60 A.  
60 to 120 A.  
100 to 180 A.  
160 to 250 A.  
5-10  
5-10  
5-10  
(3-5) 5-10 (3-5)  
(3-5) 5-10 (3-5)  
(3-5) 9-13 (4-6)  
13-17 (6-8) 11-15 (5-7)  
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.  
*
PRECISION TIG 275  
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C-1  
C-1  
ACCESSORIES  
K814 Arc Start Switch  
OPTIONAL EQUIPMENT  
Needed for TIG welding without an Amptrol. Includes  
25plug cable, and attaches to torch for convenient  
finger control.  
FACTORY INSTALLED OPTIONS  
The basic Precision TIG 275 machine is factory  
equipped with:  
K1831-1 Power Factor Capacitor Kit  
Used when welding at higher output currents to  
reduce input current and help keep electricity costs  
to a minimum.  
A 3/8" Adapter (S20403-4) for air cooled torch con-  
nection of a PTA-9 or PTA-17.  
Magnum® PTA and PTW Series Torches  
FIELD INSTALLED OPTIONS  
All Air Cooled or Water-Cooled Magnum® TIG  
Torches may be used with the PRECISION TIG 275.  
Connection adapters are only required for Air-Cooled  
Torches (Refer to Diagrams on A-7):  
The following Options/Accessories are available for the  
Precision TIG 275 and are installed per instructions in  
this manual and / or provided in the package:  
K2166-1 7/8Torch Connector for PTA-26 (one  
piece)  
K1829-1 Precision TIG Advanced Control Panel  
Provides 2/4-step trigger with adjustable Pulser con-  
trols and Down slope timer for TIG welding. Also  
includes adjustable Hot Start and Arc Force internal  
panel controls for Stick welding, and other user  
selectable features.  
K2166-2 1/2stud Connector for PTA Torch (two-  
piece).  
K2166-3 3/8TIG Torch Connector for PTA-9,-17  
(one piece). (Included as S20403-4 with Precision  
TIG models.)  
K1828-1 Under-Cooler Cart  
Includes a "cooler-in-a-drawer" with hoses and a  
lockable storage drawer on a dual bottle undercar-  
riage (see below).  
3100211 Harris Argon Flow Regulator (Includes 10’  
hose.)  
K1869-1 Undercarriage  
K2150-1 Work Lead Assembly  
15ft. 2/0 cable with 1/2" stud lug and work clamp.  
Includes a dual bottle rack with chain and an under-  
carriage with 5" front casters,10" rear wheels and a  
handle.  
K1830-1 Water Solenoid Kit  
Provides for stopping flow of external water supply.  
Connects to coolant inlet and cooler receptacle of  
Precision TIG.  
(Can not be used with a water cooler.)  
K870 Foot Amptrol  
Single pedal foot activation of arc start switch and  
output control, with 25plug cable.  
K870-1 Start Pedal Foot Amptrol  
Independent start pedal on control pedal provides  
two-stage foot action to easily feel start switch clo-  
sure at minimum output level for enhanced arc start  
and crater-fill control. Provided with adjustable, or  
removable, heel stop and 25plug cable.(Refer to  
Figure B.5)  
K963-3 Hand Amptrol  
Fastens to torch for convenient thumb activation of  
arc start switch and output control, with 25plug  
cable:  
PRECISION TIG 275  
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D-1  
D-1  
MAINTENANCE  
SAFETY PRECAUTIONS  
OVERLOAD PROTECTION  
FAN-AS-NEEDED (F.A.N.)  
WARNING  
The Precision TIG 275 has the F.A.N. circuit feature,  
which means the cooling fan will operate only while  
welding; then for about 8 minutes after welding has  
stopped to assure proper machine cooling. This helps  
reduce the amount of dust and dirt drawn into the  
machine with the cooling air. The cooling fan will oper-  
ate briefly when the machine power is initially turned  
on, and continuously while the yellow Thermal  
Shutdown Light is lit (see Thermostatic Protection).  
ELECTRIC SHOCK can kill.  
Only qualified personnel should  
perform this maintenance.  
Turn the input power OFF at the  
disconnect switch or fuse box  
before working on this  
equipment.  
Do not touch electrically hot  
parts.  
THERMOSTATIC PROTECTION  
This welder has thermostatic protection from excessive  
duty cycles, overloads, loss of cooling, and excessive  
ambient temperatures. When the welder is subjected  
to an overload, or inadequate cooling, the primary coil  
thermostat and/or secondary coil thermostat will open.  
This condition will be indicated by the illumination of  
the yellow Thermal Shutdown Light on the front panel  
(see Item 10 in Section B). The fan will continue to run  
to cool the power source. Postflow occurs when TIG  
welding is shut down, but no welding is possible until  
the machine is allowed to cool and the yellow Thermal  
Shutdown Light goes out.  
WARNING  
To avoid receiving a high frequency shock, keep the  
TIG torch and cables in good condition.  
ROUTINE AND PERIODIC MAINTENANCE  
Very little routine maintenance is necessary to keep  
your Precision TIG 275 running in top condition. No  
specific schedule can be set for performing the follow-  
ing items; factors such as hours of usage and machine  
environment should be considered when establishing  
a maintenance schedule.  
NO ARC PROTECTION  
The machine outputs (Background / OCV, gas and HF)  
will be shutdown, if the trigger is closed without weld-  
ing for 15 seconds to protect the Background resistor  
from overheating with F.A.N. cooling off, as well as to  
conserve on gas waste.  
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.  
AUXILIARY POWER CIRCUIT BREAKER  
Inspect the spark gap at regular intervals to maintain  
the recommended spacing. See the Service  
Procedures (See Service Procedures in this  
Section) for complete information on spark gap set-  
tings.  
The 115vac auxiliary circuits and rear receptacle (see  
Section A Auxiliary Power Connections) are protected  
from overloads by a 15 amp circuit breaker, located  
above the receptacle. If the breaker trips its button  
pops out exposing a red ring. When the circuit breaker  
cools the button can be reset by pressing it back in.  
Note: When the breaker trips not only will the recepta-  
cles auxiliary and cooler power be interrupted, but so  
will the power to the shielding gas solenoid and  
machine cooling fan.  
The fan motor has sealed ball bearings which  
require no maintenance.  
Overload Protection  
The Export models also include a 5 amp circuit break-  
er, located on the opposite side of the upper case back,  
for protection of the 220vac Schuko type cooler recep-  
tacle.  
PRECISION TIG 275  
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D-2  
D-2  
MAINTENANCE  
FIGURE C.1 SPARK GAP  
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:  
.015 Spark Gap  
COMPONENT ACCESS  
Note: In highly dirty environments where there is an  
abundance of conductive contaminants, use a low  
pressure air stream or a firm piece of paper to clean  
out the spark gap. Do not disturb the factory gap set-  
ting.  
The following components are accessible for routine  
set up and periodic service without requiring removal  
of the case sides or roof:  
Input Reconnect Panel (refer Section A) is located  
behind a removable panel on the rear of the left case  
side. Remove the two screws (with a screwdriver or  
a 3/8"/ 9.5mm hex driver) on the bottom corners of  
this panel to remove it.  
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.  
Control Box components and PC Boards (refer  
Section B-6) are located behind the front control  
panel. Remove the two screws (with a screwdriver or  
a 3/8"/ 9.5mm hex driver) on the top corners of this  
panel to swing it down.  
If adjustment is required:  
1. Adjust the gap by loosening the Allen head screw  
on one of the aluminum blocks, reset the gap and  
tighten the screw in the new position.  
Hi-Freq. Spark Gap assembly (refer Spark Gap  
Adjustment) is located behind a removable panel on  
the rear of the right case side, under the torch box.  
Remove the screw (with a screwdriver or a 3/8"/  
9.5mm hex driver) on the bottom center of this panel  
to remove it.  
If spark gap is correct:  
1. Reinstall the access panel on the right case side.  
UNDER-COOLER SERVICE  
The required maintenance and service instructions for  
the Under-Cooler are provided in the operators manu-  
al (IM723) provided with the Under-Cooler Cart.  
SPARK GAP ADJUSTMENT  
The spark gap is set at the factory to a gap of 0.015  
inches (0.4 mm) See Figure C.1. This setting is ade-  
quate for most applications. Where less high frequen-  
cy is desired, the setting can be reduced to 0.008 inch-  
es (0.2 mm).  
WARNING  
Use extreme caution when working with circuit of  
the high frequency. The high voltages developed  
can be lethal. Turn the input power off using the  
disconnect switch or fuse box before working  
inside the machine. This is particularly important  
when working on the secondary circuit of the high  
voltage transformer (T3) because the output volt-  
age is dangerously high.  
------------------------------------------------------------------------  
PRECISION TIG 275  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and machine  
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please  
observe all safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Look under the column labeled PROBLEM (SYMP-  
TOMS). This column describes possible symptoms  
that the machine may exhibit. Find the listing that best  
describes the symptom that the machine is exhibiting.  
Step 2. POSSIBLE CAUSE.  
The second column labeled POSSIBLE CAUSElists  
the obvious external possibilities that may contribute to  
the machine symptom.  
Step 3. RECOMMENDED COURSE OF ACTION  
CAUTION  
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  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local  
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
PRECISION TIG 275  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Thermal light comes on  
1. Thermal shut down. Dirt and dust  
may have clogged the cooling  
channels inside machine; air  
intake and exhaust louvers may  
be blocked; welding application  
may exceed recommended duty  
cycle. Wait until machine cool  
down and thermal light goes out.  
Blow out machine with clean, dry  
low pressure air; check air intake  
and louvers; stay within recom-  
mended duty cycle.  
2. Bad thermostat or its connections  
Meter doesnt light up  
1. Losing AC supply to Control PC  
board  
2. Loosing input to machine  
3. Faulty Control PC board  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Has output in  
Stick mode  
No gas & no hi-freq 1. Faulty trigger or hand/foot Amptrol  
or connections.  
Contact  
your  
local  
Lincoln  
Authorized Field Service Facility.  
but no output  
in Tig mode  
2. Faulty Protection PC board or  
bad connection to Control PC  
board  
3. Losing trigger supply to Control  
PC board  
Gas & hi-freq are o.k. 1. Faulty Control PC board  
No output in both Stick and Tig  
modes  
1. Bad connection at P4 of Control  
PC board  
2. Faulty Control PC board  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local  
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
PRECISION TIG 275  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
METER PROBLEMS  
Meter does not light up  
1. Bad meter or its connection  
2. Bad connection at P8 of Control  
PC board  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
3. Faulty Control PC board  
Contact  
your  
local  
Lincoln  
Authorized Field Service Facility.  
Meter does not display V (Volt) or  
Min A (Minimum current)  
1. Bad Display switch or its connec-  
tion  
2. Bad connection at P9 of Control  
PC board  
GAS PROBLEMS  
No gas  
1. Circuit breaker CB1 open. Press  
CB1 in to reset  
2. Bad connection at P12 of Control  
PC board  
3. Faulty gas solenoid valve SV1 or  
its connection  
4. Faulty Control PC board  
No control on post flow time  
1. Faulty potentiometer R3 or its  
connection  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
2. Bad connection at P9 of Control  
PC board  
Contact  
your  
local  
Lincoln  
Pre flow & Post flow time too long  
1. If an Advanced Control PC board  
was installed, check setting of  
DIP switch on that board  
Authorized Field Service Facility.  
2. Missing plug P3 on Control board  
or bad connection at P3 when an  
Advanced Control PC board is not  
present  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local  
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
PRECISION TIG 275  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
HI-FREQ PROBLEMS  
No hi-freq  
1. Circuit breaker CB1 open  
2. Bad connection at P12 of Control  
PC board  
3. Spark gaps shorted  
4. Faulty Control PC board  
Hi-freq intensity too weak  
1. Dirty spark gap or improper gap  
setting  
2. Faulty Arc Starter assembly  
Hi-freq on continuously in DC Tig  
1. Bad connection at P11 of Control  
PC board  
2. Micro-switch S2A is not engaged &  
disengaged properly when switch-  
ing between DC & AC polarity.  
(S2A locates on the Polarity  
switch)  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
3. Faulty Control PC board  
Contact  
your  
local  
Lincoln  
Authorized Field Service Facility.  
Hi-freq shuts off after starting in AC 1. Micro-switch S2A is not engaged &  
Tig  
disengaged properly when switch-  
ing between DC & AC polarity.  
(S2A locates on the Polarity  
switch)  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local  
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
PRECISION TIG 275  
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E-5  
E-5  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
PRESET & OUTPUT CONTROL PROBLEMS  
Meter does not display preset  
1. Faulty potentiometer R1 or its con-  
nection  
2. Bad connection at P9 of Control  
PC board  
3. Faulty Advanced Control PC board  
( if present ) or its connection to  
the main Control PC board  
4. Missing plug P3 on Control board  
or bad connection at P3 when an  
Advanced Control PC board is not  
present  
High output current in both DC & AC 1. Bad connection at P6 of Control  
polarities regardless of preset  
PC board  
2. Bad shunt connection  
3. Faulty Control PC board  
4. Faulty SCR bridge  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact  
your  
local  
Lincoln  
High output current in DC polarity 1. Shorted free wheeling diode D1  
Authorized Field Service Facility.  
regardless of preset, o.k. in AC polar-  
ity  
In 2-step Tig, output stays on for 1. Bad 2/4 step switch or its connec-  
more than downslope time after trig-  
ger open (machine with Advanced  
Control panel only)  
tion  
2. Bad connection at P1 of Advanced  
Control PC board  
Output stays on after releasing 1. Downslope is not set at min.  
hand/foot Amptrol (machine with  
Advanced Control panel only)  
2. Bad Downslope potentiometer  
R12 or its connection  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local  
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
PRECISION TIG 275  
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E-6  
E-6  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
STICK WELDING PROBLEMS  
Stick electrode "blast off" when arc 1. Current may be set too high for  
is struck  
electrode size  
2. (Machine with Advanced Control If all recommended possible areas  
PC board only) Hot Start level set of misadjustment have been  
too high  
checked and the problem persists,  
Contact your local Lincoln  
Stick electrode "sticks" in the weld  
puddle  
1. Current may be set too low for Authorized Field Service Facility.  
electrode size  
2. (Machine with Advanced Control  
PC board only) Arc Force level set  
too low  
TIG WELDING PROBLEMS  
Poor starting in DC polarity  
1. Input line may be too low  
2. Bad connection at P11 of Control  
PC board  
3. Bad Background rectifier, back-  
ground resistor R7, or background  
diode D2  
Arc "flutters" in DC polarity, o.k. in  
AC polarity  
1. Tungsten not "sharp"  
2. Bad free wheeling diode D1 or its  
connection  
If all recommended possible areas  
of misadjustment have been  
Arc "flutters" in both DC & AC polari- 1. Tungsten electrode may be too checked and the problem persists,  
ties large in diameter for the current Contact your local Lincoln  
Authorized Field Service Facility.  
setting  
2. Gas shielding may be insufficient.  
3. Contaminated gas or leaks in the  
gas line, torch, or connections  
4. Helium blend is used as a shield-  
ing gas  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local  
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
PRECISION TIG 275  
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E-7  
E-7  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
TIG PROBLEMS  
Arc "pulsates" in AC polarity, DC 1.Micro switch S2A on polarity switch  
polarity is o.k.  
does not open in AC polarity  
Black area along weld bead  
1. Oily or organic contamination from  
work piece  
2. Tungsten electrode may be conta-  
minated  
3. Leaks in gas line, torch, or con-  
nections  
Output quits momentarily; gas flow 1. May be caused by hi-freq interfer-  
and hi-freq are also interrupted  
ence. Check that machine is  
grounded properly. Surrounding  
machines that generate hi-freq  
also should be properly grounded.  
2. Ground connection of Protection  
PC board may has become loose  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
3. Ground  
connection  
of  
Bypass/Stabilizer PC board may  
has become loose.  
Contact  
your  
local  
Lincoln  
Authorized Field Service Facility.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local  
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
PRECISION TIG 275  
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F-1  
F-1  
WIRING DIAGRAM  
3 A 2 3  
2 6 2  
6 6 2  
5 6 2  
A 6 6 2  
A 5 6 2  
N E G  
6 8 2  
3 5 2  
1 2 2  
2 2 2  
W
R
2 5 2  
G E N  
1 A 2 3  
2 3 3 A  
8
2 3  
2 3 9  
2 3 1 E  
A 0 2 2  
6
2 3  
O N A L ( ) O P T I  
O I N T G I T O P  
B C  
P
4 B 3 0  
4 0 1 D  
5 3 3  
3 1 3  
8 1 3  
A 6 1 3  
7 0 4  
4 3 3  
3 3 3  
5 1 3  
B 6 1 3  
C 6 1 3  
1 2 3  
4 1 0  
4 0  
4 0  
2 1 3  
1 1 3  
A 1 1 3  
9
8
A 6 1 3  
B 6 1 3  
4 0 4  
6 1 3  
7 1 3  
4 0 6  
4 0  
1 D 4 0  
0 2 3  
4 1 3  
5
2 3 3  
C 3 1 3  
B 1 0 4  
A 1 0 4  
1 0 4  
2 2 3  
A 1 1 3  
4 0 3  
4 0 2  
3 3 1  
C 6 1 3  
1 B 4 0  
9 1 3  
1 1 4  
PRECISION TIG 275  
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F-2  
F-2  
DIMENSION PRINT  
PRECISION TIG 275  
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NOTES  
PRECISION TIG 275  
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NOTES  
PRECISION TIG 275  
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l
l
Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
l
l
Keep flammable materials away.  
l
l
Wear eye, ear and body protection.  
WARNING  
Spanish  
l
No toque las partes o los electrodos  
bajo carga con la piel o ropa moja-  
da.  
Mantenga el material combustible  
fuera del área de trabajo.  
Protéjase los ojos, los oídos y el  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
l
l
Aislese del trabajo y de la tierra.  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
l
l
Gardez à l’écart de tout matériel  
inflammable.  
l
l
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
l
l
Isolez-vous du travail et de la terre.  
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material!  
Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
l
l
Elektroden und dem Erdboden!  
Portuguese  
Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
l
Mantenha inflamáveis bem guarda-  
dos.  
l
Use proteção para a vista, ouvido e  
corpo.  
ATENÇÃO  
l
Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO  
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-  
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
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l
l
Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
l
l
Turn power off before servicing.  
l
l
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
l
l
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
l
l
Débranchez le courant avant l’entre-  
tien.  
l
l
N’opérez pas avec les panneaux  
ouverts ou avec les dispositifs de  
protection enlevés.  
l
l
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
l
l
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
l
l
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
l
l
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
l
l
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
l
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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