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PRECISION TIG 275
For use with machines having Code Numbers:
10806; 10807; 10893; 11158; 11159
SVM162-B
January, 2008
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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.
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SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888-935-3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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i
i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
The engine exhaust from this product contains
are known to the State of California to cause canchemicals known to the State of California to cause
cer, birth defects, and other reproductive harm.
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
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Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ʻ95
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ii
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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.
3.g. Never dip the electrode in water for cooling.
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ii
SAFETY
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.
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.
ARC RAYS can burn.
4.a.
Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
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 exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
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 products.
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.
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5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Aug ʻ06
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iii
WELDING SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
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7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
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.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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.
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CYLINDER may explode
if damaged.
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.
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.
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iii
SAFETY
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.
6.h. Also see item 1.c.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
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.
FOR ELECTRICALLY
powered equipment.
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 manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
Mar ʻ95
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iv
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 suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode 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 sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique 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 defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau 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.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent 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 nʼimporte quelle partie du
corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
iv
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de
la zone de travail quʼil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dʼautres 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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar ʻ93
v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
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Page
Safety .................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Operation...............................................................................................................................Section B
Accessories ..........................................................................................................................Section C
Maintenance ..........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair ................................................................................................Section F
How to Use Troubleshooting Guide ............................................................................................F-2
Safety Precautions ......................................................................................................................F-3
Troubleshooting Guide ................................................................................................................F-4
Test Procedures ........................................................................................................................F-19
Oscilloscope Waveforms ...........................................................................................................F-39
Replacement Procedures .........................................................................................................F-45
Retest After Repair ....................................................................................................................F-61
Electrical Diagrams ..............................................................................................................Section G
Parts Manual ........................................................................................................P404 & P558 Series
PRECISION TIG 275
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TABLE OF CONTENTS
- INSTALLATION SECTION -
A-1
Installation
Technical Specifications..............................................................................................................A-2
Rated Output...............................................................................................................................A-3
Additional Output Capacity .........................................................................................................A-3
Wire and Fuse Sizes...................................................................................................................A-3
Physical Dimensions...................................................................................................................A-3
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Temperature Ranges ..................................................................................................................A-3
Safety Precautions......................................................................................................................A-4
Stacking ......................................................................................................................................A-4
Lifting and Moving.......................................................................................................................A-4
Tilting...........................................................................................................................................A-4
High Frequency Interference Protection .....................................................................................A-4
Input Electrical Connections .......................................................................................................A-5
Ground Connection...............................................................................................................A-5
Output Cables, Connections & Limitations .................................................................................A-6
TIG Torch Connection .................................................................................................................A-7
Auxiliary Power Connections ......................................................................................................A-8
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Remote Control...........................................................................................................................A-8
Robotic Interface Connection .....................................................................................................A-9
PRECISION TIG 275
A-1
INSTALLATION
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A-2
TECHNICAL SPECIFICATIONS-PRECISION TIG 275 (Domestic, Canadian & Export
K
Number
RATED INPUT - SINGLE PHASE ONLY
Duty Cycle-Applications
40%
AC/DC Stick / Balance TIG
K1825-1
K1826-1 Unbalance (70% Penetration#) AC TIG
60%
K2619-1
AC/DC Stick / Balance TIG
Unbalance (70% Penetration#) AC TIG
100%
AC/DC Stick / Balance TIG
Unbalance (70% Penetration#) AC TIG
NRTL/C
Idle Amps
40%
AC/DC Stick / Balance TIG
K1826-2
K2619-2 Unbalance (70% Penetration#) AC TIG
60%
AC/DC Stick / Balance TIG
Unbalance (70% Penetration#) AC TIG
100%
AC/DC Stick / Balance TIG
Unbalance (70% Penetration#) AC TIG
NRTL/C
Idle Amps
Idle Power
40%
AC/DC Stick / Balance TIG
Unbalance (70% Penetration#) AC TIG
60%
AC/DC Stick / Balance TIG
K1827-1 Unbalance (70% Penetration#) AC TIG
100%
AC/DC Stick / Balance TIG
Unbalance (70% Penetration#) AC TIG
N80
Idle Amps
IEC 60974-1
Idle Power
Voltage + 10%
Max. Amps With Out
Power Factor Capacitor
Max. Amps With
Power Factor Capacitor
86/78/39
95/86/43
64/58/29
62/56/28
104/94/47
124/112/56
208/230/460
77/70/35
73/66/33
6/5/3
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R
R
RATED POWER FACTOR (STICK)
47/38
56/45
39/31
43/35
460/575
35/28
33/26
3/2
300W
80/72/36
95/86/43
55/50/25
40/36/18
36/32/16
35/28
43/34
29/23
28/23
25/20
18/14
16/13
500W
95/55/50
109/63/58
80/46/43
86/50/46
70/41/37
65/38/35
10/6/5
400W
52/30/28
46/27/25
23/13/12
500W
80/46/42
85/49/45
220-230/
380-400/415
K1825-1,K1826-1 & K1826-2
K1827-1
.63 min.
.65 min.
64/37/34
67/39/36
.85 min.
.77 min.
RATED OUTPUT - NEMA EW1 Class ll (40) K1825-1,K1826-1,-2, K2619-1.-2
Duty Cycle-Applications
40%
AC/DC Stick / Balance TIG
Unbalance (70% Penetration#) AC TIG
60%
AC/DC Stick / Balance TIG
Unbalance (70% Penetration#) AC TIG
100%
AC/DC Stick / Balance TIG
Unbalance (70% Penetration#) AC TIG
Volts at Rated Amperes
Amps
29.0
15.4
225
200
31.0
16.1
28.0
14.8
*Shown on Front of this IM manual with Under-Cooler Cart and Advanced Control Panel (Refer to Optional Equipment)
#Exceeds
A-2
NEMA Unbalanced Load Specification comparable for Auto-Balance.
PRECISION TIG 275
275
255
200
150
INSTALLATION
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A-3
RATED OUTPUT - IEC 60974-1 (K1827-1)
Duty Cycle-Applications
40%
AC/DC Stick / Balance TIG
Unbalance (70% Penetration#) AC TIG
60%
AC/DC Stick / Balance TIG
Unbalance (70% Penetration#) AC TIG
100%
AC/DC Stick / Balance TIG
Unbalance (70% Penetration#) AC TIG
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Output Current
Range
Volts at Rated Amperes
Amps
29.0
18.0
225
200
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28.0
16.0
ADDITIONAL OUTPUT CAPACITY
Maximum Open
Circuit Voltage
Type of Output
2Amps DC
(STICK AND TIG)
to
CC (Constant Current)
AC/DC
OCV: 75/68
340Amps AC-DC*
AC/DC (GTAW)
Stick (SMAW)
Auxiliary Power
200
150
K1825-1, K1826-1, K1826-2
15Amp Circuit Breaker and NEMA 5-15R Duplex
Receptacle for up to:
115VAC 8Amp Auxiliary Power Receptacle
115VAC weld Switched Cooler Receptacle load
K1834-1
5 Amp Circuit Breaker
and grounded 220VAC
Euro(Schuko) receptacle
RECOMMENDED INPUT WIRE AND FUSE SIZES
For all Stick, DC TIG, and Balanced AC TIG Welding
at 275A/40% Duty Cycle with out Standard Power
Factor Correction Capacitors
Based on the 1999 U.S. National Electrical Code
For Unbalanced AC TIG Welding Above 275 Amps:
255A/40% Duty Cycle, Auto-Balance Penetration with
out Standard Power Factor Correction Capacitors
Based on the 1999 U.S. National Electrical Code
Input
Ampere
Rating
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
112
3 (26.7 mm2)
6 (13.3 mm2)
208/1/60
125
104
4 (21.2 mm2)
6 (13.3 mm2)
150
124
460/1/60
60
47
8 (8.4mm2)
10 (5.3mm2)
70
56
230/1/60
575/1/60
125
415/1/50/60
80
K1825-1
38
50
220-230/1/50/60
380-400/1/50/60
94
125
6 (13.3 mm2)
4 (21.2 mm2)
10 (5.3mm2)
10 (5.3mm2)
150
95
6 (13.3 mm2)
150
50
8 (8.4mm2)
8 (8.4mm2)
90
8 (8.4mm2)
8 (8.4mm2)
Height
31.0 in.
787 mm
49.7 in.
1262 mm
90
PHYSICAL DIMENSIONS
Width
22.0 in.
559 mm
180°C (H)
8 (8.4 mm2)
8 (8.4 mm2)
6 (13.3 mm2)
8 (8.4 mm2)
10 (5.3mm2)
109
6 (13.3 mm2)
58
6 (13.3 mm2)
8 (8.4 mm2)
63
41.0 in.
1041 mm
TEMPERATURE RANGES
3 (26.7 mm2)
4 (21.2 mm2)
Depth
26.0 in.
660 mm
28.0 in.
711 mm
OPERATING TEMPERATURE RANGE
-20°C to +40°C (-04° to +104°F)
TRANSFORMER INSULATION CLASS
45
60
4 (21.2 mm2)
55
80
K1826-1, -2
K1827-1
K2619-1,-2
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275
255
31.0
20.2
Input
Type 75°C
Type 75°C
Input
Ampere Copper Wire in
Fuse
Fuse
Copper
Conduit AWG
Voltage / (Super Lag) Rating
Ground Wire in (Super Lag)
(IEC) Sizes
phase/
or Breaker Rating on
Conduit AWG or Breaker
40°C (104°F)
Frequency
Nameplate
Size1
Size1
(IEC) Sizes
Ambient
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A-3
6 (13.3 mm2)
8 (8.4 mm2)
Weight
Approx. 397 lbs.
180 kgs.
Approx.641 lbs.
291 kgs.
STORAGE TEMPERATURE RANGE
-40°C to +85°C (-40° to +185°F)
1 ALSO CALLED ʻINVERSE TIME" OR "THERMAL/MAGNETIC " CIRCUIT BREAKERS; CIRCUIT BREAKERS WHICH HAVE A DELAY IN TRIPPING ACTION THAT DECREASES AS
* 50/60H
THE MAGNITUDE OF CURRENT INCREASES.
Z
IEC Max. range exceeds 310A.
PRECISION TIG 275
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A-4
SAFETY PRECAUTIONS
Read entire Installation Section before installing
the Precision Tig 275.
WARNING
ELECTRIC SHOCK can kill.
•
•
•
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•
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INSTALLATION
•
Only qualified personnel should perform this installation.
Turn the input power OFF
at the disconnect switch or
fuse box and discharge input capacitors
before working inside the equipment.
Do not touch electrically hot parts.
Always connect the Precision Tig grounding screw (behind
the reconnect panel cover located near the back of the left
case side) to a good electrical earth ground.
Always connect the Precision Tig to a power supply grounded
in accordance with the National Electrical Code and all local
codes.
SELECT SUITABLE LOCATION
Place the welder where clean cool air can freely circulate in through the rear louvers and out through the bottom opening. Dirt, dust or any foreign material that can
be drawn into the machine should be kept at a minimum. Failure to observe these precautions can result
in excessive operating temperatures and nuisance
trips.
GRINDING
Do not direct grinding particles towards the welder. An
abundance of conductive material can cause maintenance problems.
STACKING
The Precision Tig 275 cannot be stacked.
UNDERCARRIAGE LIFTING AND MOVING
When the Precision TIG 275 is purchased as a welding
package, or used with any of the available
Undercarriage optional accessories, proper installation
makes the Precision TIG 275 lift bale nonfunctional.
Do not attempt to lift the power source with an undercarriage attached. The undercarriage is designed for
hand moving only; mechanized movement can lead to
personal injury and/or damage to the Precision TIG
275.
TILTING
Each machine must be placed on a secure, level surface, either directly or on a recommended undercarriage.
A-4
The machine may topple over if this precaution is not
followed.
ENVIRONMENTAL RATING
Precision TIG 275 power sources carry an IP21S
Environmental rating. They are rated for use in damp,
dirty rain-sheltered environments.
HIGH FREQUENCY INTERFERENCE
PROTECTION
The frame of the welder must be grounded. A ground
screw marked with the symbol
is located on the
input connection panel (Figure A.1) for this purpose.
See your local and national electrical codes for proper
grounding methods.
The spark gap oscillator in the high frequency generator, being similar to a radio transmitter, can be blamed
for many radio, TV and electronic equipment interference problems. These problems may be the result of
radiated interference. Proper grounding methods can
be reduced or eliminate re-radiated interference.
The Precision TIG 275 has been field tested under recommended 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 standards for high frequency stabilized power sources.
Radiated interference can develop in the following four
ways:
* Direct interference radiated from the welder.
* Direct interference radiated from the welding leads.
* Direct interference radiated from the feedback into
the power lines.
* Interference from re-radiation of “pickup” by
ungrounded metallic objects.
Keeping these contributing factors in mind, installing
the equipment per the following instructions should
minimize problems.
1. Keep the welder power supply lines as short as possible and completely enclose them in rigid metallic conduit or equivalent shielding for a minimum distance of
50 feet (15.2 m). There must be good electrical contact
between this conduit must be connected to a driven
ground and the entire length must be continuous.
2. Keep the work and electrode leads as short as possible and as close together as possible. Lengths
should not exceed 25 feet (7.6m). Tape the leads
together when practical.
PRECISION TIG 275
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A-5
INSTALLATION
3. Be sure the torch and work cable rubber coverings
are free of cuts and cracks that allow high frequency leakage. Cables with high natural rubber content,
such as Lincoln Stable-Arc R better resist high frequency leakage than neoprene and other synthetic
rubber insulated cables.
4. Keep the torch in good repair and all connections
tight to reduce high frequency leakage.
5. The work terminal must be connected to a ground*
within ten feet of the welder, using one of the following methods.
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* A metal underground water pipe in direct contact
with the earth for ten feet or more.
* A 3/4” (19mm) galvanized pipe or a 5/8” (16mm)
solid galvanized iron, steel or copper rod driven at
least eight feet into the ground.
The ground should be securely made and the grounding 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 recommended.)
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6. Keep all access panels and covers securely in
place.
7. All electrical conductors within 50 feet (15.2m) of the
welder should be enclosed in grounded rigid metallic conduit or equivalent shielding. Flexible helicallywrapped metallic conduit is generally not suitable.
8. When the welder is enclosed in a metal building,
several earth driven electrical grounds (as in 5
above) around the periphery of the building are recommended.
Failure to observe these recommended installation
procedures can cause radio or TV interference problems and result in unsatisfactory welding performance
resulting from lost high frequency power.
A-5
INPUT and GROUNDING CONNECTIONS
WARNING
ELECTRIC SHOCK can kill.
* Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
___________________________________________
Be sure the voltage, phase, and frequency of the
input power is as specified on the rating plate, located
on the rear of the machine.
Fuse the input circuit with the recommended super
lag fuses or delay type1 circuit breakers. Choose an
input and grounding wire size according to local or
national codes or use Section A-2. Using fuses or circuit breakers smaller than recommended may result
in “nuisance” tripping from welder inrush currents
even if not welding at high currents.
Unbalanced AC TIG welding draws higher input currents 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 reconnected
panel. Welder supply line entry provision is in the
case rear panel. Entry is through a 1.75 inch (44mm)
diameter hole in the case back. Appropriate supply
line strain relief clamp is provided by installer. (See
Figure A.1)
All connections should be made in accordance
FIGURE A.1
CONNECT INPUT
POWER LEADS
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CONNECT INPUT
GROUND LEAD
CONNECT INPUT
VOLTAGE LEVEL
with all local codes and national electrical codes.
Installation by a qualified electrician is recommended.
PRECISION TIG 275
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A-6
1. Connect the terminal marked
nect panel) to an earth ground.
INSTALLATION
(below the recon-
2. Connect the input leads to terminals marked L1 (U)
and L2 (V) on the reconnect panel. Use a single
phase line or one phase of a two or three phase line.
3. On multiple input voltage welders, be sure the
reconnect panel is connected for the voltage being
supplied to the welder.
CAUTION
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Failure to follow these instructions can cause
immediate failure of components within the welder.
-----------------------------------------------------------------------Welders are shipped connected for the highest input
voltage as listed on the rating plate. To change this
connection, designations on the reconnect panel LOW,
MID, and HIGH correspond to the name plated input
voltages of a triple voltage welder. Dual voltage
welders use only LOW and HIGH.
EXAMPLE: On a 208/230/460 volt welder, LOW is
208V, MID is 230V, and HIGH is 460V.
NOTE: Export model has a voltage range for LOW and
MID connections: LOW is 220-230V, MID is 280400V and high is 415V.
Reconnect the jumper strap to the terminal stud corresponding to the input voltage level used. Make sure all
connections are tight.
WARNING
OUTPUT CABLES, CONNECTIONS AND
LIMITATIONS
• To avoid being startled by a high frequency
shock, keep the TIG torch and cables in good
condition
• Turn the power switch of the power source OFF
before installing adapters on cable or when connecting or disconnecting adapter plugs to power
source.
-----------------------------------------------------------------------
A-6
Recommended Cable Sizes for Combined Lengths of
Copper Work and Electrode Cables using 75o C Wire:
Machine Rating
275A/40%
0 to 100 Ft.
101 to 200 Ft
201 to 250 Ft
#1 (42.4 mm2) 1/0 (53.5 mm2) 2/0 (67.4 mm2)
WORK CABLE CONNECTION
A 15ʼ (2/0) weld cable with clamp is available (K2150-1), or
included with the Precision TIG Welding Package model.
Otherwise, it is user provided.
With power source off, connect a separate work cable
to the 1/2-13 threaded "WORK" stud of the welder, and
secure a tight connection with the flange nut provided.
The work cable should be routed through the cable
strain relief hole provided in the base directly below the
welding output terminal.
Note: If the Precision TIG is equipped with an UnderCooler or Under-Storage unit, the coiled work cable
and clamp, or excess work cable length, may be conveniently stored in the drawer while remaining connected.
STICK ELECTRODE CABLE CONNECTION
If manual stick welding is desired, with power source
off, connect a stick electrode cable to the 1/2-13
threaded "STICK Electrode" stud of the welder, and
secure a tight connection with the flange nut provided.
The electrode cable should be routed through the
cable strain relief hole provided in the base directly
below the welding output terminal.
WARNING
DISCONNECT STICK ELECTRODE
CABLE WHEN TIG WELDING.
WELDING
EVEN THOUGH HI-FREQ IS NOT APPLIED TO THE
PRECISION TIG STICK TERMINAL, IT WILL BE
ELECTRICALLY "HOT" TO WORK WHEN TIG
WELDING.
------------------------------------------------------------------------
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
INSTALLATION
A-7
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FIGURE A.2
TIG TORCH
CONNECTION
P ANEL
REMOTE
CONTROL
RECEPTACLE
STICK
WORK
STICK
ELECTRODE
STUD
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FIGURE A
(Shown without hinged stud cover)
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 aircooled and water-cooled TIG torches with fittings conforming to Compressed Gas Association (CGA) standards:
Note: The Precision TIG provides an insulated Torch
Reel and Holster for handy and safe storage of connected torch when not welding, and excess torch cable
length while welding.
WARNING
Combination connectors (Power/Water and
Power/Gas) are electrically "hot" while welding in
STICK or TIG modes.
If using an Air-Cooled Torch be sure coolant is
shut off and/or Cooler is unplugged from the
Precision TIG Water Cooler Receptacle on the
torch side of the upper case back.
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WORK
STUD
TIG TORCH CONNECTION
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A-7
Observe the safety precautions necessary for handling and using compressed gas containers.
Contact your supplier for specifics.
CABLE
STRAIN
RELIEF HOLES
CYLINDER could explode
if damaged.
• Keep cylinder upright and
chained to a support.
• Keep cylinder away from areas
where it could be damaged.
• Never allow the torch to touch the cylinder.
• Keep cylinder away from live electrical circuits.
• Maximum inlet pressure 150 psi.
-----------------------------------------------------------------
The Precision TIG machines do not have Hi-Freq.
available at the Stick electrode stud, therefore stud
connection adapters (such as LECO. S19257-series)
cannot be used for torch connection.
Single-piece cable air-cooled torches with a 3/8-24 RH
connector fitting (such as the Magnum PTA-9/-17, or LA9/-17) require the provided S20403-4 Torch Connector,
while those with a 7/8-14 RH connector fitting (such as
the Magnum PTA-26, or LA-26) require the available
K2166-1 Torch Connector. (See Figure A.3)
Two-piece cable air-cooled torches (such as PTA-, or LAtorches) can be used with the available 1/2” Stud
Connector (S20403-3) with with a 7/8-14 LH male fitting.
Magnum PTW-18/-20 (or LW-) water-cooled Torches
require no adapter for Precision TIG connection.
PRECISION TIG 275
INSTALLATION
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A-8
FIGURE A.3
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A-8
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)
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-AsNeeded machine cooling fan, see Maintenance
Section), so the Coolerʼs fan and water pump will not
run continuously in idle, but will run while welding.
• The top outlet of this duplex receptacle provides at
least 8 amps at 115VAC, whenever the Precision TIG
Power switch is ON. This auxiliary circuit is intended
for running 115VAC accessories or small power tools.
Note: Some types of equipment, especially pumps
and large motors, have starting currents which are
significantly higher than their running current. These
higher starting currents may cause the circuit breaker
to open. (See next paragraph)
• 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 breaker cools the button can be reset by pressing it back
in.
Note: When the breaker trips not only will the auxiliary and cooler power be interrupted, but so will the
power to the shielding gas solenoid and machine
cooling fan.
The Precision TIG Export models also provide a
grounded 220 VAC Euro type Schuko receptacle and a
5 amp circuit breaker, located on the upper case back
on the reconnect side of the machine, intended for use
with a 220 VAC water cooler.
REMOTE CONTROL (If Used)
The Foot Amptrol (included with the Precision TIG
Welding Package), or other Remote accessory, is
installed by routing the plug of its control cable up
through the left cable strain relief hole provided in the
base (see Figure A.2), then connecting the 6-pin plug
to the mating Remote receptacle behind the stud panel
cover. (See Operation Section B-2 for mating plug
wiring.)
Note: If the Precision TIG is equipped with an UnderCooler or Under-Storage unit, the Foot Pedal (or other
remote control accessory) and coiled control cable, or
excess cable length, may be conveniently stored in the
drawer while remaining connected.
PRECISION TIG 275
INSTALLATION
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A-9
ROBOTIC INTERFACE CONNECTION
Robotic interface can be made at the Remote
Receptacle (See Operation Section). 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 interface to function. When in the REMOTE position with
robotic interface neither the MAXIMUM OUTPUT nor
the MINIMUM OUTPUT panel controls limit the interface 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:
FIGURE A.4
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REMOTE RECEPTACLE
(Front View)
For 18-12P Plug
(LECO S12020-27)
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A-9
ARC START
INPUT FROM ROBOT
(18Vac,10ma switch)
D
E
C
*
F
B
+
+VCC = 70Vdc max.
A
R = VCC / 5ma
5ma
* Precision TIG Control Common.
PRECISION TIG 275
Robotic
Common
PRESET CONTROL
INPUT FROM ROBOT
(0 -10Vdc = Rated Output Range)
Note: The Interface connection
cable may pick up noise
interference. Additional
bypass/filtering circuits may be
needed for the external circuits.
ARC ESTABLISHED
OUTPUT TO ROBOT
(High = Not Welding)
(Low = Welding)
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A-10
NOTES
PRECISION TIG 275
A-10
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B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation ...............................................................................................................................Section B
Safety Precautions ......................................................................................................................B-2
Product Description.....................................................................................................................B-2
Recommended Process and Equipment ....................................................................................B-3
Controls and Settings..................................................................................................................B-4
Welding Operation ................................................................................................................B-5/B-8
Internal Set Up Controls..............................................................................................................B-9
2 Step Trigger Modes................................................................................................................B-10
4 Step Trigger Modes ................................................................................................................B-11
TIG Weld Cycle Chart ...............................................................................................................B-12
Making a TIG Weld with an Amptrol .........................................................................................B-14
Recommended Electrode Amperage Ranges...........................................................................B-14
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Set Up for TIG Amptrol Welding................................................................................................B-13
PRECISION TIG 275
B-1
OPERATION
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B-2
Read and understand this entire section before operating the machine.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
*Only qualified personnel should perform the 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 clothing.
* Insulate yourself from work and
ground.
* Always dry insulating gloves.
* Read and follow “Electric Shock
Warnings” in the Safety section if
welding must be performed under
electrically hazardous conditions
such as welding in wet areas or on
or in the workpiece.
......................................................................................
FUMES AND GASES
can be dangerous.
* Keep your head out of fumes.
*Use ventilation or exhaust to
remove fumes from breathing
zone.
......................................................................................
WELDING SPARKS
can cause fire and explosion
* Keep flammable material away.
* Do not weld on containers that
have held combustibles.
......................................................................................
ARC RAYS
can burn.
* Wear eye, ear and body protection.
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......................................................................................
Observe additional Safety Guidelines detailed in
the beginning of this manual.
PRODUCT DESCRIPTION
B-2
The Precision TIG 275 is part of a new family of industrial arc welding power sources providing constant current, single range square wave AC/DC TIG (GTAW)
with new patented (pending) Micro-StartTM Technology,
Presettable Min. and Max. Output controls, and built-in
high frequency stabilization for continuous AC TIG and
DC TIG starting. It also has AC/DC Stick (SMAW)
capability, with adjustable Arc Force availability. A TIG
Pulse Panel. Power Factor Capacitors and a Water
Solenoid are available as field installed optional kits.
Also, a new Undercarriage (with double gas bottle
rack) is available for field installation, as well as a new
Under-Cooler Cart, which is also included in an available efficiently integrated entire TIG Welding Package
with convenient built-in storage provisions for welding
equipment and components.
The Precision TIG 275 includes advanced features
such as a Digital Meter, Presettable control, Auto
BalanceTM, Fan As Needed (F.A.N.) fixed Preflow, variable Postflow shielding gas and Timers. In addition, 2Step/4-Step and Pulse TIG operation with adjustable
Downslope Time control are included with an available
field installed kit. It also features a Stick stud panel and
a universal TIG torch connection box for simultaneous,
but separated, electrode outputs.
The Precision TIG 275 has enhanced Features which
includes the following:
• MicroStart™ Codes Below 11000
• MicroStart™ II Codes Above 11000
• Auto-Balance optimized
• Menu button added
• Spot On selection added
PIPE THAWING
The Precision TIG 275 is not recommended for pipe
thawing.
Duty Cycle
The duty cycle is based upon a 10-minute time period;
i.e., for 40% duty cycle, it is 4 minutes welding and 6
minutes idling. If the rated duty cycle is significantly
exceeded, the thermostatic protection will shut off the
output until the machine cools to a normal operating
temperature. (Refer to Specification Section A-1)
PRECISION TIG 275
OPERATION
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B-3
RECOMMENDED PROCESSES AND
EQUIPMENT
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 to Equipment
Limitations), as well as many industry standard items,
such as TIG torches, hoses, and water coolers.
PROCESS LIMITATIONS
Precision TIG machines are not recommended for arc
gouging due to it's limited output capacity, and are also
not recommended for pipe thawing.
B-3
EQUIPMENT LIMITATIONS
The Precision TIG machines are protected from overloads beyond the electrical ratings and duty cycles, per
the Specifications Section A-2, A-3, with Thermostat
protection of the primary and secondary transformer
coils.
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.
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RECOMMENDED EQUIPMENT/INTERFACE FOR CODES ABOVE 11000
Machine:
Input Cable/Clamp:
Gas Reg./Hose:
Magnum Torch:
Magnum Parts:
Work Clamp/Lead:
Foot Amptrol:
TIG (water cooled)
PT275 Welding Package (K2618-1)
User provided
(included)
(PTW20 included)
(KP510 and K918-2 included)
(15 ft. included)
(K870 included)
TIG (air cooled)
PT275(K2619-1,-2)
User provided
LE/Harris 3100211
PTA9 or PTA17
KP507 or KP508
K2150-1 Work Lead Assembly
K870
RECOMMENDED EQUIPMENT/INTERFACE FOR CODES BELOW 11000
Machine:
Input Cable/Clamp:
Gas Reg./Hose:
Magnum Torch:
Magnum Parts:
Work Clamp/Lead:
Foot Amptrol:
TIG (water cooled)
PT275 Welding Package (K1825-1)
User provided
(included)
(PTW20 included)
(KP510 and K918-2 included)
(15 ft. included)
(K870 included)
PRECISION TIG 275
TIG (air cooled)
PT275(K1826-1, -2, K1827-1)
User provided
LE/Harris 3100211
PTA9 or PTA17
KP507 or KP508
K2150-1 Work Lead Assembly
K870 or K870-1
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B-4
CONTROLS AND SETTINGS
OPERATION
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
7
8
7a
9
5
6
9
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3
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B-4
4
12
13
14
15
1
16
17
10
1. POWER SWITCH
2. POLARITY SWITCH
3. MODE SWITCH
4. AC BALANCE CONTROL
5. LOCAL/REMOTE CURRENT CONTROL
SWITCH
6. MAXIMUM OUTPUT CONTROL
7. MINIMUM OUTPUT CONTROL AND
DISPLAY SWITCH
7.a MENU BUTTON AND DISPLAY
SWITCH FOR CODES ABOVE 11000
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
11
2
1. POWER SWITCH - Input line switch turns input
power ON or OFF, as indicated by the on or off status of the front panel displays.
2. POLARITY SWITCH – The 3-position rotary power
switch has detente positions for DC-, AC and DC+
selections for the Electrode output welding polarity.
3. MODE SWITCH – The mode switch allows vertically positioned selection of the two machine welding
modes. The selected mode is indicated by a lit colored panel light which permits viewing the machine
setting from a distance:
3.a STICK mode (Top position) –Red panel light
WARNING
• The CC Stick mode may be used for general purpose stick welding (SMAW ) within the capacity of
the machine. The capacity is too limited for air carbon arc gouging (CAC-A).
• 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.b TIG mode (Bottom position) – No panel light.
• When the Polarity Switch is set to AC, the TIG
mode provides continuous high frequency to stabilize the arc for AC TIG welding.
• Hi-Freq. turns on after preflow time with the arc
ELECTRIC SHOCK can kill.
start switch closure, and turns off when the arc
• When the Power Source is ON in
goes out* after the arc start switch opens.
STICK mode the Electrode circuits of
both the Stick and TIG torch cables
* Arc voltage and current are sensed to determine if
are electrically HOT to Work.
the arc is established or out.
-----------------------------------------------------------------------PRECISION TIG 275
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B-5
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 position, 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*
• DC+ polarity can also be used for ”balling” of the
tungsten for AC TIG welding.
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 minimum CCW position.
• The new MicroStartTM Technology minimum current
circuit provides for low end welding (down to 2
amps) previously unobtainable on an SCR platform
TIG machine.
7. MINIMUM OUTPUT CONTROL AND DISPLAY SWITCH–
A smaller knob is used to preset the minimum current level only for TIG mode. Pressing the Display
(momentary) switch toggle left to Minimum Set position 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 setting range for this Start control is the 2 amp minimum 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 independent 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 normal AC TIG welding
• The mid position is the Balanced position (~50%
positive and negative waves).
• This setting also serves as the Crater-fill level, but
with a Precision TIG Advanced Panel it can be
selected (see Section B-7) to be either the Minimum
Output control setting (same as Start setting) as
shipped, or the minimum rating of the machine (2
amps).
• The Balance control is only functional if the machine
is set to AC polarity and TIG mode.
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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)
• 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 receptacle (See Item 11) This switch selection is indicated
by the Green panel light turning on.
In either position the arc start switch functions when
connected to the Remote receptacle (See Item 11).
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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.
B-5
.
• The Remote Amptrol range of control is between
this Minimum setting and the Maximum Output control knob setting, so these knobs can set the resolution of the Amptrol. Also, the Minimum setting
serves as both the minimum Amptrol start level
when the arc start switch is closed, as well as the
minimum Amptrol crater-fill level before the arc start
switch is opened to help prevent premature arc out
and Hi-Freq re-initiation.
• In 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.
PRECISION TIG 275
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B-6
OPERATION FOR CODES ABOVE 11000 ONLY
a MENU BUTTON AND DISPLAY SWITCH (Codes
7a
above 11000) – Pressing and holding the (Menu)
Button for about 5 seconds enters the menu display
which allows:
• Selection of up to seven programmable parameters
(Preflow, Upslope, Hot Start, Arc Force, etc.) on the
digital meter is achieved by momentarily pressing
and releasing the MENU button to step through the
parameters.
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• Setting of the desired level, displayed on the digital
meter for the selected parameter, is done by pressing the DISPLAY (momentary) switch toggle to the
right to increase the level setting, or to the left to
decrease it.
DIGITAL DISPLAY
(SELECT)
DISPLAY
(SET)
DISPLAY
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TIG Mode Menu
* Default Factory Setting. (Indicated by "blinking" decimal point.)
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Only selectable with Advanced Control Panel installed.
TIG Mode Menu (with Advanced Control Panel installed):
Setting:
Selection 4:
0*
1
2
3
4
5
6
7
8
9
Selection 5:
0
1*
2
3
4
5
Description:
HS (TIG Hot Start % of output setting)
+0%
(Only setting for SS0, above.)
+10%
+20%
+30%
+40%
+50%
+60%
+70%
+80%
+90%
UP (Upslope Time)
None
(Only setting for SS1 & SS2, above.)
0.5 sec.
1.0 sec.
1.5 sec.
2.0 sec.
2.5 sec.
* Default Factory Setting. (Indicated by "blinking" decimal point.)
Setting:
Description:
Selection 1: HF (High Freq.)
0
Scratch start TIG (No Hi-Freq.)
1*
Normal Hi-Freq. start and weld
2
Lift TIG (Touch start w/o Hi-Freq.)
Selection 2: PF (Preflow time)
0
No Preflow
1
0.1 sec.
2*
0.5 sec.
3
1.0 sec.
4
1.5 sec.
5
2.0 sec.
Selection 3: SS (MicroStart™ Start Pulse)
0*
No AC pulse/Low DC pulse (soft start)
1
High AC/DC pulse (forceful start)
2
HS setting (see below) for each pulse when Pulse
∆
mode welding anodized aluminum.
∆
B-6
STICK Mode Menu (with Advanced Control Panel installed ◊ ):
Setting:
Selection 6:
0
1
2
3
4
5*
6
7
8
9
Selection 7:
0
1*
2
3
4
5
6
7
8
9
Description:
HS (Stick Hot Start % added to output setting)
+0%
+10%
+20%
+30%
+40%
+50%
+60%
+70%
+80%
+90%
AF (Stick Arc Force % added to output setting)
+0%
("Softer" arc)
+10%
+20%
+30%
+40%
+50%
+60%
+70%
+80%
+90%
("Crisper" arc)
* Default Factory Setting. (Indicated by "blinking" decimal point.)
◊ If no Advanced Control Panel the Stick menu
displays “- - -“.
• Any of the following actions will exit the menu display:
1. Pressing and holding the (Menu) Button again for about 5 seconds.
2. Allowing the menu display to be unchanged for about 15 seconds.
3. Closing the arc start switch (TIG Mode) or starting the arc (Stick Mode).
Note: In Stick Mode the machine output will remain on while in menu display.
• Re-entering the menu displays the last parameter and setting that was displayed when the menu was
exited.
• All settings may be reset to the Factory Default Settings (above) by holding the (Menu) button pressed while
turning on the machineʼs Power switch. The display will show “rES” to indicate the defaults are reset.
PRECISION TIG 275
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B-7
OPERATION
8. DIGITAL METER AND DISPLAY SWITCH– A 3digit LED meter is used to monitor the preset and
actual welding procedure based on the Display
(momentary) switch position:
• Before welding with Display switch in center (normal) 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 welding amps set by the Remote control. (See Item 11)
• While welding with Display switch in center (normal)
position, the digital meter displays the actual welding amps with one amp resolution (XXX) and accuracy within 4%+/-2A of reading.
• At any time in TIG mode, pressing the Display
switch to left causes the digital meter displays the
amps preset by the Minimum Output control knob
(See Item 7).
• At any time in Stick mode, pressing the Display
switch to left causes the digital meter to display the
minimum amps rating of the machine (See Item 7).
• In either mode, while pressing the Display switch
right to Volts position, the digital meter displays
actual output volts. Volts is displayed with 0.1 volt
resolution (XX.X) and accuracy within 3%+/-1V of
reading.
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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 seconds, with no panel control.
• Both time ranges are x2 extendable, if needed, by
internal control box selection. (See Section B-7)
10. THERMAL SHUTDOWN LIGHT – This yellow LED
panel light turns on if the machine output is shutdown because internal overheating has occurred,
and turns off when the thermostat resets.
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11. REMOTE RECEPTACLE – A 6-socket receptacle
is provided for the connection of an Amptrol, or
other remote control: (See Figure B.2)
• When the Current Control Switch (See Item 5) is in
the REMOTE position, the Amptrol or other remote
(10K pot) connected to the Remote receptacle controls the TIG or Stick mode output within the range
preset by the Maximum and Minimum Output controls. (See Item 6, 7, and 8 for meter display.)
B-7
• When the Current Control Switch is in either LOCAL
or REMOTE positions the arc start switch functions
when connected to the Remote receptacle.
FIGURE B.2
ARC START
SWITCH
REMOTE RECEPTACLE*
(Front View)
D
E
C
F
REMOTE OUTPUT
CONTROL
B
A
Max
10K ohm
Min
*For 18-12P Plug
(LECO S12020-27)
The following controls are included only if the Precision
TIG 275 has the Advanced Control Panel (K1829-1)
option installed: (Refer to Figure B.3 Tig Weld Cycle
Chart for graphic illustration of these TIG welding functions.)
ADVANCED PANEL CONTROLS
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 control in the amptrol will function normally to shut
off or control the output. ONLY USE 2-STEP.
-----------------------------------------------------------------------• In 2-Step position the arc start switch functions the
same as without the Advanced Panel:
1. Closing switch starts preflow, then a fixed
(0.5 sec.) ramp time from Minimum (Start)
setting level (See Item 7) to Weld setting.
2. Opening switch initiates Downslope ramp
time setting (See Item 17), from Weld setting to Crater-fill level (See Item 7), which
then stops the arc and initiates Postflow
time (See Item 9).
Note: See Figure B.3 for 2-Step operation during
Downslope with Restart feature selected to be disabled, instead of enabled (as shipped).
PRECISION TIG 275
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B-8
OPERATION
• The 4-Step position allows welding without continuously holding the start switch trigger. The arc start
switch functions in the following manner:
1. Closing the 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.
2. Opening the switch initiates fixed (0.5 sec.)
ramp time from Start setting level to Weld
setting.
3. Reclosing the switch initiates Downslope
ramp time setting (See item 17) from Weld
setting down to the Crater-fill level (See
Item 7) of the machine.
4. Reopening the switch after Downslope time
holds Crater-fill level until it times out, then
stops the arc and initiates the Postflow Time
(See Item 9). Reopening switch during
Downslope time immediately stops the arc
and initiates the Postflow.
Note: See Figure B.4 for 4-Step operation during
Downslope with Restart feature selected to be
enabled, instead of disabled (as shipped).
13.PULSE MODE SWITCH (PULSE / SPOT MODE
SWITCH for codes above 11000) – Turns on the
Pulse Mode as indicated by the Green panel light
turning on.
• PULSE ON position provides a Peak current level
set by REMOTE and/or LOCAL control of the output
current (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).
B-8
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 (PULSE% ON /
SPOT TIME CONTROL for codes above 11000) •
• % ON TIME controls 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)
• SPOT TIME sets the duration of the SPOT pulse
(0.5 to 5.0seconds on the red scale).
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).
17. DOWNSLOPE TIME– This knob is used to set the
time, over the range of zero to about 10 seconds,
to ramp down from weld setting to Crater-fill level
(See Item 7).
• If the arc goes out after the Downslope time is initiated, the Downslope time is interrupted and the
Postflow time is initiated. This prevents Hi-Freq reinitiation during ramp down crater fill
• 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.
• Pulsing begins after upslope when the output current rises above the Background Current level and
ends when the output current drops below this level
.
• SPOT ON position provides the peak current level
set by the Maximum Output Control for a time determined by the SPOT TIME control. A red panel light
is ON to indicate SPOT mode.
PRECISION TIG 275
OPERATION
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B-9
INTERNAL SET UP CONTROLS
Precision TIG 275 models which have an Advanced
Panel (K1829-1) option installed* have the following
additional control features which are set up using the
DIP Switch (S1) provided on the internal panel of this
option.
Access to this internal panel is obtained by removing
the two screws securing the top corners of the
Precision TIG front control panel and swinging the control panel down to reveal the panel mounted on the surface of the Precision TIG Control board:
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CAUTION
• THE CONTROL BOARDS CONTAIN STATIC SENSITIVE COMPONENTS
• To avoid possible damage to these components
be sure to ground yourself by touching the
machineʼs sheet metal while handling or making
settings on the internal control box components.
-----------------------------------------------------------------------PRECISION TIG ADVANCED PANEL
(Internal Panel)
^ ON
1234567
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S
HOT START
F
ARC FORCE
ON
2
3
4
5
6
7
8
OFF
DIP SWITCH POSITIONS (FACTORY SETTINGS)
STICK WELDING FEATURES
The following DIP switch feature selections function
only when the Precision TIG is set to Stick mode. (See
Item 3):
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• Switch #7 Arc Force Level(codes below 11000)–
Prevents "stubbing" of the electrode by providing
extra output current if the arc voltage drops below
the level required to sustain the welding arc. High
(+65%) and Low (+12%) factory set levels are
selectable which are good for most stick welding
applications.
ON – Higher for a "crisper" arc, often desired for 6010
type electrodes.
OFF – Lower Arc Force (as shipped) for a "softer" arc
with 7018 or general type electrodes.
• Switch #6 & #7 - Not functional on codes
above 11000 - See item 7a for
adjustment of Hot Start and
Arc Force
• Switch #8 - (NOT CURRENTLY FUNCTIONAL)
TIG WELDING FEATURES
The following DIP switch feature selections function
only when the Precision TIG is set to TIG mode (See
Item 3):
• Switch #1 Preflow/Postflow Time Extension*
(See Item 9)
ON – Doubles the time ranges.
OFF – Standard time ranges (as shipped).
DIP SWITCH (S1)
1
B-9
• Switch #6 Hot Start Level (codes below 11000) –
Provides an extra output "boost" pulse at the arc
strike to enhance arc starting. This is factory set for
a level (about 50% extra) which is usually good for
most stick welding applications
ON – Hot Start level is used (as shipped).
OFF – No Hot Start.
• Switch #2 2-Step Trigger Restart Feature (See
Figure B.3)
ON – Restart Enabled (as shipped).
OFF – Restart Disabled.
• Switch #3 4-Step Trigger Restart Feature (See
Figure B.4)
ON – Restart Enabled.
OFF – Restart Disabled (as shipped)
• Switch #4 (NOT CURRENTLY FUNCTIONAL)
• Switch #5 Crater-Fill Level (See Item 7)
ON - Level is minimum rating of the machine (2A)
OFF – Level (as shipped) is Minimum Output setting
(same as Start level).
* The Preflow/Postflow Time doubling feature can also be selected
on Precision TIG 275 models without the Advanced Panel by
accessing the Control board in the control box per above instructions, then disconnecting the jumper terminals attached to the
jumper plug connected to receptacle J3 of the Control board.
(Refer to Machine Wiring Diagram.)
PRECISION TIG 275
OPERATION
B-10
B-10
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FIGURE B.3
START/CRATER CURRENT
2 Step Trigger Modes
UP-SLOPE
DOWN-SLOPE
Torch
Button
Output
Current
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Pre-Flow
Post Flow
Gas
Normal Sequence
2 Step - Restart Disabled
(With DIP Switch #2 OFF)
Torch
Button
Output
Current
Pre-Flow
Post Flow
Gas
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Actuate the trigger a second
time, during down-slope, to
immediately end down-slope.
Hold the trigger to maintain
crater current.
2 Step - Restart Enabled
(With DIP Switch #2 ON. As Shipped)
Torch
Button
Output
Current
Pre-Flow
Post Flow
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Gas
Actuate the trigger a second
time, during down-slope, to
activate up-slope and restart.
2 Step.eps
12-17-07
JRH
PRECISION TIG 275
OPERATION
B-11
B-11
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FIGURE B.4
START/CRATER CURRENT
4 Step Trigger Modes
UP-SLOPE
DOWN-SLOPE
Torch
Button
Output
Current
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Pre-Flow
Pre-Flow
Post Flow
Post Flow
Gas
Normal Sequence
Hold the first trigger pull to maintain
the starting current and delay
up-slope.
4 Step - Restart Enabled
(With DIP Switch #3 ON)
Torch
Button
Output
Current
Post Flow
Pre-Flow
Post Flow
Gas
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Hold the second trigger
pull for more than 1
second to activate the
restart function. When the
trigger is released
up-slope will occur.
Actuate the trigger
holding it less than 1
second, to begin
normal down-slope.
The following two
options are available
during the normal
down-slope period.
Actuate the trigger
again, during
down-slope, to
immediately end
down-slope and stop.
Or actuate and hold the trigger,
during down-slope, to immediately
end down-slope and maintain
crater current. Hold the trigger for
more than 1 second to activate the
restart function. When the trigger
is released up-slope will occur.
4 Step - Restart Disabled
(With DIP Switch #3 OFF. As Shipped)
Torch
Button
Output
Current
Pre-Flow
Post Flow
Post Flow
Post Flow
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Gas
Hold the second trigger
pull for more than 1
second to maintain
crater current before
stopping.
Actuate the trigger
holding it less than 1
second, to begin
normal down-slope.
The following two
options are available
during the normal
down-slope period.
Actuate the trigger a third
time, during down-slope, to
immediately end down-slope
and stop.
PRECISION TIG 275
Or actuate the trigger a third time,
during down-slope, to immediately
end down-slope. Hold the third trigger
pull to maintain crater current.
4 Step.eps
12-17-07
JRH
OPERATION
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B-12
TIG WELD CYCLE CHART
2 or 4-STEP
Trigger
Closed
CODES BELOW 11000 (K1829-1)
MAXIMUM OUTPUT
SETTING
Adjustable 2-Max.A
Amptrol or Remote
(PEAK) Range
PULSE FREQ.
Adjustable
0.1-20 pps
MINIMUM OUTPUT
(Start) SETTING
Adjustable 2-50A
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With PULSE ON
No Pulsing
During Upslope Time
or
When Downslope
Drops Below
Background Setting
4-STEP
Trigger
ST
1 Open
PREFLOW
Fixed 0.5 sec
or x2
B-12
UPSLOPE
Fixed<0.5 sec
w/o Amptrol
4-STEP Trigger
Re-closed or
2-STEP Trigger
Opened
CRATER-FILL
LEVEL
Advanced
Panel Select:
Mach. Min.
or
MIN. Setting
(as w/o Panel)
% ON TIME
Adjustable
5-95%
BACKGROUND
Adjustable
MIN.Setting -100% Peak
DOWNSLOPE
Adjust 0 –10 sec
w/ Advan. Panel
(Fixed 0 sec w/o)
START TIME
Manual
in 4-Step
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POSTFLOW
Adjust 2-60 sec
or x2
CRATER-FILL TIME
Manual in 2/4-Step
w/ Restart Disabled
CODES ABOVE 11000 (K2621-1)
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4-STEP Trigger
Re-opened
after
Downslope Time
PRECISION TIG 275
OPERATION
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B-13
B-13
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FIGURE B.6
Setup for TIG Amptrol Welding
Standard Controls
Power Switch
ON
Mode Switch
TIG
Polarity Switch
AC or DC-
AC Balance
AUTO
or
Set:
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More +
for alum. oxide “Cleaning“
w/o “spitting”or“wetting“ loss.
Balanced for equal + and - current.
More for higher “Penetration“.
Local/Remote
Switch
REMOTE
Maximum Output
Set to desired max.
Amptrol output level.
Minimum Output
Min. to Max.
Amptrol
Max. to Min.
Amptrol
Press Display switch
and Set to desired min.
Amptrol (Start/Crater)
output level.
Postflow
Set as low as required.
Higher for larger
tungsten and current.
Advanced Panel
(If used)
Trigger Switch
2-STEP
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Pulse Frequency
4-6 pps is a typical initial setting.
Set for bead shape and travel speed:
Higher for thinner plate and faster travel.
Lower for thicker plate and slower travel.
% On Time
40-60% is a typical initial setting.
Set for total heat of Peak current:
Lower reduces distortion and burn-thru.
Background Current
40-60% is a typical initial setting.
Set as low as will maintain a pulse arc
(Will not drop below Min.Output setting.)
SETUP GUIDELINES FOR TIG WELDING
WITH AN AMPTROL
Both the Hand and Foot Amptrols work in a similar
manner. They are meant to be used for remote current
control for TIG welding using the machineʼs 2-Step trigger mode (See Item 12).
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Pulse Switch
ON
or
OFF
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 fullyactivated state.
Downslope
ZERO
For no arc-out delay.
Advanced Pa nel
Controls
It is important to note that even with the Precision TIGʼs
new MicroStartTM Technology, some tungsten may be
difficult to start at the low (2 amps) minimum rating of
the machine. Rather than guessing where to depress
the Amptrol to start the arc reliably, the Minimum
Output control allows presetting the exact level, so reliable starts, as well as minimum crater-fill levels, can be
consistently obtained at the minimum Amptrol (inactivated ) state. FIGURE B.6 shows Precision TIG setup
for TIG welding with an Amptrol.
PRECISION TIG 275
OPERATION
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B-14
Close the arc start switch. This opens the gas valve
to automatically purge air from the hose and torch,
then shields the arc strike area. After the 0.5 second 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-9.
3. Turn on the shielding gas supply, and torch coolant
input supply (if used).
Note: The Precision TIG Under-Cooler (or Water
Solenoid connected to the Cooler receptacle) runs with
the Fan-As-Needed machine cooling fan (See
Maintenance Section D), so the cooler fan and water
pump will also not run continuously in idle, but will run
while welding.
4. With the torch held safely away from everything,
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.
B-14
6. Hold the arc start switch closed at minimum Amptrol
Start level (See Section B-10) until an arc is established, then increase the output to the desired welding level and push the torch in the direction of travel.
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 postflow 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-AsNeeded feature) to assure torch cooling.
• Repeat steps 5 through 7 to make another weld.
RECOMMENDED ELECTRODE AMPERAGE RANGES - PRECISION TIG 275
ELECTRODE
Fleetweld 5P, Fleetweld 5P+
Fleetweld 180
Fleetweld 37
Fleetweld 47
Jet-LH MR
Blue Max Stainless
Red Baron Stainless
POLARITY
DC+
DC+
DC+
DCDC+
DC+
DC+
SMAW Process
3/32"
40 - 70
40 - 80
70 - 95
75 - 95
85 - 110
40 - 80
40 - 70
1/8"
75 - 130
55 - 110
100 - 135
100 - 145
110 - 160
75 - 110
60 - 100
5/32"
90 - 175
105 - 135
145 - 180
135 - 200
130 - 220
95 - 110
90 - 140
Mild steel procedures are based on recommended procedures listed in C2.10 8/94 and the maximum rating of the PRECISION TIG 275
Excaliber 7018 procedures are based on Jet-LH 78 MR
Blue Max procedures are based on C6.1 6/95
Red Baron Procedure are based on ES-503 10/93
Electrode Polarity
Electrode Tip Preparation
Electrode Type
Electrode Size (in.)
.010
.020
.040
1/16
3/32
1/8
DCSharpened
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
GTAW Process
AC*
Balled
EWP
Up to 15 A.
10 to 15 A.
20 to 30 A.
30 to 80 A.
60 to 130 A.
100 to 180 A.
EWZr
EWTh-1, EWTh-2
EWCe-2, EWLa-1
EWG
Up to 15 A.
5 to 20 A.
20 to 60 A.
60 to 120 A.
100 to 180 A.
160 to 250 A.
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
Approximate Argon
Gas Flow Rate
C.F.H. (l/min.)
Stainless
Aluminum
Steel
3-8
(2-4) 3-8
(2-4)
5-10
(3-5) 5-10 (3-5)
5-10
(3-5) 5-10 (3-5)
5-10
(3-5) 9-13 (4-6)
13-17 (6-8) 11-15 (5-7)
15-23 (7-11) 11-15 (5-7)
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Optional Equipment for Codes Below 11000 ..............................................................................C-2
Optional Equipment for Codes Above 11000..............................................................................C-3
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C-1
PRECISION TIG 275
C-1
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C-2
ACCESSORIES FOR CODES BELOW 11000
OPTIONAL EQUIPMENT
FACTORY INSTALLED OPTIONS
The basic Precision TIG 275 machine is factory
equipped with:
• A 3/8" Adapter (S20403-4) for air cooled torch connection of a PTA-9 or PTA-17.
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Accessories that are factory installed with the
Domestic model (K1826-1) to make up the Domestic
Welding Package (K1825-1) include:
• K1828-1
• 3100211
Under-Cooler Cart
Harris Argon Flow Regulator with 10ʼ
Hose.
• K870 Foot Amptrol
• K1784-4
25ʼ PTW-20 water-cooled TIG Torch
• K918-2
Zippered Torch Cover
• KP510
Parts Kit for Torch
• K2150-1
Work Lead Assembly
See below for more detailed descriptions.
FIELD INSTALLED OPTIONS
The following Options/Accessories are available for the
Precision TIG 275 and are installed per instructions in
this manual and / or provided in the package:
• K1829-1 Precision TIG Advanced Control Panel
Provides 2/4-step trigger with adjustable Pulser controls and Down slope timer for TIG welding. Also
includes adjustable Hot Start and Arc Force internal
panel controls for Stick welding, and other user
selectable features.
• K1828-1 Under-Cooler Cart
Includes a "cooler-in-a-drawer" with hoses and a
lockable storage drawer on a dual bottle undercarriage (see below).
• K1869-1 Undercarriage
Includes a dual bottle rack with chain and an undercarriage with 5" front casters,10" rear wheels and a
handle.
• K1830-1 Water Solenoid Kit
Provides for stopping flow of external water supply.
Connects to coolant inlet and cooler receptacle of
Precision TIG.
(Cannot be used with a water cooler.)
C-2
• K870 Foot Amptrol
Single pedal foot activation of arc start switch and
output control, with 25ʼ plug cable.
• K870-1 Start Pedal Foot Amptrol
Independent start pedal on control pedal provides
two-stage foot action to easily feel start switch closure at minimum output level for enhanced arc start
and crater-fill control. Provided with adjustable, or
removable , heel stop and 25ʼ plug 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 25ʼ plug
cable:
K963-1 is for PTA-9,-17 and PTW-20 Torches.
K963-2 is for PTA-26 and PTW-18 Torches.
• K814 Arc Start Switch
Needed for TIG welding without an Amptrol. Includes
25ʼ plug cable, and attaches to torch for convenient
finger control.
• K1831-1 Power Factor Capacitor Kit
Used when welding at higher output currents to
reduce input current and help keep electricity costs
to a minimum.
• Magnum® PTA and PTW Series Torches
All Air Cooled or Water-Cooled Magnum® TIG
Torches may be used with the PRECISION TIG 275.
Connection adapters are only required for Air-Cooled
Torches (Refer to Diagrams on A-7):
K2166-1 7/8” Torch Connector for PTA-26 (one
piece)
K2166-2 1/2” stud Connector for PTA Torch (twopiece).
K2166-3 3/8” TIG Torch Connector for PTA-9,-17
(one piece). (Included as S20403-4 with Precision
TIG models.)
• 3100211 Harris Argon Flow Regulator (Includes 10ʼ
hose.)
• K2150-1 Work Lead Assembly
15ft. 2/0 cable with 1/2" stud lug and work clamp.
PRECISION TIG 275
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C-3
ACCESSORIES FOR CODES ABOVE 11000
OPTIONAL EQUIPMENT
FACTORY INSTALLED OPTIONS
The basic Precision TIG 275 machine is factory
equipped with:
• A 3/8" Adapter (S20403-4) for air cooled torch connection of a PTA-9 or PTA-17.
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Accessories that are factory installed with the
Domestic model (K1826-1) to make up the Domestic
Welding Package (K1825-1) include:
• K1828-1
• 3100211
Under-Cooler Cart
Harris Argon Flow Regulator with 10ʼ
Hose.
• K870 Foot Amptrol
• K1784-4
25ʼ PTW-20 water-cooled TIG Torch
• K918-2
Zippered Torch Cover
• KP510
Parts Kit for Torch
• K2150-1
Work Lead Assembly
See below for more detailed descriptions.
FIELD INSTALLED OPTIONS
The following Options/Accessories are available for the
Precision TIG 275 and are installed per instructions in
this manual and / or provided in the package:
• K2621-1 Precision TIG Advanced Control Panel
Provides 2/4-step trigger with adjustable Pulser
controls and Down slope timer for TIG welding. Also
includes adjustable Hot Start and Arc Force internal
panel controls for Stick welding, and other user
selectable features.
• K1828-1 Under-Cooler Cart
Includes a "cooler-in-a-drawer" with hoses and a
lockable storage drawer on a dual bottle undercarriage (see below).
C-3
• K870 Foot Amptrol
Single pedal foot activation of arc start switch and
output control, with 25ʼ plug cable.
• K963-3-3 Hand Amptrol
Fastens to torch for convenient thumb activation of
arc start switch and output control, with 25ʼ plug
cable:
• K814 Arc Start Switch
Needed for TIG welding without an Amptrol. Includes
25ʼ plug cable, and attaches to torch for convenient
finger control.
• K1831-1 Power Factor Capacitor Kit
Used when welding at higher output currents to
reduce input current and help keep electricity costs
to a minimum.
• Magnum® PTA and PTW Series Torches
All Air Cooled or Water-Cooled Magnum® TIG
Torches may be used with the PRECISION TIG 275.
Connection adapters are only required for Air-Cooled
Torches (Refer to Diagrams on A-7):
K2166-1 7/8” Torch Connector for PTA-26 (one
piece)
K2166-2 1/2” stud Connector for PTA Torch (twopiece).
K2166-3 3/8” TIG Torch Connector for PTA-9,-17
(one piece). (Included as S20403-4 with Precision
TIG models.)
• 3100211 Harris Argon Flow Regulator (Includes 10ʼ
hose.)
• K2150-1 Work Lead Assembly
15ft. 2/0 cable with 1/2" stud lug and work clamp.
• K1869-1 Undercarriage
Includes a dual bottle rack with chain and an undercarriage with 5" front casters,10" rear wheels and a
handle.
• K1830-1 Water Solenoid Kit
Provides for stopping flow of external water supply.
Connects to coolant inlet and cooler receptacle of
Precision TIG.
(Cannot be used with a water cooler.)
PRECISION TIG 275
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C-4
NOTES
PRECISION TIG 275
C-4
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D-1
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance ..........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance.............................................................................................D-2
Overload Protection ....................................................................................................................D-2
Fan As Needed (F.A.N.)..............................................................................................................D-2
Service Procedures.....................................................................................................................D-3
Component Location and Access ...............................................................................................D-3
Spark Gap Adjustment ................................................................................................................D-3
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Major Component Location.........................................................................................................D-4
PRECISION TIG 275
D-1
MAINTENANCE
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D-2
SAFETY PRECAUTIONS
OVERLOAD PROTECTION
WARNING
FAN-AS-NEEDED (F.A.N.)
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this maintenance.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this
equipment.
• Do not touch electrically hot
parts.
WARNING
To avoid receiving a high frequency shock, keep the
TIG torch and cables in good condition.
ROUTINE AND PERIODIC MAINTENANCE
Very little routine maintenance is necessary to keep
your Precision TIG 275 running in top condition. No
specific schedule can be set for performing the following items; factors such as hours of usage and machine
environment should be considered when establishing
a maintenance schedule.
• Periodically blow out dust and dirt which may accumulate within the welder using an air stream.
• Inspect welder output and control cables for fraying,
cuts, and bare spots.
• Inspect the spark gap at regular intervals to maintain
the recommended spacing. See the Service
Procedures (See Service Procedures in this
Section) for complete information on spark gap settings.
• The fan motor has sealed ball bearings which
require no maintenance.
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D-2
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 operate briefly when the machine power is initially turned
on, and continuously while the yellow Thermal
Shutdown Light is lit (see Thermostatic Protection).
THERMOSTATIC PROTECTION
This welder has thermostatic protection from excessive
duty cycles, overloads, loss of cooling, and excessive
ambient temperatures. When the welder is subjected
to an overload, or inadequate cooling, the primary coil
thermostat and/or secondary coil thermostat will open.
This condition will be indicated by the illumination of
the yellow Thermal Shutdown Light on the front panel
(see Item 10 in Section B). The fan will continue to run
to cool the power source. Postflow occurs when TIG
welding is shut down, but no welding is possible until
the machine is allowed to cool and the yellow Thermal
Shutdown Light goes out.
NO ARC PROTECTION
The machine outputs (Background / OCV, gas and HF)
will be shutdown, if the trigger is closed without welding for 15 seconds to protect the Background resistor
from overheating with F.A.N. cooling off, as well as to
conserve on gas waste.
AUXILIARY POWER CIRCUIT BREAKER
The 115vac auxiliary circuits and rear receptacle (see
Section A Auxiliary Power Connections) are protected
from overloads by a 15 amp circuit breaker, located
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 receptacleʼs auxiliary and cooler power be interrupted, but so
will the power to the shielding gas solenoid and
machine cooling fan.
The Export models also include a 5 amp circuit breaker, located on the opposite side of the upper case back,
for protection of the 220 VAC Schuko type cooler
receptacle.
PRECISION TIG 275
MAINTENANCE
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D-3
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:
The following components are accessible for routine
set up and periodic service without requiring removal
of the case sides or roof:
COMPONENT ACCESS
• Input Reconnect Panel (refer Section A) is located
behind a removable panel on the rear of the left case
side. Remove the two screws (with a screwdriver or
a 3/8"/ 9.5mm hex driver) on the bottom corners of
this panel to remove it.
• Control Box components and PC Boards (refer
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.
• 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.
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 adequate for most applications. Where less high frequency is desired, the setting can be reduced to 0.008 inches (0.2 mm).
D-3
.015 Spark Gap
Note: In highly dirty environments where there is an
abundance of conductive contaminants, use a low
pressure air stream or a firm piece of paper to clean
out the spark gap. Do not disturb the factory gap setting.
To check the spark gap:
1. Turn the input power off per above.
2. Remove the access panel on the right case side
(See Component Access).
3. Check the spark gap spacing with a feeler gauge.
If adjustment is required:
1. Adjust the gap by loosening the Allen head screw
on one of the aluminum blocks, reset the gap and
tighten the screw in the new position.
If spark gap is correct:
1. Reinstall the access panel on the right case side.
UNDER-COOLER SERVICE
The required maintenance and service instructions for
the Under-Cooler are provided in the operatorʼs manual (IM723) provided with the Under-Cooler Cart.
WARNING
Use extreme caution when working with the high
frequency circuit. The high voltages developed can
be lethal. Turn the input power off using the 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 voltage is
dangerously high.
------------------------------------------------------------------------
PRECISION TIG 275
MAINTENANCE
5
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3
1
2
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D-4
1. Case Front Assembly
2. Arc Starter and Bypass Assembly
3. Case Back Assembly
4. Center Assembly
5. Case Cover Assembly
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D-4
PRECISION TIG 275
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E-1
E-1
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation..............................................................................................................Section E
General Description ....................................................................................................................E-2
Input Power Circuit......................................................................................................................E-2
Output Rectification, Control Board and Feedback ....................................................................E-3
High Voltage/High Frequency Circuit ..........................................................................................E-4
DC Welding Output .....................................................................................................................E-5
SCR Operation............................................................................................................................E-7
Protective Circuits .......................................................................................................................E-8
Fan As Needed (F.A.N.)........................................................................................................E-8
Thermal Protection ...............................................................................................................E-8
Overload Protection ..............................................................................................................E-8
FIGURE E.1 – PRECISION TIG 275 BLOCK LOGIC DIAGRAM
OPTIONAL POWER
FACTOR
CORRECTION
CAPACITORS
BACKGROUND
CIRCUIT
REAR GANG
BYPASS
BOARD
HIGH FREQUENCY
TRANSFORMER
AC
DC
SCR
BRIDGE
THERMOSTAT
115 VAC
20 VAC
20 VAC
ADVANCED CONTROL
PANEL RECEPTACLE
MINIMUM
OUTPUT
CONTROL
PROTECTION
BOARD
MAXIMUM
OUTPUT
CONTROL
HIGH VOLTAGE
TRANSFORMER
SHUNT
FAN
115 VAC
115 VAC
REAR
ELECTRODE
GAS
SOLENOID
115 VAC
DC
FRONT
ELECTRODE
CHOKE
AC
FEEDBACK
X2
GATE LEADS
78 VAC
X1
RECONNECT
PANEL
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POWER
SWITCH
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WORK
POLARITY
SWITCH
115 VAC
FROM
CONTROL
BOARD
63.5 VAC
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AC Welding Output .....................................................................................................................E-6
THERMOSTAT
CONTROL BOARD
METER
STICK
TIG
SWITCH
REMOTE
RECEPTACLE
PRECISION TIG 275
BALANCE
CONTROL
POST
FLOW
LED's
LOCAL/REMOTE
SWITCH
THEORY OF OPERATION
CORRECTION
CAPACITORS
REAR GANG
POWER
SWITCH
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DC
THERMOSTAT
20 VAC
ADVANCED CONTROL
PANEL RECEPTACLE
MINIMUM
OUTPUT
CONTROL
PROTECTION
BOARD
MAXIMUM
OUTPUT
CONTROL
The PRECISION TIG 275 is part of a new family of
industrial arc welding power sources able to provide
constant current and single range square wave AC/DC
Tig (GTAW) with new MicroStartTM Technology. It incorporates independent presettable minimum and maximum output control with built-in high frequency stabilization for continuous AC Tig welding and reliable DC
Tig starting. The Precision TIG 275 also has AC/DC
stick (SMAW) capabilities. This new design includes
advanced features such as a digital meter, presettable
controls, auto balanceTM , fan as needed and timers for
fixed preflow and variable post flow of shielding gas. It
features a stick output terminal (front) and a universal
Tig torch connection box (rear) for simultaneous, but
separate, electrode outputs.
The desired single-phase input power is connected to
the PRECISION TIG 275 through the power switch to
the reconnect panel located in the rear of the machine.
The machine can be configured for any one of three
input voltages (208 VAC, 230 VAC or 460 VAC) by connecting the jumper strap to the appropriate terminal on
FRONT
ELECTRODE
REAR
ELECTRODE
HIGH VOLTAGE
TRANSFORMER
SHUNT
FAN
GAS
SOLENOID
115 VAC
AC
20 VAC
INPUT POWER CIRCUIT
BOARD
CHOKE
DC
SCR
BRIDGE
115 VAC
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AC
FEEDBACK
X2
GATE LEADS
78 VAC
X1
GENERAL DESCRIPTION
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BYPASS
HIGH FREQUENCY
TRANSFORMER
115 VAC
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WORK
POLARITY
SWITCH
115 VAC
OPTIONAL POWER
FACTOR
BACKGROUND
CIRCUIT
63.5 VAC
FROM
CONTROL
BOARD
115 VAC
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E-2
FIGURE E.2 – GENERAL DESCRIPTION AND INPUT POWER CIRCUIT
RECONNECT
PANEL
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E-2
THERMOSTAT
CONTROL BOARD
METER
STICK
TIG
SWITCH
BALANCE
CONTROL
POST
FLOW
LED's
LOCAL/REMOTE
SWITCH
REMOTE
RECEPTACLE
the reconnect panel. When the input power switch is
turned “on,” the input voltage is applied directly to the
primary winding of the main transformer.
The main transformer changes the high voltage, low
current input power to a low voltage, high current output available at the main secondary winding (X1 and
X2). This 78 VAC winding supplies power to the welding arc. In addition, four auxiliary windings are incorporated in the main transformer. The 115 VAC winding
supplies power to the 115 VAC receptacle. Through
the control board, it also powers the gas solenoid, the
high voltage transformer, and the cooling fan. The
cooling fan is activated only when welding current is
sensed. The 63.5 VAC winding provides power for the
DC background current. This circuit is active in the DC
TIG welding mode. The 20 VAC windings are included
in the main transformer assembly. The 20 VAC winding
is rectified on the control board and is used in the trigger circuitry. The other 20 VAC winding is used by the
control board for phase detection. This AC voltage is
also rectified to several DC voltages and regulated to
+15 VDC and +5 VDC power supplies that operate the
circuitry on the control board.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
PRECISION TIG 275
THEORY OF OPERATION
OPTIONAL POWER
FACTOR
CORRECTION
CAPACITORS
BACKGROUND
CIRCUIT
REAR GANG
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BOARD
DC
THERMOSTAT
115 VAC
20 VAC
20 VAC
ADVANCED CONTROL
PANEL RECEPTACLE
PROTECTION
BOARD
OUTPUT RECTIFICATION,
CONTROL BOARD AND FEEDBACK
The AC output from the main transformer secondary
is rectified and controlled through the SCR bridge.
Output current is sensed at the shunt as a low voltage
signal and fed back to the control board. The control
board senses the status and settings of the various
operator controls such as the Stick/TIG switch, the
output controls, the remote control receptacle, the
local/remote switch, the balance control and the postflow control. Circuitry on the control board evaluates
these commands, compares them to the feedback
information received from the shunt and sends the
appropriate gate firing signals to the output SCR
bridge. The control board regulates the firing of the
output SCRs, which control the output of the machine.
See SCR Operation.
HIGH VOLTAGE
TRANSFORMER
SHUNT
FAN
115 VAC
115 VAC
REAR
ELECTRODE
GAS
SOLENOID
115 VAC
AC
FRONT
ELECTRODE
CHOKE
DC
SCR
BRIDGE
MAXIMUM
OUTPUT
CONTROL
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AC
FEEDBACK
X2
GATE LEADS
78 VAC
X1
RECONNECT
PANEL
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BYPASS
HIGH FREQUENCY
TRANSFORMER
MINIMUM
OUTPUT
CONTROL
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WORK
POLARITY
SWITCH
115 VAC
FROM
CONTROL
BOARD
POWER
SWITCH
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E-3
FIGURE E.3 – OUTPUT RECTIFICATION, CONTROL BOARD AND FEEDBACK
63.5 VAC
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E-3
THERMOSTAT
CONTROL BOARD
METER
STICK
TIG
SWITCH
BALANCE
CONTROL
POST
FLOW
LED's
LOCAL/REMOTE
SWITCH
REMOTE
RECEPTACLE
The control board also monitors the thermostats and
controls the gas solenoid, the thermal light, the high
voltage transformer and the cooling fan. The optional
advanced control panel also plugs into and interfaces
with the control board.
PRECISION TIG 275
THEORY OF OPERATION
CORRECTION
CAPACITORS
REAR GANG
POWER
SWITCH
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BOARD
HIGH FREQUENCY
TRANSFORMER
DC
THERMOSTAT
115 VAC
20 VAC
20 VAC
ADVANCED CONTROL
PANEL RECEPTACLE
MINIMUM
OUTPUT
CONTROL
PROTECTION
BOARD
REAR
ELECTRODE
HIGH VOLTAGE
TRANSFORMER
SHUNT
FAN
GAS
SOLENOID
115 VAC
AC
FRONT
ELECTRODE
CHOKE
DC
SCR
BRIDGE
FEEDBACK
AC
GATE LEADS
78 VAC
X2
115 VAC
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BYPASS
X1
MAXIMUM
OUTPUT
CONTROL
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WORK
POLARITY
SWITCH
115 VAC
OPTIONAL POWER
FACTOR
BACKGROUND
CIRCUIT
63.5 VAC
FROM
CONTROL
BOARD
115 VAC
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E-4
FIGURE E.4 – HIGH VOLTAGE / HIGH FREQUENCY CIRCUIT
RECONNECT
PANEL
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E-4
THERMOSTAT
CONTROL BOARD
METER
STICK
TIG
SWITCH
BALANCE
CONTROL
POST
FLOW
LED's
LOCAL/REMOTE
SWITCH
REMOTE
RECEPTACLE
HIGH VOLTAGE/HIGH FREQUENCY
CIRCUIT
The control board passes the 115 VAC voltage to the
primary of the high voltage transformer. The secondary
of the high voltage transformer is coupled to a spark
gap generator and also to the primary winding of the
high frequency transformer. The secondary of the high
frequency transformer is in series with the rear electrode output terminal. The high frequency “spark” is
present at the electrode terminal and is transferred to
the Tig torch.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
PRECISION TIG 275
THEORY OF OPERATION
REAR GANG
POWER
SWITCH
BYPASS
AC
DC
SCR
BRIDGE
THERMOSTAT
20 VAC
HIGH VOLTAGE
TRANSFORMER
SHUNT
FAN
115 VAC
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20 VAC
ADVANCED CONTROL
PANEL RECEPTACLE
MINIMUM
OUTPUT
CONTROL
PROTECTION
BOARD
MAXIMUM
OUTPUT
CONTROL
GAS
SOLENOID
THERMOSTAT
CONTROL BOARD
METER
STICK
TIG
SWITCH
BALANCE
CONTROL
POST
FLOW
LED's
LOCAL/REMOTE
SWITCH
REMOTE
RECEPTACLE
DC WELDING OUTPUT
When the polarity switch is placed in either DC position, the
AC voltage from the main transformer secondary is applied
to the SCR bridge. The SCR bridge and choke circuits are
connected in the conventional full wave bridge and filter
configuration, resulting in a controlled DC output. Since
the choke is in series with the negative leg of the bridge
and also in series with the welding load, a filtered DC is
applied to the output terminals. The bypass board protects the internal circuitry from interference.
When the machine is in the DC mode, the background circuitry provides an added boost of voltage to the output
terminals. This circuitry is controlled by the control board.
FIGURE E.6 DC WELDING CURRENT GENERATION
CHOKE
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REAR
ELECTRODE
115 VAC
DC
FRONT
ELECTRODE
CHOKE
AC
X2
FEEDBACK
RECONNECT
PANEL
78 VAC
X1
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BOARD
HIGH FREQUENCY
TRANSFORMER
115 VAC
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WORK
POLARITY
SWITCH
115 VAC
OPTIONAL POWER
FACTOR
CORRECTION
CAPACITORS
BACKGROUND
CIRCUIT
63.5 VAC
FROM
CONTROL
BOARD
115 VAC
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E-5
FIGURE E.5 – DC WELDING OUTPUT
GATE LEADS
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E-5
PRIMARY
10
ELECTRODE
G
G
G
G
PRECISION TIG 275
DC
WORK
THEORY OF OPERATION
REAR GANG
POWER
SWITCH
115 VAC
20 VAC
20 VAC
ADVANCED CONTROL
PANEL RECEPTACLE
MINIMUM
OUTPUT
CONTROL
PROTECTION
BOARD
MAXIMUM
OUTPUT
CONTROL
FAN
115 VAC
THERMOSTAT
SHUNT
THERMOSTAT
CONTROL BOARD
METER
STICK
TIG
SWITCH
BALANCE
CONTROL
POST
FLOW
LED's
LOCAL/REMOTE
SWITCH
REMOTE
RECEPTACLE
Rotating the polarity switch to the AC position changes
the welding power circuit. One lead (X1) of the main
transformer secondary is connected to the machineʼs
output work terminal. The other secondary lead (X2) is
connected to one of the AC connections of the SCR
bridge. The electrode terminal is connected to the
other AC side of the bridge. The choke is now
electrically across the negative and positive SCR
bridge connections. With the ability of the choke to
store energy and the SCRs to turn on at the appropriate times, an AC square wave is developed and
applied to the output terminals. The bypass board protects the internal circuitry from interference.
FIGURE E.8 DC WELDING CURRENT GENERATION
CHOKE
G
G
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GAS
SOLENOID
115 VAC
DC
REAR
ELECTRODE
CHOKE
AC
FRONT
ELECTRODE
HIGH VOLTAGE
TRANSFORMER
FEEDBACK
DC
GATE LEADS
78 VAC
AC
SCR
BRIDGE
115 VAC
AC WELDING OUTPUT
BOARD
HIGH FREQUENCY
TRANSFORMER
X2
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BYPASS
X1
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WORK
POLARITY
SWITCH
115 VAC
OPTIONAL POWER
FACTOR
CORRECTION
CAPACITORS
BACKGROUND
CIRCUIT
63.5 VAC
FROM
CONTROL
BOARD
G
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E-6
FIGURE E.7 – AC WELDING OUTPUT
RECONNECT
PANEL
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E-6
ELECTRODE
G
DC
PRIMARY
10
PRECISION TIG 275
WORK
THEORY OF OPERATION
E-7
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FIGURE E.9 – SCR OPERATION
E-7
INPUT
CATHODE
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OUTPUT
ANODE
NOTE: AS THE GATE
PULSE IS APPLIED
LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.
GATE
GATE
SCR OPERATION
A silicon controlled rectifier (SCR) is a three-terminal
device used to control rather large currents to a load.
An SCR acts very much like a switch. When a gate signal is applied to the SCR, it is turned ON and there is
current flow from anode to cathode. In the ON state
the SCR acts like a closed switch. When the SCR is
turned OFF there is no current flow from anode to cathode. Thus, the device acts like an open switch. As the
name suggests, the SCR is a rectifier, so it passes current only during positive half cycles of the AC supply.
The positive half cycle is the portion of the sine wave in
which the anode of the SCR is more positive than the
cathode.
When an AC supply voltage is applied to the SCR, the
device spends a certain portion of the AC cycle time in
the ON state and the remainder of the time in the OFF
state. The amount of time spent in the ON state is controlled by the gate.
An SCR is fired by a short burst of current into the gate.
This gate pulse must be more positive than the cathode voltage. Since there is a standard PN junction
between gate and cathode, the voltage between these
terminals must be slightly greater than 0.6V. Once the
SCR has fired, it is not necessary to continue the flow
of gate current. As long as current continues to flow
from anode to cathode, the SCR will remain on. When
the anode to cathode current drops below a minimum
value, called holding current, the SCR will shut off.
This normally occurs as the AC supply voltage passes
through zero into the negative portion of the sine wave.
If the SCR is turned on early in the positive half cycle
the conduction time is longer, resulting in greater SCR
output. If the gate firing occurs later in the cycle the
conduction time is less, resulting in lower SCR output.
PRECISION TIG 275
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E-8
THEORY OF OPERATION
PROTECTION CIRCUITS
Protection circuits are designed into the PRECISION
Tig 275 machine to sense trouble and shut down the
machine before the trouble damages internal machine
components. Both thermal protection and current overload are included.
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FAN-AS-NEEDED (F.A.N.)
The PRECISION Tig 275 has the F.A.N. circuit feature,
which means that the cooling fan will operate only
while welding; then for about eight minutes after welding has stopped to assure proper machine cooling.
This helps reduce the amount of dirt and dust drawn
into the machine along with the cooling air. The cooling
fan will operate briefly when the machine power is initially turned on, and continuously while the yellow
Thermal shutdown light is lit.
THERMAL PROTECTION
This welder has thermostatic protection from excessive
duty cycles, overloads, loss of cooling and excessive
ambient temperatures. When the welder is subjected
to an overload, or inadequate cooling, the primary coil
thermostat and/or secondary coil thermostat will open.
This condition will be indicated by the illumination of
the yellow Thermal Shutdown light on the front panel.
The fan will continue to run to cool the power source.
Postflow occurs when Tig welding is shut down, but no
welding is possible until the machine is allowed to cool
and the yellow Thermal Shutdown light goes out. Once
the machine cools sufficiently, the thermostats are selfresetting. If the shutdown is caused by excessive output or duty cycle and the fan is operating normally, the
power may be left on and the reset should occur within a 15 minute period. If the fan is not functioning properly or the air intake louvers are obstructed, the input
power must be removed and the fan problem or air
obstruction corrected.
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OVERLOAD PROTECTION
The machine is electronically protected from producing
excessively high output currents. The output is limited
to 350 amps.
PRECISION TIG 275
E-8
TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION
Troubleshooting & Repair Section ................................................................................Section F
How to Use Troubleshooting Guide .......................................................................................F-2
PC Board Troubleshooting Procedures and Replacement....................................................F-3
Troubleshooting Guide...........................................................................................................F-4
Test Procedures
Meter Calibration Adjustments ......................................................................................F-19
High Frequency Circuit Disable Procedure ...................................................................F-23
Protection Board Test ....................................................................................................F-25
T1 Main Transformer Test .............................................................................................F-27
Gas (Water) Solenoid Test ............................................................................................F-31
Static SCR Test .............................................................................................................F-33
Active SCR Test.............................................................................................................F-35
Typical Output Voltage Waveform (DC Tig Mode) ........................................................F-39
Typical Output Voltage Waveform (AC Tig Mode).........................................................F-40
Typical AC Voltage Waveform - 50 AMPS (AC Tig Mode) ............................................F-41
Typical AC Voltage Waveform - 2 AMPS (AC Tig Mode) ..............................................F-42
Typical Output Voltage Waveform - 200 AMPS ( DC Tig Mode)..................................F-43
Replacement Procedures
High Voltage Transformer Removal & Replacement.....................................................F-45
Control Board Removal and Replacement....................................................................F-49
SCR Bridge Assembly Removal and Replacement ......................................................F-53
Polarity Switch Removal and Replacement ..................................................................F-57
SCR Removal and Replacement ..................................................................................F-59
Retest after Repair ........................................................................................................F-61
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F-1
PRECISION TIG 275
F-1
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F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM” (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into four main categories: Output Problems,
Function Problems, Cutting Problems and LED
Function Problems.
Step 2.
PERFORM EXTERNAL TESTS.
The second column, labeled “POSSIBLE AREAS
OF MISADJUSTMENT(S)”, lists the obvious
external possibilities that may contribute to the
machine symptom. Perform these tests/checks in
the order listed. In general, these tests can be
conducted without removing the case wraparound cover.
CAUTION
Step 3.
RECOMMENDED COURSE OF
ACTION
The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the subject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.
All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this chapter.
Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced electrical Wiring Diagrams and Schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.
CAUTION
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If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 1-888-935-3877.
WARNING
HIGH VOLTAGE/ HIGH FREQUENCY can damage test equipment.
* Perform all voltage and wave form checks with high frequency circuit OFF.
Perform High Frequency Disable Procedure.
PRECISION TIG 275
F-2
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F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK can kill.
*Have an electrician install and service
this equipment. Turn the machine
OFF before working on equipment.
Do not touch electrically hot parts.
Sometimes machine failures appear to be due to PC
Board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC Boards,
please use the following procedure:
1. Determine to the best of your technical ability that
the PC Board is the most likely component causing
the failure symptom.
2. Check for loose connections at the PC Board to
assure that the PC Board is properly connected.
3. If the problem persists, replace the suspect PC
Board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the
following procedures:
PC Board can be damaged by
static electricity.
• Remove your bodyʼs static charge
before opening the static-shielding
bag. Wear an anti-static wrist
ATTENTION
strap. For safety, use a 1 Meg ohm
Static-Sensitive resistive cord connected to a
Devices
grounded part of the equipment
Handle only at
frame.
Static-Safe
• If you donʼt have a wrist strap,
Workstations
touch an unpainted, grounded,
part of the equipment frame. Keep
touching the frame to prevent static build-up. Be sure not to touch
any electrically live parts at the
same time.
• Tools which come in contact with the PC Board must
be either conductive, anti-static or static-disipative.
F-3
• Remove the PC Board from the static-shielding bag
and place it directly into the equipment. Donʼt set the
PC Board on or near paper, plastic or cloth which
could have a static charge. If the PC Board canʼt be
installed immediately, put it back in the static-shielding
bag.
• If the PC Board uses protective shorting jumpers,
donʼt remove them until installation is complete.
• If you return a PC Board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow proper failure analysis.
4. Test the machine to determine if the failure symptom has been corrected by the replacement PC
Board.
.......................................................................................
NOTE: It is desirable to have a spare (known good) PC
Board available for PC Board troubleshooting.
NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.
5. Remove the replacement PC Board and substitute
it with the original PC Board to recreate the original
problem.
a. If the original problem does not reappear
by substituting the original board, then the
PC Board was not the problem. Continue
to look for bad connections in the control
wiring harness, junction blocks, and terminal strips.
b. If the original problem is recreated by
substitution of the original board, then
PC Board was the problem. Reinstall
replacement PC Board and test
machine.
the
the
the
the
6. Always indicate that this procedure was followed
when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the
warranty
report,
“INSTALLED
AND
SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC
Board warranty claims.
PRECISION TIG 275
TROUBLESHOOTING & REPAIR
F-4
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
The machine is dead. No weld output – no 115 VAC at the receptacle.
1. Check the input voltage. The
input voltage must match the rating plate and the voltage connection. Refer to Reconnect
Procedure in the Installation
section of this manual.
OUTPUT PROBLEMS
2. Make sure that the input power
switch is in the “ON” position.
3. Check for blown or missing
fuses in the input lines.
4. Check circuit breaker
Reset if necessary.
RECOMMENDED
COURSE OF ACTION
1. Check the input power switch,
reconnect panel and associated
wires for loose or faulty connections.
2. The input power switch may be
faulty.
3. Perform the T1 Transformer
Test.
CB1.
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F-4
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
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F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
No welding output. The 115 VAC is
present at the receptacle.
NOTE: BEFORE REPLACING A
CONTROL BOARD
If an Advanced Control Panel is
installed, remove it and replace
the Jumper in connector J-3. If
the machine functions normally,
the Advanced Process panel or
harness is defective.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-5
Observe Safety Guidelines
detailed in the beginning of this manual.
OUTPUT PROBLEMS
1. Make sure the polarity switch is
in the proper position and functioning correctly.
2. One of the thermostats may be
tripped. Allow the machine to
cool. The thermal light will be
on.
3. Make sure the welding cables,
torch and connections are in
good operating condition.
RECOMMENDED
COURSE OF ACTION
1. Check for loose or faulty connections on the heavy current carrying leads. ( Polarity switch, output choke, output terminals, etc.)
2. Check for faulty connections or a
defective thermostat. Check
leads #213 and #214. See the
Wiring Diagram. The thermal
light will be on.
3. Perform the T1 Transformer
Test.
4. Perform the SCR Bridge Test.
5. Check the output controls R1, R4
and associated wiring. See
Wiring Diagram.
6. Check the J4 connection on the
control board.
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7. The control board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
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F-6
TROUBLESHOOTING & REPAIR
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TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
No output from the machine in
either Stick or TIG modes. The
thermal light is on.
1. The welding application may
have exceeded the recommended duty cycle. Allow the fan to
cool the until the thermal light is
off.
1. One of the thermostats may be
faulty. Check or replace. See
the Wiring Diagram.
NOTE: BEFORE REPLACING A
CONTROL BOARD
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F-6
If an Advanced Control Panel is
installed, remove it and replace
the Jumper in connector J-3. If
the machine functions normally,
the Advanced Process panel or
harness is defective.
The machine does not respond (no
gas flow, no high frequency and no
open circuit voltage) when the arc
start switch or Amptrol is activated.
The thermal light is not lit.
NOTE: BEFORE REPLACING A
CONTROL BOARD
If an Advanced Control Panel is
installed, remove it and replace
the Jumper in connector J-3. If
the machine functions normally,
the Advanced Process panel or
harness is defective.
OUTPUT PROBLEMS
2. The air louvers may be blocked.
Remove the air obstruction and
allow the unit to cool.
2. Check for loose or faulty wires
on the thermostats and associated circuitry. See the Wiring
Diagram.
3. The fan motor may be faulty or
mechanically obstructed. The
fan should run when welding or
when a thermostat is open.
4. The control board may be faulty.
1. Make sure the machine is in the
TIG mode.
2. The Amptrol or arc start switch
may be defective. Check for
continuity ( zero ohms) between
pins “D” and “E” on the cable
connector when the Amptrol or
arc start is pressed.
1. Perform the Protection Board
Test.
2. Perform the T1 Transformer
Test.
3. The control board may be faulty.
3. Check the Local/Remote switch
for proper operation.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
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F-7
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
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Observe Safety Guidelines
detailed in the beginning of this manual.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The machine does not have welding
output in the Stick mode. The
machine operates correctly in the
TIG mode.
1. Check the electrode cable and
holder for loose or faulty connections.
2. Make sure the Stick/TIG switch is
in the proper position and operating correctly.
1. Check the Stick/TIG switch and
associated leads. See the Wiring
Diagram.
2. The control board may be faulty.
The machine has welding output in
the Stick mode but no output in the
TIG mode. ( no gas flow or high frequency).
1. Make sure the Stick/TIG switch
is in the proper position and
operating correctly.
1. Check the remote control receptacle and associated wiring. See
the Wiring Diagram.
SEE NOTE BELOW
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F-7
SEE NOTE BELOW
OUTPUT PROBLEMS
2. The remote control device may
be faulty.
2. Perform the Protection Board
Test.
3. Check the J11 plug on the control board.
See the Wiring
Diagram.
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4. The control board may be faulty.
The machine welds at a very low
output regardless of the current
control setting.
NOTE: BEFORE REPLACING A
CONTROL BOARD
If an Advanced Control Panel is
installed, remove it and replace
the Jumper in connector J-3. If
the machine functions normally,
the Advanced Process panel or
harness is defective.
1. If welding in the TIG mode, the
remote control device may be
defective.
2. Make certain the input line voltage is correct for the machineʼs
reconnect configuration.
3. Check the welding cables and/
or torch for loose or faulty connections.
1. Check the polarity switch and
associated leads.
2. Check the interior connections of
the heavy current carrying leads.
3. Perform the SCR Bridge Test.
4. Perform the T1 Transformer
Test.
5. Check the output current controls for proper operation.
Normal resistance is 10,000
ohms. See the Wiring Diagram.
6. The control board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
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F-8
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The machine welds at a very high
output regardless of the current
control setting.
1. If welding in the TIG mode, the
remote control device may be
defective.
1. Perform the SCR Bridge Test.
OUTPUT PROBLEMS
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NOTE: BEFORE REPLACING A
CONTROL BOARD
If an Advanced Control Panel is
installed, remove it and replace
the Jumper in connector J-3. If
the machine functions normally,
the Advanced Process panel or
harness is defective.
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Accessories plugged into the volt
receptacle do not work.
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F-8
2. Perform the T1 Transformer
Test.
3. Check the output current controls for proper operation.
Normal resistance is 10,000
ohms. See the Wiring Diagram.
4. Check leads #221 and #222
between the output shunt and
the control board. See the
Wiring Diagram.
5. The control board may be faulty
1. Make sure the accessory plug
and associated leads are in good
working condition.
2. Make certain the correct input
voltage is being applied to the
machine. (The reconnect lead
must be in the correct position.)
3. The circuit breaker CB1 may be
tripped. Reset if necessary.
1. The circuit breaker (CB1) may be
faulty.
2. Check the receptacle and associated leads for loose or faulty
connections.
3. Perform the T1 Transformer
Test.
4. Only the top part of the receptacle is electronically “Hot” all of
the time.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
The machine makes a very loud
buzzing noise in DC Stick or in DC
TIG modes. There is no current
draw from the machineʼs output terminals. (The machine is not externally loaded).
1. Inspect the output terminal insulators for cracks or signs of overheating.
OUTPUT PROBLEMS
F-9
RECOMMENDED
COURSE OF ACTION
1. Diode D1 may be shorted.
Check and replace if necessary.
2. Check the polarity switch (S2) for
proper function and correct connections.
3. Perform the SCR Bridge Tests.
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Return to Section TOC
F-9
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
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Return to Section TOC
F-10
TROUBLESHOOTING & REPAIR
F-10
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The machine output is intermittently lost. Gas flow and high frequency are also interrupted.
1. The problem may be caused by
high frequency interference.
Make sure that the machine is
grounded properly according to
the installation instructions. If
there are other high frequency
sources in the area, make certain that they are grounded properly.
1. Check for loose or faulty connections on the leads between
the remote receptacle, the protection board and plug J22 on
the protection board. See the
Wiring Diagram.
NOTE: BEFORE REPLACING A
CONTROL BOARD
If an Advanced Control Panel is
installed, remove it and replace
the Jumper in connector J-3. If
the machine functions normally,
the Advanced Process panel or
harness is defective.
No gas or water flow (with optional water solenoid) when the arc
start switch or Amptrol is activated
in the TIG mode. All other machine functions are normal.
TIG WELDING PROBLEMS
2. Make sure the Amptrol is operating properly.
3. Check to make sure that the
input voltage is correct for the
machine. Refer to Reconnect
Procedure in the Installation
section of this manual.
1. The gas (or water) supply is
either empty or not turned on.
2. The low regulator may be set too
low.
2. Check plugs J5 and J23 on the
protection board for loose or
faulty connections.
3. Perform the Protection Board
Test.
4. The control board may be faulty.
5. Check the ground connection of
the bypass/ stabilizer P.C.
Board. See the Wiring Diagram.
1. Perform the Gas Solenoid Test.
2. The control board may be faulty.
3. Check the supply hoses for
kinks or blockages.
4. The filters may be blocked.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-11
F-11
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
No high frequency. The machine is
in the TIG mode and has normal
output.
NOTE: BEFORE REPLACING A
CONTROL BOARD
If an Advanced Control Panel is
installed, remove it and replace
the Jumper in connector J-3. If
the machine functions normally,
the Advanced Process panel or
harness is defective.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
Observe Safety Guidelines
detailed in the beginning of this manual.
TIG WELDING PROBLEMS
1. If the machine is in a dirty environment with conductive contaminants, check and clean the
spark gap with a low pressure air
stream per the maintenance
instructions.
2. Check the spark gap operations
and setting. Normal is (0.015”).
Refer to the Maintenance
Section of this manual.
3. Check circuit breaker
Reset if necessary.
CB1.
4. Check connection J12 on the
control board.
RECOMMENDED
COURSE OF ACTION
1. Check the high voltage transformer (T2). The normal resistance of the secondary winding is
12.5k ohms.
WARNING
ELECTRIC SHOCK
CAN KILL. When
115 VAC is applied
to T2, a very high
voltage is developed on the secondary winding. For
assistance, call the Lincoln Electric
Service Department. 1-888-9353877.
2. Check R5, C6, C7, L2 and L3.
Replace if defective.
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3. The control board may be faulty.
The High frequency is on continuously in DC TIG or shuts off in AC
TIG.
1. None
1. Check plug J11 on the control
board. See the Wiring Diagram.
2. Check micro-switch S2A for
proper operation. See the Wiring
Diagram.
3. The control board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
High frequency “spark” is present
but weak.
1. The spark gap may be too large.
Check and reset per instructions
in the Maintenance Section of
this manual.
1. The high voltage transformer
(T2) may be faulty.
TIG WELDING PROBLEMS
2. The work and/or torch cables
may be in poor condition allowing the high frequency to “leak”
to ground. Use good quality
cables, preferably those with a
high natural rubber content and
as short as possible.
Return to Master TOC
4. Make sure the tungsten electrode is the correct size for the
process.
1. The input line voltage may be
low.
2. Check the torch and work cable
for loose or faulty connections.
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2. Capacitor C6 may be faulty.
3. The high frequency transformer
(T3) may be faulty.
3. If helium shielding gas is being
used, reduce the percentage of
helium.
Poor arc starting in the DC TIG
mode.
Return to Section TOC
F-12
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
Return to Section TOC
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Return to Section TOC
F-12
1. Check the J11 plug on the control board. See Wiring Diagram.
2. Check the background resistor
R7. Normal resistance is 20
ohms.
3. Check the background diode
bridge.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
The high frequency “spark” is present at the tungsten electrode, but
the operator is unable to establish
a welding arc. The machine has a
normal open circuit voltage. Refer
to Technical Specifications in the
Installation section.
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F-13
Return to Master TOC
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Observe Safety Guidelines
detailed in the beginning of this manual.
TIG WELDING PROBLEMS
1. The torch may be faulty. Check
or replace.
2. The current control may be set
too low.
3. The tungsten electrode may be
contaminated.
Replace or
sharpen.
4. The electrode may be too large
for the process.
RECOMMENDED
COURSE OF ACTION
1. Check spark gap adjustment.
See the Maintenance Section.
2. This may be a welding procedure problem. Contact the
Lincoln Service Department,
Technical Sales group at 1-888935-3877.
5. If a helium blend is being used
as a shielding gas, reduce the
percentage of helium.
6. Check the welding cables for
loose or faulty connections.
When AC TIG welding, the arc is
erratic and there is a loss of “cleaning” of the work piece.
Return to Section TOC
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-13
1. The tungsten electrode may be
small for the process. Use a larger diameter tungsten or a pure
tungsten.
2. If a helium blend is used as a
shielding gas, reduce the percentage of helium.
1. Check components R5 and C7 in
the high voltage transformer primary circuit.
2. Perform the SCR Bridge Test.
3. Check the balance control setting.
Arc “pulsates” in AC polarity. DC
TIG is OK.
1. Check that the machine controls
are set correctly for the process.
CAUTION
1. Micro switch S2A may be faulty.
It should “open” in the AC mode.
See the Wiring Diagram.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
Return to Master TOC
Return to Section TOC
Return to Master TOC
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F-14
TROUBLESHOOTING & REPAIR
The stick electrode “blasts-off”
when touched to the work piece.
NOTE: BEFORE REPLACING A
CONTROL BOARD
Return to Master TOC
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POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
1. Welding current may be too high
for the electrode size. Reduce
current control setting or use a
larger diameter electrode.
1. Perform the SCR Bridge Test.
1. Check the work and electrode
cables for loose or poor connections.
1. Check the polarity switch for
excessive wear or faulty connections.
STICK WELDING PROBLEMS
2. The control board may be faulty.
If an Advanced Control Panel is
installed, remove it and replace
the Jumper in connector J-3. If
the machine functions normally,
the Advanced Process panel or
harness is defective.
Variable or sluggish welding arc
when welding in the Stick mode.
Return to Section TOC
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
F-14
2. The welding cables may be too
small or too long to permit the
desired current to flow.
3. The welding current may be set
too low.
2. Check the interior heavy current
carrying leads and connections.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
The meter does not display V (volt)
or minimum current.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
Observe Safety Guidelines
detailed in the beginning of this manual.
1. Check that either the advanced
control board or jumper plug is in
J3 on the control board.
NOTE: BEFORE REPLACING A
CONTROL BOARD
F-15
RECOMMENDED
COURSE OF ACTION
1. Check R1 potentiometer and
associated leads between the
control board and plug J9. See
the Wiring Diagram.
2. The control board may be faulty.
If an Advanced Control Panel is
installed, remove it and replace
the Jumper in connector J-3. If
the machine functions normally,
the Advanced Process panel or
harness is defective.
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Return to Section TOC
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Return to Section TOC
F-15
Return to Master TOC
Return to Section TOC
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
Return to Master TOC
Return to Section TOC
F-16
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
The AC wave balance control does
not function properly.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
Observe Safety Guidelines
detailed in the beginning of this manual.
FUNCTION PROBLEMS
1. The AC wave balance control is
operational only in the TIG mode.
Return to Master TOC
RECOMMENDED
COURSE OF ACTION
1. Check the AC balance control
(R2) and associated leads for
loose or faulty connections. See
the Wiring Diagram.
2. The control board may be faulty.
NOTE: BEFORE REPLACING A
CONTROL BOARD
Return to Section TOC
F-16
If an Advanced Control Panel is
installed, remove it and replace
the Jumper in connector J-3. If
the machine functions normally,
the Advanced Process panel or
harness is defective.
1. If an advanced control board is
installed, check dip switch setting on the board.
See
Installation Manual.
1. Check plug J3 on the control
board. Either the jumper plug or
the advanced control board must
be plugged into J3.
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Gas pre-flow and post-flow time is
too long.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
F-17
TROUBLESHOOTING & REPAIR
Return to Master TOC
Return to Section TOC
Return to Master TOC
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The meter does not display V (volt)
or minimum current.
1. Toggle the display switch. It may
be dirty.
1. Check the leads between the
display switch and the control
board. See the Wiring Diagram.
FUNCTION PROBLEMS
2. The display switch may be faulty.
3. The control board may be faulty.
NOTE: BEFORE REPLACING A
CONTROL BOARD
If an Advanced Control Panel is
installed, remove it and replace
the Jumper in connector J-3. If
the machine functions normally,
the Advanced Process panel or
harness is defective.
The meter does not light up. Other
machine functions are OK.
Return to Section TOC
F-17
1. None
1. Check the leads and connections between the meter and the
control board. See the Wiring
Diagram.
2. The meter may be faulty.
NOTE: BEFORE REPLACING A
CONTROL BOARD
3. The control board may be faulty.
If an Advanced Control Panel is
installed, remove it and replace
the Jumper in connector J-3. If
the machine functions normally,
the Advanced Process panel or
harness is defective.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
PRECISION TIG 275
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
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Return to Section TOC
F-18
NOTES
PRECISION TIG 275
F-18
Return to Master TOC
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Return to Section TOC
F-19
TROUBLESHOOTING & REPAIR
METER CALIBRATION ADJUSTMENTS
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This test will help aid the technician in meter circuits calibration.
MATERIALS NEEDED
Return to Master TOC
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Voltmeter/Ohmmeter
3/8” Nut Driver
Wiring Diagram
PRECISION TIG 275
F-19
TROUBLESHOOTING & REPAIR
Return to Master TOC
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F-20
F-20
METER CALIBRATION ADJUSTMENTS (continued)
FIGURE F.1 – TRIMMER
306
TRIMMER
301
303
304B
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302
JUMPER
Note:
The Precision TIG meter circuits are factory calibrated for the accuracy of the ammeter and voltmeter and
should not need adjustment. However, the factory trimmers are accessible inside the control box:
CALIBRATION CHECK
The Digital Meter Calibration Trimmer is located on the
back of the meter housing near the right side connector plug (with two leads and a jumper attached). This
trimmer adjusts calibration of the meter used for both
ammeter and voltmeter readings, so its calibration
should be checked first, as follows:
1. Set the TIG mode and, without closing the arc start
switch, preset the panel maximum output control so
the panel digital meter reads 200 amps.
2. Using a DC (avg.) digital test voltmeter with at least
0.5% accuracy at 1,000v, measure the DC voltage
between (+) pin 2 (lead #303) and (-) pin 1 (lead
#306) at the right side meter plug (nearest the trimmer).
3. This voltage should match the 200A panel meter
reading (as 0.200v, or 200mv) within 1%. If not,
adjust the trimmer so that the panel meter accuracy
is corrected. (See Figure F.1)
PRECISION TIG 275
TROUBLESHOOTING & REPAIR
F-21
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METER CALIBRATION ADJUSTMENTS (continued)
FIGURE F.2 - CONTROL BOARD TRIMMERS
R-2
C157
XX
XX
X
X
Return to Master TOC
X
X
X
1. Locate the Ammeter Calibration Trimmer (R5). See
Figure F.1.
Return to Master TOC
C17
X11
X4
Q23
Y1
Q26
X17
R257
R258
R259
X15
Q27
C127
R293
R336
C151
R290
DZ12
C110
R291
R292
C126
R250
DZ11
C77
C109
C108
R254
R255
R253
R287
R288
R289
R136
C128
R294
C107
C125
R256
X16
R206
R207
R212
C93
R135
R295
R296
R1
C16
R39
R171
R172
R251
DZ10
2. Set to TIG mode with DC polarity and LOCAL control. Without closing the arc start switch, preset the
maximum output panel control so the panel digital
meter reads approx. 200 amps.
3. Using a DC (AVG.) test ammeter with at least 1%
accuracy at up to 300 amps, connect it to measure
the DC current through a short weld cable shorting
out the work(+) to electrode(-) studs on the front stud
panel. Remove the TIG torch if connected.
4. Close the arc start switch just long enough to compare the panel meter reading to that of the test
ammeter. The short circuit current readings should
match within 4% +/-2A. If not, adjust the trimmer so
that the panel meter accuracy is corrected.
XX
XX
J9
J8
X
D59
D55
D83
C158
D58
X
X
X
X
X
X
X
X
XXX X XX
J10
C155
R338
R339
DZ20
C154
DZ18
XX
XX
C153
DZ19
DZ16
R335
C150
R337
C152
DZ17
AMMETER CALIBRATION PROCEDURE
Return to Section TOC
R252
C123
J7
X
R176
R211
C92
C149
C143
R7
J6
J5A
XX
XX
R173
R174
R208
C91
R209
R210
R284
R285
R286
R274
R312
C144
R313
C156
DZ21
D65
R249
C120
R277
R278
R279
R315
R316
R317
R318
R321
R361
D54
C106
R282
R275
R276
R6
R314
XX
XX
C57
R248
D67
R134
R175
R326
R327
R328
R329
R330
R331
R332
R334
R333
C141
DZ9
C64
X
X
X
X
X
X
X
C62
R324
C148
D82
R310
C142
D80
C140
R309
D81
C105
Q28
R267
R5
OCI7
R245
R270
R271
R272
R273
C119
R311
R357
R246
R247
R323
D73
D72
R268
D90
R351
XXX
XXX
D79
R307
R308
R-5
R244
C102
R269
C90
DZ23
Q25
X
X
X
X
X
X
X
X
X
XXX
C122
C147
R281
C88
C104
C165
DZ15
R364
R243
Q24
C86
C103
R358
D89
C89
C87
R132
R133
C61
C146
D64
C63
C76
R205
R170
C75
D34
R359
Q21
C60
C59
C145
C73
R204
C85
R4
X14
R169
D23
C36
R130
R131
Q20
J2
R168
D63
R104
C58
R128
C74
X19
D62
C139
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C71
R202
OCI6
Q18
Q19
R356
DZ6
R161
R162
C70
R103
R3
D42
C56
R125
R167
R123
R124
R163
R164
C72
R203
R165
R166
X13
R119
Q17
R129
R127
R122
D41
Return to Section TOC
R97
R98
R126
C55
R75
R76
D21
R280
C46
DZ22
D31
D30
R121
R92
DZ25
R72
D20
R101
R102
R320
R322
R325
R120
C48
R99
R100
R319
R94
C45
C35
R42
R79
R107
R80
R81
R82
R105
R106
C49
R77
R78
D22
D24
Q16
C47
R95
R96
DZ4
C20
D11
R74
C121
R93
X10
R91
R67
C32
C31
R64
R65
R61
C29
C30
D19
C18
C19
R73
C14
C34
R2
D10
R40
R41
C15
R283
C124
R63
R62
X3
R34
R35
R36
R68
R69
R70
R71
C33
X2
D7
R60
C28
C44
Q9
R30
R31
R32
R66
Q8
D2
DZ24
R38
R29
C13
X7
D5
DZ2
R26
C12
R28
R11
D6
C5
C4
R12
R33
R37
C3
R27
R10
Q14
Return to Section TOC
F-21
R352
R353
C159
XXX X XX
VOLTMETER CALIBRATION PROCEDURE
1. Locate the Voltmeter Calibration Trimmer (R2) on
the control board. See Figure F1.
2. To prevent maximum OCV output, disconnect the
SCR gate lead plug from receptacle J4.
3. Set to TIG mode with DC- polarity without closing the
arc start switch.
4. Using a DC (avg.) test voltmeter with at least 1%
accuracy at up to 100 volts, connect it across the
work (+) and electrode (-) studs on the front stud
panel. Remove the TIG torch, if connected.
5. Press the display panel switch to V (volts) position,
then close the arc start switch just long enough to
compare the panel meter reading to that of the test
volt meter. The open circuit voltage readings (about
50 VDC) should match within 3% +/-1v. If not, adjust
the trimmer so that the panel meter accuracy is corrected.
NOTE: If the Arc Start switch is held closed longer than
about 15 seconds, the machine will shut down
to protect internal holding resistor from overheating.
PRECISION TIG 275
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F-22
NOTES
PRECISION TIG 275
F-22
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F-23
TROUBLESHOOTING & REPAIR
HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will disable the high frequency circuit allowing the technician to take voltage measurements without the possibility of high frequency damage to his test equipment.
MATERIALS NEEDED
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3/8” Nut Driver
Electrical Insulating Tape
PRECISION TIG 275
F-23
TROUBLESHOOTING & REPAIR
F-24
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HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE (continued)
FIGURE F.2 – SPARK GAP ASSEMBLY
VIEWED FROM ABOVE
LEADS
ATTACH
HERE
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.015 Spark Gap
MO
DE
MIN
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PROCEDURE
1. Remove the input power to the PRECISION
TIG 275 machine.
2. Using the 3/8” nut driver, remove the right
side case cover.
3. Locate the Spark Gap Assembly at the lower
rear right side of the machine. See Figure
F.2.
6. When voltage testing and scope measurements are complete, reconnect the three
leads to the Spark Gap Assembly.
7. Reassemble the right side case cover.
4. Carefully remove the three leads from the
Spark Gap Assembly. See Figure F.2.
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5. Insulate the leads from each other and from
the case.
PRECISION TIG 275
F-24
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F-25
TROUBLESHOOTING & REPAIR
PROTECTION BOARD TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the Protection board is functioning properly.
MATERIALS NEEDED
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3/8” Nut Driver
Voltmeter/Ohmmeter (Multimeter)
Tig 275 Wiring Diagrams
PRECISION TIG 275
F-25
TROUBLESHOOTING & REPAIR
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F-26
PROTECTION BOARD TEST (continued)
1. Using a 3/8” nut driver, remove the case top
and sides.
2. Check that P5 is connected to J5, not J5A.
See the Wiring Diagram.
3. Unplug P5 from the control board. Measure
resistance at P5. See Figure F3. See tables
below.
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Table F.1
RESISTANCE BETWEEN
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READING
TRIGGER
Pins 5 & 7
Open when trigger open, short when trigger closed.
B-A
Pins 2 & 3
Decreasing from 10K to 0 when working on remote
amptrol from min. to max.
B-C
Increasing from 0 to 10K when working on remote
amptrol from min. to max.
Pins 3 & 4
4. If the readings above are OK, the protection
board is OK. If not, go to step 5.
5. Unplug P23 from the protection board and
check continuity from P23 to P5. If OK, go
to step 6. See Wiring Diagram.
6. Unplug P22 from protection board. Measure
resistance at P22. See Tables.
7. If readings below are OK, protection board
is bad.
8. If readings below are wrong, remote amptrol
or remote receptacle is bad.
Table F.2
RESISTANCE BETWEEN
READING
TRIGGER
Pins 3 & 6
Open when trigger open, short when trigger closed.
B-A
Pins 1 & 4
Decreasing from 10K to 0 when working on remote
amptrol from min. to max.
B-C
Increasing from 0 to 10K when working on remote
amptrol from min. to max.
Pins 1 & 2
FIGURE F.3 – Plug J5 (viewed from pin end)
1
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F-26
8
2
7
3
6
4
5
Jumper
PRECISION TIG 275
TROUBLESHOOTING & REPAIR
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F-27
T1 MAIN TRANSFORMER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will determine if the correct voltage is being applied to the primary of the
T1 transformer and also if the correct voltages are being induced on the secondary windings of the transformer.
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MATERIALS NEEDED
3/8” Nut Driver
Voltmeter/Ohmmeter (Multimeter)
Tig 275 Wiring Diagrams
PRECISION TIG 275
F-27
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F-28
TROUBLESHOOTING & REPAIR
T1 MAIN TRANSFORMER TEST (continued)
F-28
Figure F.4 Plug J11
G3909
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263
214
204
210
Plug
J11
209
201
265
262
TEST PROCEDURES
1. Using the 3/8” nut driver, remove the two screws
from the front control panel. Carefully lower the
panel. This will allow access to the control board.
2. Locate plug J11 on the control board. See Figure
F.4.
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WARNING
ELECTRIC SHOCK can kill.
*With input power ON, there are high voltages inside
the machine. Do not reach
into the machine or touch any
internal part.
...........................................................................
3. Carefully apply the correct input power making certain the reconnect configuration at the reconnect
panel is correct for the input voltage applied. Turn
the Precision TIG 275 ON.
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Plug
J11
266
220
270
253
4. Using the voltmeter, carefully test for the correct
transformer secondary voltages per Table F.3.
252
269
271
213
5. Carefully check for 63.5 VAC at leads 267 to lead
268. Lead 268 is located at the background rectifier.
Note: Lead 267 is located at resistor R8. See Wiring
Diagram.
6. Carefully check for 115 VAC at leads 231 to 232.
Note: Lead 231 is located at the 115 VAC receptacle on the back of the machine. Lead 232 is
located at the 15 amp circuit breaker CB1.
7. If all of the secondary voltages are correct, the T1
transformer is functioning properly.
a. If all of the secondary voltages are missing or
incorrect, make certain that the correct input
voltage is being applied to the correct primary
leads. See Table F.3.
b. If the correct input voltage is being applied to
the primary leads and any or all of the secondary voltages are incorrect, the T1 transformer may be faulty. Also check the leads for
broken or loose connections between plug J11
and the T1 transformer.
8. Replace the case side covers.
PRECISION TIG 275
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F-29
TROUBLESHOOTING & REPAIR
T1 MAIN TRANSFORMER TEST (continued)
Table F.3 - T1 Transformer Voltages
TEST POINTS
ACCEPTABLE VOLTAGES
PLUG J11 PIN 8 (LEAD W209)
TO
PLUG J11 PIN 16 (LEAD R210)
20 VAC
SECONDARY WINDINGS
SECONDARY VOLTAGES
PLUG J11 PIN 7 (LEAD #201)
TO
PLUG J11 PIN 15 (LEAD #204)
X1 TO X2
PRIMARY WINDINGS
18VAC
PRIMARY VOLTAGES
208 VAC
230 VAC
460 VAC
H1 TO H2
H1 TO H3
H1 TO H4
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NOTE: If the input voltages vary, the secondary voltages will vary accordingly.
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78 VAC
Based on 208/230/460 models. For other voltage models refer to appropriate Wiring Diagram.
PRECISION TIG 275
F-29
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F-30
NOTES
F-30
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F-31
TROUBLESHOOTING & REPAIR
GAS (WATER) SOLENOID TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will help the technician to determine if the solenoid is receiving the correct
voltage also if the solenoid is functional.
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MATERIALS NEEDED
3/8” Nut Driver
Voltmeter/Ohmmeter (Multimeter)
Isolated 115 VAC Power Supply
PRECISION TIG 275
F-31
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F-32
TROUBLESHOOTING & REPAIR
GAS (WATER) SOLENOID TEST (continued)
TEST PROCEDURE
1. Remove input power to the Precision TIG
275 machine.
2. Remove the left case side.
3. Perform the High Frequency Circuit
Disable Procedure.
4. Locate the gas solenoid in the torch connection box.
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5. Put the mode switch S3 in the 2-Step TIG
position.
WARNING
ELECTRIC
KILL.
SHOCK
CAN
*With input power ON, there
are high voltages inside the
machine. Do not reach into
the machine or touch any
internal part.
8. If voltage is present at leads #231A and
#235 and the solenoid does not activate, the
solenoid may be defective. The solenoid
can be further checked by removing leads
#231A and #235 from the solenoid and
applying the external isolated 115 VAC supply to the solenoid terminals. If the solenoid
activates with the external supply but not
when powered by the control board, the
problem may be in the control board. If you
hear solenoid activation but there is still no
gas flow, check for restrictions in the line.
9. When the test is complete, replace leads
#231A and #235.
10. Reassemble the two leads previously
removed in the High Frequency Circuit
Disable Procedure.
11. Reassemble the left case side.
12. If a water solenoid is used, it can be tested
using the same procedures.
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6. Apply the correct input power to the TIG 275.
7. Activate the torch trigger and check for
approximately 115 VAC at the solenoid leads
(#231A and # 235). If the correct voltage is
present, the solenoid should activate and
gas should flow.
PRECISION TIG 275
F-32
TROUBLESHOOTING & REPAIR
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F-33
STATIC SCR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The SCR test is a quick check to determine if an SCR is “shorted” or “leaky”. See machine
waveform section for normal and abnormal SCR waveforms.
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MATERIALS NEEDED
3/8” Nut Driver
Analog Ohmmeter (Multimeter)
Tig 275 Wiring Diagrams
SCR Heatsink Assembly Drawing
PRECISION TIG 275
F-33
TROUBLESHOOTING & REPAIR
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F-34
F-34
STATIC SCR TEST (continued)
Figure F.5 - Plug J4 Location
G3909
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Plug
J4
TEST PROCEDURE
Removal and Replacement.
1. Remove main supply power to the PRECISION TIG 275 and remove the case top and
left side.
4. Repeat Step #3 testing SCR2, SCR3 and
SCR4.
2. Locate and remove plug J4 from the control
board. See Figure F.5.
5. To further check the SCRʼs functions, use an
SCR tester and proceed to the Active SCR
Test.
3. Using an analog ohmmeter, test the resistance from anode to cathode of SCR1.
Reverse the meter leads and check from
cathode to anode of SCR1. See Figure F.5. If
a low resistance is indicated in either direction, SCR1 is faulty. Replace the SCR Bridge
Assembly. See SCR Bridge Assembly
NOTE: Also check diode D1.
6. Replace plug J4 on the control board.
7. Replace the case top and left side.
Figure F.6 - SCR TEST POINTS
LIFT BAIL STABILIZER
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DIODE D1
SCR1 ANODE
SCR4 CATHODE
SCR3 / SCR4 ANODE
PRECISION TIG 275
SCR3 CATHODE
SCR2 ANODE
SCR1 / SCR2 CATHODE
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F-35
TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
Return to Master TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The Active SCR test will determine if the device is able to be gated “ON” and conduct current from anode to cathode.
MATERIALS NEEDED
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3/8” Nut Driver
TIG 275 Wiring Diagrams
An SCR Tester as Outlined in this Procedure
PRECISION TIG 275
F-35
TROUBLESHOOTING & REPAIR
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F-36
ACTIVE SCR TEST (continued)
Figure F.7 - Plug J4 Location
G3909
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Plug
J4
TEST PROCEDURE
1. Remove main supply power to the PRECISION TIG 275 machine.
2. Locate and remove plug J4 from the control
board. See Figure F.7.
5. Battery Test - Check the battery by shorting
leads (A) and (C) and then close switch SW1. Replace the battery if voltage is less than
4.5 volts.
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3. Perform the following test for all four SCRs.
See Figure F.8.
4. Construct the circuit outline in Figure F.8.
One 6V lantern battery can be used. Resistor
values are +\- 10%. The voltmeter scale
should be approximately 0-5 or 0-10 volts.
PRECISION TIG 275
F-36
TROUBLESHOOTING & REPAIR
Figure F.8 - Active SCR Test Set-Up
R2
SW1
+
6 volt
lantern
battery
R1
V
A
SCR
under
test
C
SW2
G
R1 = 4 ohms / 10 watts
R2 = 3 ohms / 10 watts
Resistor values are +/- 10%
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F-37
ACTIVE SCR TEST (continued)
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F-37
PRECISION TIG 275
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F-38
TROUBLESHOOTING & REPAIR
F-38
ACTIVE SCR TEST (continued)
Figure F.9 - SCR Gate Locations
LIFT BAIL STABILIZER
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DIODE D1
SCR3 / SCR4 ANODE
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6. Connect SCR into the test circuit as shown
in Figure F.8. (A)Lead to anode (C) lead to
cathode and (G) lead to the gate.
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SCR1 ANODE
SCR4 CATHODE
7. Close switch SW-1 (Switch SW-2 should be
open). The voltmeter should read zero. If
the voltmeter reads higher than zero, the
SCR is shorted.
8. With switch SW-1 closed, close switch SW-2
for two seconds and release. The voltmeter
should read 3 to 6 volts before and after
switch SW-2 is released. If the voltmeter
does not read, or reads only while SW-2 is
depressed, the SCR or battery is defective.
(Repeat Battery Test Procedure described in
Step 5.)
SCR3 CATHODE
SCR2 ANODE
SCR1 / SCR2 CATHODE
9. Open switch SW-1, disconnect the gate lead
(G) and reverse the (A) and (C) leads on
the SCR. Close switch SW-1. The voltmeter
should read zero. If the voltage is higher
than zero, the SCR is shorted.
10. Replace any SCRs that do not pass the
test. See SCR Bridge Assembly
Removal and Replacement.
11. Replace plug J4 on the control board.
12. Replace the case sides and top.
PRECISION TIG 275
TROUBLESHOOTING & REPAIR
DC - TIG MODE
HIGH VOLTAGE/ HIGH FREQUENCY can damage test equipment.
Perform all voltage and waveform checks with high frequency circuit OFF.
Perform High Frequency Disable Procedure.
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0V
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20V
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F-39
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED TO 2 AMPS
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F-39
5 ms
AC BALANCE CONTROL IN “AUTO”
OUTPUT CONTROL AT MINIMUM
This is the typical AC output voltage
waveform generated from a properly
operating machine. Note that each vertical division represents 20 volts and
that each horizontal division represents
5 milliseconds in time.
NOTE: Scope probes connected at
machine output terminals: (+) probe to
electrode, (-) probe to work.
SCOPE SETTINGS
Volts/Div......................20V/Div.
Horizontal Sweep......5 ms/Div.
Coupling..............................DC
Trigger..........................Internal
PRECISION TIG 275
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED TO 200 AMPS
AC - TIG MODE
HIGH VOLTAGE/ HIGH FREQUENCY can damage test equipment.
Perform all voltage and waveform checks with high frequency circuit OFF.
Perform High Frequency Disable Procedure.
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0V
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20V
5 ms
AC BALANCE CONTROL IN “AUTO”
This is the typical AC output voltage
waveform generated from a properly
operating machine. Note that each vertical division represents 20 volts and
that each horizontal division represents
5 milliseconds in time. The machine
was loaded with a resistance grid bank.
NOTE: Scope probes connected at
machine output terminals: (+) probe to
electrode, (-) probe to work.
SCOPE SETTINGS
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F-40
TROUBLESHOOTING & REPAIR
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F-40
Volts/Div......................20V/Div.
Horizontal Sweep......5 ms/Div.
Coupling..............................DC
Trigger..........................Internal
PRECISION TIG 275
TROUBLESHOOTING & REPAIR
AC - TIG MODE
HIGH VOLTAGE/ HIGH FREQUENCY can damage test equipment.
Perform all voltage and waveform checks with high frequency circuit OFF.
Perform High Frequency Disable Procedure.
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0V
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20V
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F-41
TYPICAL AC VOLTAGE WAVEFORM - MACHINE LOADED TO 50 AMPS
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F-41
5 ms
AC BALANCE CONTROL IN “AUTO”
This is the typical DC (+) output voltage
waveform generated from a properly
operating machine. Note that each vertical division represents 20 volts and
that each horizontal division represents
5 milliseconds in time.
NOTE: Scope probes connected at
machine output terminals: (+) probe to
electrode, (-) probe to work.
SCOPE SETTINGS
Volts/Div......................20V/Div.
Horizontal Sweep......5 ms/Div.
Coupling..............................DC
Trigger..........................Internal
PRECISION TIG 275
TROUBLESHOOTING & REPAIR
AC - TIG MODE
HIGH VOLTAGE/ HIGH FREQUENCY can damage test equipment.
Perform all voltage and waveform checks with high frequency circuit OFF.
Perform High Frequency Disable Procedure.
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0V
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20V
5 ms
AC BALANCE CONTROL IN “AUTO”
OUTPUT CONTROL AT MINIMUM.
This is the typical AC output voltage
waveform generated from a properly
operating machine. Note that each vertical division represents 20 volts and
that each horizontal division represents
5 milliseconds in time.
NOTE: Scope probes connected at
machine output terminals: (+) probe to
electrode, (-) probe to work.
SCOPE SETTINGS
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F-42
TYPICAL AC VOLTAGE WAVEFORM - MACHINE LOADED TO 2 AMPS
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F-42
Volts/Div......................20V/Div.
Horizontal Sweep......5 ms/Div.
Coupling..............................DC
Trigger..........................Internal
PRECISION TIG 275
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F-43
TROUBLESHOOTING & REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED TO 200 AMPS
DC - TIG MODE
HIGH VOLTAGE/ HIGH FREQUENCY can damage test equipment.
Perform all voltage and waveform checks with high frequency circuit OFF.
Perform High Frequency Disable Procedure.
0V
20V
5 ms
This is the typical AC output voltage
waveform generated from a properly
operating machine. Note that each vertical division represents 20 volts and
that each horizontal division represents
5 milliseconds in time.
NOTE: Scope probes connected at
machine output terminals: (+) probe to
electrode, (-) probe to work.
NOTE: AC balance control set at
“Balanced” position.
SCOPE SETTINGS
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F-43
Volts/Div......................20V/Div.
Horizontal Sweep......5 ms/Div.
Coupling..............................DC
Trigger..........................Internal
PRECISION TIG 275
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F-44
NOTES
PRECISION TIG 275
F-44
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F-45
TROUBLESHOOTING & REPAIR
HIGH VOLTAGE TRANSFORMER REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the high voltage
transformer.
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MATERIALS NEEDED
3/8” Nut Driver
7/16” Nut Driver
Phillips Head Screwdriver (Off-set)
Wire Cutters
PRECISION TIG 275
F-45
TROUBLESHOOTING & REPAIR
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F-46
F-46
HIGH VOLTAGE TRANSFORMER
REMOVAL AND REPLACEMENT (continued)
Figure F.10 - High Voltage Transformer
MOUNTING SCREW
INSULATORS
MOD
E
MIN
IMU
M
DIS
PLA
Y
LOC
AL
AC
BALA
BAL
ANC
NCE
E
!
REM
OTE
OTE
WA
RN
ING
MAX
IMU
M
ON
POW
ER
DC
OFF
AC
~
POS
TFL
LIN
CO
LN
ELE
CTR
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OW
OW
SQ
UAR
E WA
fea
turi
VE
ng
POW
...
DC
IC
PR
MIC ER
SO
UR
RO
CE
STA
+
TEC
EC
ISIO
RT
HNO
LOG
Y
DO
WHINOT
LE SWI
WEL TCH
DING
NT
IG
TM
THE
LINC
OLN
ELE
TM
37
CTR
IC
COM
PAN
5
Y CLE
VEL
AND
, OHIO
USA
HIGH VOLTAGE
TRANSFORMER
REMOVAL PROCEDURE
1. Remove input power to the TIG 275
machine.
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Return to Section TOC
2. Using the 3/8” nut driver, remove the case
sides and top.
3. Using a 3/8” nut driver, remove the case
back.
Note: The case back will be connected to
the fan assembly and will have leads
connected to it, so just set aside.
4. Cut any necessary cable ties.
5. Disconnect black lead from the high voltage
transformer connecting to leads 231D and
231E.
6. Disconnect the black lead from the high
voltage transformer connecting to the
capacitor. It may be necessary to cut lead.
Return to Master TOC
Return to Section TOC
7. Using a 7/16” nut driver disconnect heavy
black leads S and F. See Figure F.11.
8. Using a 3/8” nut driver, remove the screw
securing the spark gap assembly box. See
Figure F.11. This will allow access to the
high voltage transformer mounting screws.
9. Using an off set phillips head screw driver,
remove the four high voltage transformer
mounting screws. Note insulator positioning. See Figure F.10.
10. Remove the high voltage transformer.
REPLACEMENT PROCEDURE
1. Replace the high voltage transformer.
2. Secure the new transformer using the four
phillips head mounting screws. Refer to
Figure F10 for insulator location.
3. Replace the 3/8” screw securing the spark
gap assembly box.
4. Reconnect leads S and F.
5. Reconnect high voltage transformer lead to
the capacitor.
6. Reconnect leads 231D and 231E to single
black lead.
7. Replace any necessary cable ties.
8. Secure the case back using the 3/8” mounting bolts previously removed.
9. Replace the case sides and top.
PRECISION TIG 275
TROUBLESHOOTING & REPAIR
F-47
HIGH VOLTAGE TRANSFORMER
Return to Master TOC
Return to Section TOC
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F-47
REMOVAL AND REPLACEMENT (continued)
Figure F.11 - 3/8” Screw & Leads S and F Locations
MO
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M
DISP
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AC
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5
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AN
Return to Master TOC
Return to Section TOC
Return to Master TOC
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D,
OH
IO
US
A
SPARK GAP
ASSEMBLY BOX
3/8" SCREW
PRECISION TIG 275
LEADS S & F
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F-48
NOTES
PRECISION TIG 275
F-48
Return to Master TOC
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F-49
TROUBLESHOOTING & REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the control board.
MATERIALS NEEDED
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
3/8” Nut Driver
Phillips Head Screwdriver
Wire Cutters
PRECISION TIG 275
F-49
Return to Master TOC
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F-50
TROUBLESHOOTING & REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
Figure F.12 - Case Front Screw Location
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CASEFRONT SCREWS
MO
DE
MI
NIM
UM
DIS
PL
AY
AY
LO
CA
AC
BAL
BA
LA
AN
NC
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L
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WA
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MA
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PO
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fea
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IG
Return to Master TOC
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REMOVAL PROCEDURE
TM
TM
37
5
EL
EC
TR
IC
CO
MP
AN
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EV
EL
AN
D,
OH
IO
US
A
REPLACEMENT PROCEDURE
1. Remove input power to the TIG 275
machine.
2. Using a 3/8” nut driver, remove the two
screws from the top of the case front. See
Figure F.12.
3. The top front control box cover can now be
tilted forward to gain access to the control
board and its plugs.
4. From left to right, label and disconnect plugs
J4, J5, J6, J8, J9, J10, J11, J12. See Figure
F.13.
5. Cut any necessary cable ties.
Return to Master TOC
CH
NO
LO
GY
DO
WH NO
ILET SW
WE ITC
LD H
ING
TH
E LIN
CO
LN
Return to Section TOC
SO
UR
RO
CE
ST
AR
T
1. Replace the control board.
2. Mount the new control board in its proper
position using the eight phillips head mounting screws.
3. Replace any necessary cable ties.
4. Reconnect plugs previously removed from
the control board.
5. Secure the control box assembly using the
two 3/8” mounting screws previously
removed.
6. Using a phillips head screwdriver, remove
the eight P.C. Board mounting screws. See
Figure F.13.
7. Carefully maneuver the control board out of
the front of the machine.
PRECISION TIG 275
F-50
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F-51
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING & REPAIR
Figure F.13 - Control Board Plug Locations
J4
J5
J6
J8
J9
PRECISION TIG 275
J10
J11
J12
F-51
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F-52
NOTES
PRECISION TIG 275
F-52
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F-53
TROUBLESHOOTING & REPAIR
SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the SCR bridge
for maintenance or replacement.
Return to Master TOC
Return to Section TOC
Return to Master TOC
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MATERIALS NEEDED
3/8” Nut Driver
1/2” Nut Driver
7/16” Nut Driver
Pliers
Crimp Wire Cutters
PRECISION TIG 275
F-53
Return to Master TOC
Return to Section TOC
F-54
TROUBLESHOOTING & REPAIR
SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT (continued)
REMOVAL PROCEDURE
1. Remove input power to the TIG 275
machine.
2. Using the 3/8” nut driver, remove the case
sides and top.
3. Label and cut leads G1 and G2. See
Figure F.14.
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4. Label and cut leads G3 and G4. See
Figure F.14.
5. Remove the 1/2 “ nut securing leads B and
217. See Figure F.14.
6. Using a 7/16” nut driver, disconnect Pos.
lead and lead 218.See Figure F.14.
7. Using a 1/2” nut driver, disconnect Pos.
lead and lead 218. See Figure F.14.
8. Using a 1/2” nut driver, remove lead 216
and aluminum lead X1 connecting to the
main transformer. See Figure F.14. Note
washer placement upon removal.
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9. Using a 1/2” nut driver, disconnect lead
220A and shunt from the output bridge. See
Figure F.14.
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F-54
REPLACEMENT PROCEDURE
1. Replace the SCR bridge.
2. Replace the four SCR bridge mounting
bolts previously removed.
Note: Be sure to replace insulating washers in their proper positions.
3. Reconnect lead 218 and Pos. lead previously removed.
4. Replace the shunt and lead 220A previously removed.
5. Replace the 1/2” bolt securing lead 216 and
the aluminum lead X1 originating from the
main transformer.
6. Reconnect the negative lead to the free
wheeling diode.
7. Replace the 1/2” bolt securing leads B and
217 previously removed.
8. Reconnect leads G1, G2, G3, and G4.
Splice, solder and insulate as necessary.
9. Replace case sides and top.
10. Using a 3/8” nut driver, remove the four
SCR bridge mounting bolts. Note insulator
washer placement upon removal.
PRECISION TIG 275
F-55
F-55
TROUBLESHOOTING & REPAIR
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SCR BRIDGE REMOVAL AND REPLACEMENT (continued)
Figure F.14 - SCR BRIDGE CONNECTIONS
LIFT BAIL STABILIZER
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217
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Negative
X1
B
G2
216
G3
G4
Shunt
218
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220A
Bridge
Mounting
Bolts
PRECISION TIG 275
G1
Pos.
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F-56
TROUBLESHOOTING & REPAIR
MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS (CONT’D)
PROCEDURE
1. Loosen the appropriate diode nut and remove the
diode that is to be replaced.
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2. Clean the area on the heat sink around the diode
mounting surface using a putty knife, or similar
tool, DO NOT SCRATCH THE DIODE MOUNTING
SURFACE.
DIODE STUD
SIZE
3/4 - 16
3/8 - 24
1/4 - 28
3. Polish each heat sink's mounting surface using
NO. 000 fine steel wool. Wipe surface clean with
a lint free cloth or paper towel.
4. Inspect the mounting surfaces of each new diode.
Remove all burrs and wipe clean. Do not use steel
wool or any abrasive cleanser on the diode
mounting surface.
5. Apply a thin (0.0003" to 0.0007") uniform layer of
E1868 (Dow Corning 340) heat sink compound to
the heat sink mounting surface.
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a. Do not apply compound to diode stud or
mounting threads.
b. The diode threads must be clean and free of
defects so that the nut can be finger tightened
before applying torque. A "slip" type torque
wrench must be used to tighten the diode nut.
6. Tighten the diode nuts to the specifications in the
following table.
a. The nuts for diodes with steel studs are to be
started by hand and then torqued as per the
following table.
b. The nuts for diodes with copper studs are to
run on all the way by hand then torqued as per
the following table.
c. Turn a minimum of 1/2 turn more while
torquing per the table.
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F-56
PRECISION TIG 375
FOOTPOUNDS
25-27
10±.5
INCHPOUNDS
300-324
125+0/-5
22-25
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F-57
TROUBLESHOOTING & REPAIR
POLARITY SWITCH REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the polarity
switch.
Return to Master TOC
Return to Section TOC
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MATERIALS NEEDED
3/8” Nut Driver
1/2” Wrench
7/16” Wrench
Phillips Head Screw Driver
Slot Head Screw Driver (2 Required)
PRECISION TIG 275
F-57
Return to Master TOC
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F-58
TROUBLESHOOTING & REPAIR
POLARITY SWITCH REMOVAL AND REPLACEMENT (continued)
Figure F.15 - Switch Location
MO
DE
MI
NIMU
M
DISP
LA
Y
LO
CA
L
AC
BAL
BA
LA
AN
NC
CE
E
!
WAR
RE
MO
TE
NI
NG
MA
XIMU
M
ON
PO
WER
OFF
DC
AC
~
PO
ST
Return to Master TOC
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C
ELOLN
EC
TR
IC
FL
OW
OW
SQ
UA
feat RE W
AV
ur
ing
E PO
...
WER
LIN
DC
PR
MIC SO
ROURCE
ST
AR
T
+
TE
CH
NO
EC
IS
LO
TM
GY
DO
WH NOT
ILE SW
WE ITC
LD H
ING
IO
NT
IG
TH
E LIN
CO
LN
TM
EL
EC
37
TR
IC
CO
5
MP
AN
Y CL
EV
EL
AN
D,
OH
IO
US
A
REMOVAL PROCEDURE
1. Remove the input to the PRECISION TIG
275 machine.
2. Using the 3/8” nut driver, remove the case
sides and top.
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3. Locate the polarity switch. See Figure F.15.
4. Using a 1/2”wrench label and disconnect
leads B,C,252, Pos, Neg, D2 diode assembly,S,253, choke lead, X2 and all leads from
the main transformer. Be sure to label leads
for reassembly.
5. Disconnect leads 265 and 266A using quick
disconnects.
6. Using a phillips head screw driver, remove
the screw from the polarity switch handle.
See Figure F.15.
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7. With the 2 slot head screw drivers, carefully
pry the polarity switch handle
8. Carefully peel back the lower nameplate on
the case front located around the polarity
switch to gain access to the polarity switch
mounting nuts.
NOTE: Do not remove the sticker completely.
9. Using a 7/16” nut driver remove the two
polarity switch mounting nuts located behind
the previously removed nameplate.
10. The polarity switch is ready for removal.
REPLACEMENT PROCEDURE
1. Replace the polarity switch.
2. Secure the polarity switch in its original position with the 7/16” mounting nuts.
3. Firmly press the lower nameplate back into
its original position on the case front.
4. Press the polarity switch handle back onto
its shaft.
5. Secure polarity switch handle with the
phillips head screw previously removed.
6. Reconnect leads 265 and 266A previously
removed.
7. Reconnect all previously removed leads to
their proper terminals. See Wiring Diagram.
8. Replace case sides and top.
PRECISION TIG 275
F-58
TROUBLESHOOTING & REPAIR
Return to Master TOC
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F-59
SCR REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
The following procedure will aid the technician in removing the SCRs from the output rectifier heat sink for maintenance or replacement.
Return to Master TOC
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MATERIALS NEEDED
No. 000 Fine Steel Wool
Penetrox A-13 (Lincoln E2529) or Penetrox A
7/16” Open End Wrench
Allen Head Type Wrenches
PRECISION TIG 275
F-59
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F-60
TROUBLESHOOTING & REPAIR
SCR REMOVAL AND REPLACEMENT (continued)
Figure F.16 - SCR DETAILS
Anode
Return to Master TOC
Cathode
Outer Metal
Ring
SPECIAL INSTRUCTIONS
NOTE: Before disassembling the existing rectifier, note toward which heat sink the outer
metal ring of the power SCR is mounted. Also,
note the positioning of the gate lead of the
SCR. Failure to reinstall the new SCR in the
same orientation as the original may result in
subsequent damage to the new SCR and
other components of the welder. See Figure
F.16.
CAUTION
The unclamping and clamping procedure outlined below is critical for the prevention of
internal SCR damage. Failure to follow this
procedure may result in subsequent damage
of the SCR. Handle all SCRs with care.
PROCEDURE
1. Remove the main input supply power to the
machine.
2. Perform the SCR/Diode Rectifier
Assembly Removal procedure.
Return to Section TOC
Gate
3. Using a 7/16” open end wrench, alternately
loosen nuts 1/2 turn each until heat sinks
are loose. Remove nuts and leaf spring. IT
IS RECOMMENDED THAT NEW HARDWARE, LEAF SPRING AND HOUSING BE
USED FOR ASSEMBLY.
4. Remove the old SCR.
5. Clean the area on the heat sink around the
SCR mounting surface, using a putty knife
or similar tool. DO NOT SCRATCH THE
SCR MOUNTING SURFACE.
6. Polish each heat sinkʼs mounting surface
using NO.000 fine steal wool. Wipe surface
clean with a lint free cloth or paper towel.
7. Inspect the mounting surfaces of each new
SCR.
a. Remove all burrs and wipe clean. Do
not use steel wool or any abrasive
cleanser on the SCR mounting surfaces.
8. Apply a thin (0.001” to 0.003”) layer of
PENETROX A-13 (Lincoln Electric #E2529)
or PENTROX A, heat sink compound, to
each heat sinkʼs SCR mounting surface.
a. Care must be used to prevent foreign
material contamination of the SCR to
heat sink junction.
9. Place the new SCR between the heat
sinks. Be sure that the outer metal ring of
the SCR is facing toward the same heat
sink as the old SCRʼs metal ring. Be sure
that the roll pin of the heat sink engages
the “hole” in the SCR. The SCR contact
surfaces must sit flat against both heat sink
surfaces.
10. Perform the SCR/Diode Rectifier
Assembly Replacement Procedure.
11. Replace the case sides and top.
PRECISION TIG 275
F-60
TROUBLESHOOTING & REPAIR
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F-61
RETEST AFTER REPAIR
Should a machine under test be rejected for any reason requiring the removal of any
mechanical part that could effect the machineʼs electrical characteristics, or if any electrical
components are required or replaced, the machine must be retested.
Input Volts/Hertz
208/60
230/60
460/60
575/60
INPUT IDLE AMPS
Maximum Idle Amps
(without PFC)
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Maximum Idle Amps
(without PFC)
6
5
3
2
36
32
16
13
OPEN CIRCUIT VOLTAGES
MAXIMUM AC OPEN CIRCUIT VOLTAGE
75 VAC
MAXIMUM DC OPEN CIRCUIT VOLTAGE
68 VDC
MAXIMUM ACCEPTABLE OUTPUT VOLTAGE
AT MINIMUM OUTPUT SETTINGS
DC TIG Mode
2 Amps @ 20 Volts
MAXIMUM ACCEPTABLE OUTPUT VOLTAGE
AT MAXIMUM OUTPUT SETTINGS
DC TIG Mode
Return to Section TOC
F-61
300 Amps @ 32 Volts
RECOMMENDED METERS FOR MACHINE OUTPUT TESTS
VOLTMETER: AC and DC True RMS Meter - Fluke 8922A or equivalent
AMMETER: Columbia Type AX AC or DC Tong Ammeter
IMPORTANT: IF OTHER TYPE METERS ARE USED, RESULTS MAY NOT BE ACCURATE.
PRECISION TIG 275
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F-62
NOTES
PRECISION TIG 275
F-62
Return to Master TOC
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
ELECTRICAL DIAGRAMS SECTION
Electrical Diagrams Section ..........................................................................................Section G
Wiring Diagram (Entire Machine) Code 10806 (G4031) .............................................................G-2
Wiring Diagram (Entire Machine) Code 10807 (G4031-1) ..........................................................G-3
Wiring Diagram (Entire Machine) Code 10893 (G4031-2) ..........................................................G-4
Wiring Diagram (Entire Machine) Code 11158 (G5692) ..............................................................G-5
Wiring Diagram (Entire Machine) Code 11159 (G5692-1)...........................................................G-6
Return to Master TOC
Schematic (Entire Machine) Codes below 11000 (G4075) .........................................................G-7
Schematic (Entire Machine) Codes above 11000 (G5691) .........................................................G-8
Control P.C. Board Schematic Codes below 11000 (G3908 Page 1) ........................................G-9
Control P.C. Board Schematic Codes below 11000 (G3908 Page 2) .......................................G-10
Control P.C. Board Schematic Codes below 11000 (G3908 Page 3)........................................G-11
Control P.C. Board Assembly Codes below 11000(G3909-2) ...................................................G-12
Control P.C. Board Schematic Codes above 11000 (G4762 Page 1) ......................................G-13
Control P.C. Board Schematic Codes above 11000 (G4762 Page 2) ......................................G-14
Control P.C. Board Schematic Codes above 11000 (G4762 Page 3) ......................................G-15
Control P.C. Board Schematic Codes above 11000 (G4762 Page 4) ......................................G-16
Control P.C. Board Schematic Codes above 11000 (G4762 Page 5) ......................................G-17
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Control P.C. Board Assembly Codes above 11000 (G4763-1)..................................................G-18
Protection P.C. Board Schematic (M16115) ..............................................................................G-19
Protection P.C. Board Assembly (M16062-1) ............................................................................G-20
ByPass / Stabilizer P.C. Board Schematic (S22530-1) (Code 10806 & 10807)........................G-21
ByPass / Stabilizer P.C. Board Assembly (L10121-1) (Code 10806 & 10807) .........................G-22
ByPass and CE P.C. Board Schematic (S24206) (Code 10893) ..............................................G-23
ByPass and CE P.C. Board Assembly (L10882-1) (Code 10893).............................................G-24
TIG Option P.C. Board Schematic Codes below 11000 (G4039 Page 1) .................................G-25
TIG Option P.C. Board Schematic Codes below 11000 (G4039 Page 2) .................................G-26
TIG Option P.C. Board Assembly Codes below 11000 (G4040-2) ............................................G-27
TIG Option P.C. Board Schematic Codes above 11000 (G4760 Page 1) .................................G-28
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TIG Option P.C. Board Schematic Codes above 11000 (G4760 Page 2) .................................G-29
TIG Option P.C. Board Schematic Codes above 11000 (G4760 Page 3) .................................G-30
TIG Option P.C. Board Assembly Codes above 11000 (G4761-1)............................................G-31
PRECISION TIG 275
G-1
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ENTIRE MACHINE - CODE 10806 (G4031)
CONTROL PANEL (VIEWED FROM REAR)
PRECISION TIG 275 WIRING DIAGRAM
1
2
3
4
5
6
METER
L2 (V)
301
H4
C5
CONTROL PC BOARD
B
Y
332
W
333
334
335
334
333
332
331
W
L7
1
3
2
5
4
6
J10
N.D.
N.C.
J7
J3
1 2 3 4 5 6 7 8 9 10
8
16
J11
ON TIME
BACKGROUND
DOWN SLOPE
1 2 3 4 5 6 7 8 9 10
R9
R10
R11
R12
OR
401
402
403
404
405
406
407
408
409
410
411
W
407
L10
401B
401A
B
W
OFF
PULSE
2-STEP
TRIGGER
404
401
411
(PULSE ON)
- G +
N.C.
401D
408
409
410
401D
405
406
401B
402
403
401C
ON
1
2
3
4
5
6
7
8
9
10
11
12
10K A-B
AT MINIMUM
OPTIONAL
REMOTE
AMPTROLTM
A
B
C
D
E
F
REMOTE
RECEPTACLE
L8
A
B
C
D
E
F
4
1
2
3
6
5
J22
J23
1
2
3
4
5
7
6
8
N.A.
1
2
3
4
5
7
6
8
H
A
F
C
D1
SCR4
POS
B
S2A
X2
POLARITY
SWITCH
NO
4
L13
0
CR4
263
R8
267
268
262
263
201
204
W209
R210
214
S
260
213
233A
GAS VALVE
235
J2
SV1
231E
J12
1
2
3
5
6
4
E
S
115VAC
260
235
T2
236
233A
L2
C6
SPARK
GAP
F
T3
R6
284
F
L3
285
237
C7
R5
236B
TRANSFORMER
SECONDARY
THERMOSTAT
233A
231D
L11
N.B.
TRANSFORMER
PRIMARY
THERMOSTAT
BYPASS/
STABILIZER
PC BOARD
ARC STARTER AS'BLY
FRONT
ELECTRODE
WORK
231
8
1
N.F.
CR4
2
6
234
SV2
220B
220A
C
C9
WATER VALVE
(OPTIONAL)
270
FAN
78VAC
F X2
(REAR VIEW, SHOWN
IN AC POSITION)
BACKGROUND
RECTIFIER
269
232
X1
233
233B
G
271A
268
231
231A
115VAC
C8
CB1
15A
NC
271
201
204
W209
R210
J5A
J5
E
232
MICRO-SWITCH
REAR GANG
R7
236
Return to Master TOC
Return to Section TOC
PROTECTION PCB
A
B
C
D
E
F
SCR3
265
266
262
263
213
214
1 2 3 4 5 6 7 8 9 10
L9
D2
D
S2
J1
1
2
3
4
5
7
6
8
FRONT GANG
B
269
270
271
220B
115VAC
F
X4
267
T1
POLARITY SWITCH MICRO SWITCH
AC A-C, D-E, B-F
OPEN
CLOSED
DC+ B-D, C-E, A-F, G-H
CLOSED
DC- B-D, A-E, C-F, G-H
G4
252
253
6
12
5
13
4
14
7
15
J3
FREQ
4-STEP
217
220
2
10
3
11
W209
R210
L1
218
216
1
9
X7
S
20VAC
F
X8
SCR2
TIG OPTION PCB
(OPTIONAL)
Return to Master TOC
ADVANCED CONTROL PANEL
(OPTIONAL)
G4
G2
217
220
G3
10
POS
266A
+
B
X5
63.5VAC
X6
S X3
F
H4 (460V)
X9
S
201
18VAC
204
F
X10
G2
265A
+ G -
W
218
265
-
B
CAPACITORS
(OPTIONAL)
H2 (208V)
H3 (230V)
266
J4
G1
G3
NEG
1
2
3
4
5
6
7
8
9
286
+ G
B
H1
POWER FACTOR
S
253
+ G -
W
COM
RECONNECT PANEL
R 222
W 221
G1
252
-
1
6
2
7
3
8
4
9
5
251
SCR1
L12
J9
NEG
(THERMAL)
(P. FLOW)
+ R
W
B
W
B
W
B
W
B
W
B
CONNECT STRAP TO
LOW (H2)
C2
250
X1
220A
(REMOTE)
331
216
231A
311A
311
312
316
L4
316A
318
313
316A
313A
1
2
3
4
5
6
7
8
9
10
11
12
208 VOLT CONNECTION
C1
LOW
TO GROUND PER
NATIONAL
ELECTRICAL CODE
W 221
R 222
233A
R3
335
Return to Section TOC
1
2
231E
POST FLOW
B
W
A
S
238
316B
313C
317
319
311A
322
(AUTO BAL)
H2
HIGH
GROUND
10
(STICK)
H3
J8
239
304B
321
316C
316B
315
314
320
316C
Return to Master TOC
MAXIMUM
OUTPUT
-
Return to Section TOC
311
312
313
314
315
316
317
318
319
320
321
322
L6
R1
REMOTE
1
2
3
4
5
6
J6
313B
R2
TIG
MODE
301
302
303
304
304A
306
(-)
LOCAL
230 VOLT CONNECTION
CONNECT STRAP TO
MID (H3)
MID
L2 (V)
DISPLAY
(+)
BALANCE
C4
N.E.
R4
STICK
POWER SWITCH
L1 (U)
L5
460 VOLT CONNECTION
CONNECT STRAP TO
HIGH (H4) (AS SHOWN)
S1
304B
302
(VIEWED FROM REAR)
MINIMUM
OUTPUT
H1
233A
1
2
3
4
5
6
306
303
L1 (U)
262
Return to Master TOC
Return to Section TOC
G-2
231A
N.A. CONNECTION IS PIN TO PIN BETWEEN J23 AND J5.
N.B. ROBOTIC INTERFACE CONNECTION.
N.C. REMOVE JUMPER PLUG IN J3 WHEN INSTALLING
TIG OPTION PC BOARD.
N.D. DISCONNECT JUMPER LEAD BETWEEN PIN 1 AND
PIN 2 IN J3 TO DOUBLE PREFLOW & POSTFLOW TIMES.
N.E. DISPLAY TOGGLE SHOWN IN MIN AMP POSITION.
N.F. PLUGS INTO LOWER SWITCHED RECEPTACLE.
C1,C2
C4,C5
C6
C7
C8,C9
CB1
CR4
D1
D2
L1
L2,L3
L4 -L13
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
S1
S2
S2A
SCR1,2,3,4
SV1
SV2
T1
T2
T3
POWER FACTOR CAPACITORS, 50/460 (OPTIONAL)
BY-PASS CAPACITORS, .0047
HIGH VOLTAGE CAPACITOR, .0015/12kV
PHASE SHIFT CAPACITOR, 15uF/250VAC
HIGH FREQ PROTECTION CAPACITORS, .22/400
CIRCUIT BREAKER, 15 AMP
12V DC RELAY COIL
FREE WHEELING DIODE
BACKGROUND DIODE
OUTPUT INDUCTOR (CHOKE)
HIGH FREQ INDUCTORS
RF TOROID CHOKES
OUTPUT CONTROL POTENTIOMETER, 10K
BALANCE CONTROL POTENTIOMETER, 10K
POST FLOW POTENTIOMETER, 10K
MIN OUTPUT POTENTIOMETER, 10K
PHASE SHIFT RESISTOR, 200/100
HOLDING RESISTOR, 50/225
RESISTOR, 20/100
RESISTOR, 5/50
FREQ CONTROL POTENTIOMETER, 10K
ON TIME CONTROL POTENTIOMETER, 10K
BACKGROUND POTENTIOMETER, 10K
DOWN SLOPE POTENTIOMETER, 10K
INPUT POWER SWITCH
POLARITY SWITCH
MICROSWITCH ON POLARITY SWITCH
MAIN POWER SCR'S
GAS SOLENOID VALVE, 115VAC
WATER SOLENOID VALVE, 115VAC (OPTIONAL)
MAIN TRANSFORMER
HIGH VOLTAGE TRANSFORMER
HIGH FREQ TRANSFORMER
LEAD COLORING CODE:
U-BLUE
B-BLACK
W-WHITE
G-GREEN
Y-YELLOW
O-ORANGE
R-RED
COMPONENT VALUE
UNITS:
RESISTORS:
OHMS/WATTS
CAPACITORS:
MFD/VOLTS
CONNECTOR PIN NUMBERS:
1 2 3
7
EXAMPLE: THIS IS PIN 7
0F CONNECTOR J5
14
8
1 2 3
J5
LATCH
VIEW OF CONNECTOR ON PC BOARD
ELECTRICAL SYMBOLS PER E1537.
REAR
ELECTRODE
8
B
G4031
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
®
PRECISION TIG 275
G-3
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ENTIRE MACHINE - CODE 10807 (G4031-1)
CONTROL PANEL (VIEWED FROM REAR)
1
2
3
4
5
6
METER
L1 (U)
L2 (V)
301
CONTROL PC BOARD
L4
B
W
B
B
W
W
333
334
335
334
333
332
335
Return to Master TOC
ADVANCED CONTROL PANEL
(OPTIONAL)
FREQ
R9
J10
N.D.
401B
401A
8
16
BACKGROUND
DOWN SLOPE
1 2 3 4 5 6 7 8 9 10
R10
R11
R12
OR
407
408
409
410
(PULSE ON)
ON
- G +
B
W
OFF
PULSE
N.C.
401D
401
402
403
404
405
406
407
408
409
410
411
W
404
401
1 2 3 4 5 6 7 8 9 10
ON TIME
401D
405
406
401B
402
403
411
J3
J11
1
2
3
4
5
6
7
8
9
10
11
12
OPTIONAL
REMOTE
AMPTROLTM
A
B
C
D
E
F
REMOTE
RECEPTACLE
L8
A
B
C
D
E
F
4
1
2
3
6
5
J22
J23
1
2
3
4
5
7
6
8
N.A.
1
2
3
4
5
7
6
8
R 222
W 221
X2
POLARITY
SWITCH
201
204
W209
R210
L13
0
CR4
263
271A
BACKGROUND
RECTIFIER
269
R8
267
268
262
263
201
204
W209
R210
214
S
260
213
233A
GAS VALVE
235
J2
SV1
231E
J12
1
2
3
5
6
4
E
S
115VAC
260
235
T2
236
233A
L2
C6
SPARK
GAP
F
T3
R6
284
F
L3
285
237
C7
R5
236B
TRANSFORMER
SECONDARY
THERMOSTAT
233A
231D
L11
N.B.
TRANSFORMER
PRIMARY
THERMOSTAT
BYPASS/
STABILIZER
PC BOARD
ARC STARTER AS'BLY
FRONT
ELECTRODE
WORK
8
2
6
231
1
N.F.
CR4
234
SV2
220B
220A
C
4
WATER VALVE
(OPTIONAL)
270
FAN
C9
233
233B
(REAR VIEW, SHOWN
IN AC POSITION)
271
J5A
J5
B
NO
G
R7
236
Return to Master TOC
Return to Section TOC
10K A-B
AT MINIMUM
A
B
C
D
E
F
POS
265
266
262
263
213
214
1 2 3 4 5 6 7 8 9 10
L9
PROTECTION PCB
D1
78VAC
F X2
115VAC
C8
CB1
15A
NC
S2
J1
1
2
3
4
5
7
6
8
C
SCR4
S2A
H
A
F
269
270
271
220B
6
12
5
13
4
14
7
15
J3
L10
2-STEP
TRIGGER
N.C.
J7
401C
4-STEP
2
10
3
11
E
232
MICRO-SWITCH
REAR GANG
G4
252
253
1
9
D2
D
SCR3
220
10
1
3
2
5
4
6
FRONT GANG
B
G3
TIG OPTION PCB
(OPTIONAL)
331
W
217
266A
B
218
216
232
X4
X1
T1
POLARITY SWITCH MICRO SWITCH
AC A-C, D-E, B-F
OPEN
CLOSED
DC+ B-D, C-E, A-F, G-H
CLOSED
DC- B-D, A-E, C-F, G-H
265A
W
332
L1
265
+
B
Y
SCR2
266
+ G -
POS
X7
S
20VAC
F
X8
G2
G4
G2
217
220
115VAC
F
267
268
231
231A
F
S
NEG
-
218
S
18VAC
W209
R210
286
+ G
G1
G3
253
J4
H4 (575V)
X9
SCR1
G1
1
2
3
4
5
6
7
8
9
252
+ G -
X5
63.5VAC
X6
S X3
F
X10
NEG
(THERMAL)
(P. FLOW)
-
1
6
2
7
3
8
4
9
5
CAPACITORS
(OPTIONAL)
201
204
231A
(REMOTE)
+ R
W
B
W
B
W
B
W
B
W
B
H1
POWER FACTOR
X1
220A
(AUTO BAL)
331
216
L12
J9
316A
318
313
316A
313A
COM
RECONNECT PANEL
TO GROUND PER
NATIONAL
ELECTRICAL CODE
W 221
R 222
233A
R3
L7
Return to Section TOC
1
2
231E
POST FLOW
311A
311
312
317
316
1
2
3
4
5
6
7
8
9
10
11
12
251
C2
S
238
316B
313C
311A
322
319
311
312
313
314
315
316
317
318
319
320
321
322
C1
H2 (460V)
10
(STICK)
A
250
LOW
J8
239
304B
321
316C
316B
315
314
320
316C
Return to Master TOC
313B
-
Return to Section TOC
L6
MAXIMUM
OUTPUT
HIGH
GROUND
(-)
1
2
3
4
5
6
J6
R1
REMOTE
301
302
303
304
304A
306
(+)
R4
TIG
MODE
C4
MID
L2 (V)
DISPLAY
R2
H2
H4
L5
BALANCE
CONNECT STRAP TO
LOW (H2)
L1 (U)
N.E.
LOCAL
460 VOLT CONNECTION
POWER SWITCH
C5
STICK
575 VOLT CONNECTION
CONNECT STRAP TO
HIGH (H4) (AS SHOWN)
S1
304B
302
(VIEWED FROM REAR)
MINIMUM
OUTPUT
H1
233A
1
2
3
4
5
6
306
303
PRECISION TIG 275 WIRING DIAGRAM
262
Return to Master TOC
Return to Section TOC
G-3
231A
N.A. CONNECTION IS PIN TO PIN BETWEEN J23 AND J5.
N.B. ROBOTIC INTERFACE CONNECTION.
N.C. REMOVE JUMPER PLUG IN J3 WHEN INSTALLING
TIG OPTION PC BOARD.
N.D. DISCONNECT JUMPER LEAD BETWEEN PIN 1 AND
PIN 2 IN J3 TO DOUBLE PREFLOW & POSTFLOW TIMES.
N.E. DISPLAY TOGGLE SHOWN IN MIN AMP POSITION.
N.F. PLUGS INTO LOWER SWITCHED RECEPTACLE.
C1,C2
C4,C5
C6
C7
C8,C9
CB1
CR4
D1
D2
L1
L2,L3
L4 -L13
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
S1
S2
S2A
SCR1,2,3,4
SV1
SV2
T1
T2
T3
POWER FACTOR CAPACITORS, 50/460 (OPTIONAL)
BY-PASS CAPACITORS, .0047
HIGH VOLTAGE CAPACITOR, .0015/12kV
PHASE SHIFT CAPACITOR, 15uF/250VAC
HIGH FREQ PROTECTION CAPACITORS, .22/400
CIRCUIT BREAKER, 15 AMP
12V DC RELAY COIL
FREE WHEELING DIODE
BACKGROUND DIODE
OUTPUT INDUCTOR (CHOKE)
HIGH FREQ INDUCTORS
RF TOROID CHOKES
OUTPUT CONTROL POTENTIOMETER, 10K
BALANCE CONTROL POTENTIOMETER, 10K
POST FLOW POTENTIOMETER, 10K
MIN OUTPUT POTENTIOMETER, 10K
PHASE SHIFT RESISTOR, 200/100
HOLDING RESISTOR, 50/225
RESISTOR, 20/100
RESISTOR, 5/50
FREQ CONTROL POTENTIOMETER, 10K
ON TIME CONTROL POTENTIOMETER, 10K
BACKGROUND POTENTIOMETER, 10K
DOWN SLOPE POTENTIOMETER, 10K
INPUT POWER SWITCH
POLARITY SWITCH
MICROSWITCH ON POLARITY SWITCH
MAIN POWER SCR'S
GAS SOLENOID VALVE, 115VAC
WATER SOLENOID VALVE, 115VAC (OPTIONAL)
MAIN TRANSFORMER
HIGH VOLTAGE TRANSFORMER
HIGH FREQ TRANSFORMER
LEAD COLORING CODE:
U-BLUE
B-BLACK
W-WHITE
G-GREEN
Y-YELLOW
O-ORANGE
R-RED
COMPONENT VALUE
UNITS:
RESISTORS:
OHMS/WATTS
CAPACITORS:
MFD/VOLTS
CONNECTOR PIN NUMBERS:
1 2 3
7
EXAMPLE: THIS IS PIN 7
0F CONNECTOR J5
14
8
1 2 3
J5
LATCH
VIEW OF CONNECTOR ON PC BOARD
ELECTRICAL SYMBOLS PER E1537.
REAR
ELECTRODE
8
B
G4031-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
®
PRECISION TIG 275
415 VOLT CONNECTION
PRECISION TIG 275 WIRING DIAGRAM
GND1
CONTROL PC BOARD
+ G -
+
W
B
B
Y
332
W
333
334
335
334
333
332
331
W
335
L7
J10
N.C.
J3
1 2 3 4 5 6 7 8 9 10
8
16
J11
DOWN SLOPE
1 2 3 4 5 6 7 8 9 10
R9
R10
R11
R12
OR
407
401D
408
409
410
401D
405
406
401B
402
403
401C
401
402
403
404
405
406
407
408
409
410
411
W
L10
401B
401A
B
OFF
PULSE
404
401
411
(PULSE ON)
W
2-STEP
TRIGGER
N.C.
1
2
3
4
5
6
7
8
9
10
11
12
OPTIONAL
REMOTE
AMPTROLTM
A
B
C
D
E
F
REMOTE
RECEPTACLE
L8
A
B
C
D
E
F
4
1
2
3
6
5
J22
J23
1
2
3
4
5
7
6
8
N.A.
1
2
3
4
5
7
6
8
B
X2
NO
POLARITY
SWITCH
L13
0
CR4
263
BACKGROUND
RECTIFIER
269
R8
267
268
262
263
201
204
W209
R210
220B
220A
214
S
260
213
C
233A
GAS VALVE
235
J2
SV1
231E
J12
1
2
3
5
6
4
E
S
115VAC
260
235
T2
236
233A
L2
C6
SPARK
GAP
F
T3
R6
284
F
L3
285
237
C7
R5
236B
TRANSFORMER
SECONDARY
THERMOSTAT
233A
231D
L11
N.B.
TRANSFORMER
PRIMARY
THERMOSTAT
BYPASS/
STABILIZER
PC BOARD
ARC STARTER AS'BLY
FRONT
ELECTRODE
REAR
ELECTRODE
WORK
4
8
2
6
231
1
50A
CR4
234
SV2
N.F.
270
FAN
C9
(REAR VIEW, SHOWN
IN AC POSITION)
271A
78VAC
F X2
233
233B
G
271
201
204
W209
R210
J5A
J5
POS
232
52
115VAC
C8
CB1
15A
NC
R7
236
Return to Master TOC
10K A-B
AT MINIMUM
A
B
C
D
E
F
D1
265
266
262
263
213
214
1 2 3 4 5 6 7 8 9 10
L9
PROTECTION PCB
H
A
C
SCR4
S2A
S2
J1
1
2
3
4
5
7
6
8
E
F
269
270
271
220B
6
12
5
13
4
14
7
15
J3
BACKGROUND
- G +
2
10
3
11
N.D.
J7
ON TIME
ON
SCR3
232
MICRO-SWITCH
REAR GANG
G4
252
253
1
9
D2
D
268
231
231A
T1
POLARITY SWITCH MICRO SWITCH
AC A-C, D-E, B-F
OPEN
CLOSED
DC+ B-D, C-E, A-F, G-H
CLOSED
DC- B-D, A-E, C-F, G-H
FRONT GANG
B
220
FREQ
4-STEP
217
TIG OPTION PCB
(OPTIONAL)
Return to Master TOC
ADVANCED CONTROL PANEL
(OPTIONAL)
218
216
G3
10
1
3
2
5
4
6
SCR2
L1
X4
105VAC
X14
X1
S
F
267
233A
-
B
G2
G4
G2
217
220
115VAC
X7
S
20VAC
F
X8
W209
R210
262
+ G
B
POS
F
H5 (440V)
X9
S
201
18VAC
204
F
X10
250
266A
+ G -
W
1
6
2
7
3
8
4
9
5
218
265A
J4
G1
G3
X5
63.5VAC
X6
S X3
S
H2 (220V)
H3 (380V)
H4 (415V)
R 222
W 221
G1
1
2
3
4
5
6
7
8
9
50A
H1
CAPACITORS
(OPTIONAL)
SCR1
L12
J9
52
POWER FACTOR
X1
265
-
W
B
W
B
W
B
W
B
W
B
216
NEG
(THERMAL)
(P. FLOW)
+ R
B
W
331
C2
COM
RECONNECT PANEL
286
(REMOTE)
251
TO GROUND PER
NATIONAL
ELECTRICAL CODE
220A
(AUTO BAL)
LOW
L2A
L2 (V)
CB2
5A
50
250
HIGH
W 221
R 222
L4
10
(STICK)
51
A
C1
L1A
GAS
VALVE
253
311A
311
312
317
316
1
2
316A
318
313
316A
313A
H2
J8
252
R3
115 VAC
RECEPT.
H3
MID
GROUND
NEG
POST FLOW
1
2
3
4
5
6
7
8
9
10
11
12
CASE
BACK
TO GROUND PER
NATIONAL
ELECTRIC CODE
231A
313B
316B
313C
311A
322
319
311
312
313
314
315
316
317
318
319
320
321
322
L6
R1
REMOTE
1
2
3
4
5
6
T1
TRANS.
FOOT
CASE
FRONT
233A
304B
321
316C
316B
315
314
320
316C
Return to Master TOC
CONTROL
PANEL
J6
MAXIMUM
OUTPUT
R2
TIG
MODE
301
302
303
304
304A
306
-
Return to Section TOC
LOCAL
H4
L1 (U)
GND6
GND5
S1
220VAC
220 VAC
RECEPT.
GND4
231E
DISPLAY
GND-H2
GND-H
H1
POWER SWITCH
BYPASS
PC BOARD
N.E.
R4
BALANCE
L2 (V)
RECONNECT PANEL SUPPORT
L5
STICK
220-230 VOLT CONNECTION
CONNECT STRAP TO
LOW (H2)
PROTECTIVE BONDING CIRCUIT
238
METER
301
304B
302
L1 (U)
266
1
2
3
4
5
6
380-400 VOLT CONNECTION
CONNECT STRAP TO
MID (H3)
239
1
2
3
4
5
6
306
303
MINIMUM
OUTPUT
Return to Section TOC
CONNECT STRAP TO
HIGH (H4) (AS SHOWN)
CONTROL PANEL (VIEWED FROM REAR)
(-)
Return to Master TOC
WIRING DIAGRAM - ENTIRE MACHINE - CODE 10893 (G4031-2)
(VIEWED FROM REAR)
Return to Section TOC
G-4
ELECTRICAL DIAGRAMS
(+)
Return to Section TOC
G-4
231A
N.A. CONNECTION IS PIN TO PIN BETWEEN J23 AND J5.
N.B. ROBOTIC INTERFACE CONNECTION.
N.C. REMOVE JUMPER PLUG IN J3 WHEN INSTALLING
TIG OPTION PC BOARD.
N.D. DISCONNECT JUMPER LEAD BETWEEN PIN 1 AND
PIN 2 IN J3 TO DOUBLE PREFLOW & POSTFLOW TIMES.
N.E. DISPLAY TOGGLE SHOWN IN MIN AMP POSITION.
N.F. PLUGS INTO LOWER SWITCHED RECEPTACLE.
C1,C2
C4,C5
C6
C7
C8,C9
CB1
CB2
CR4
D1
D2
L1
L2,L3
L4 -L13
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
S1
S2
S2A
SCR1,2,3,4
SV1
SV2
T1
T2
T3
WATER VALVE
(OPTIONAL)
POWER FACTOR CAPACITORS, 50/460 (OPTIONAL)
BY-PASS CAPACITORS, .0047
HIGH VOLTAGE CAPACITOR, .0015/12kV
PHASE SHIFT CAPACITOR, 15uF/250VAC
HIGH FREQ PROTECTION CAPACITORS, .22/400
CIRCUIT BREAKER, 15 AMP
CIRCUIT BREAKER, 5 AMP
12V DC RELAY COIL
FREE WHEELING DIODE
BACKGROUND DIODE
OUTPUT INDUCTOR (CHOKE)
HIGH FREQ INDUCTORS
RF TOROID CHOKES
OUTPUT CONTROL POTENTIOMETER, 10K
BALANCE CONTROL POTENTIOMETER, 10K
POST FLOW POTENTIOMETER, 10K
MIN OUTPUT POTENTIOMETER, 10K
PHASE SHIFT RESISTOR, 200/100
HOLDING RESISTOR, 50/225
RESISTOR, 20/100
RESISTOR, 5/50
FREQ CONTROL POTENTIOMETER, 10K
ON TIME CONTROL POTENTIOMETER, 10K
BACKGROUND POTENTIOMETER, 10K
DOWN SLOPE POTENTIOMETER, 10K
INPUT POWER SWITCH
POLARITY SWITCH
MICROSWITCH ON POLARITY SWITCH
MAIN POWER SCR'S
GAS SOLENOID VALVE, 115VAC
WATER SOLENOID VALVE, 115VAC (OPTIONAL)
MAIN TRANSFORMER
HIGH VOLTAGE TRANSFORMER
HIGH FREQ TRANSFORMER
LEAD COLORING CODE:
U-BLUE
B-BLACK
W-WHITE
G-GREEN
Y-YELLOW
O-ORANGE
R-RED
COMPONENT VALUE
UNITS:
RESISTORS:
OHMS/WATTS
CAPACITORS:
MFD/VOLTS
CONNECTOR PIN NUMBERS:
1 2 3
7
EXAMPLE: THIS IS PIN 7
0F CONNECTOR J5
14
8
1 2 3
J5
LATCH
VIEW OF CONNECTOR ON PC BOARD
ELECTRICAL SYMBOLS PER E1537.
8
B
G4031-2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
®
PRECISION TIG 275
L7
1
3
2
5
4
6
Return to Master TOC
BACKGROUND
ARRIÈRE PLAN
FONDO
ON TIME
À L 'HEURE
EL TIEMPO
FREQ
R9
DOWN SLOPE
VERS LE BAS PENTE
ABAJO CUESTA
401B
AMPTROL
B
A
B
C
D
E
F
404
413
401A
401
A
B
C
D
E
F
TM
SPOT
TACHE
PUNTO
PULSE
PULSÉ
PULSACIÓN
2 STEP
2 TEMPS
2 PASO
10K A-B
MINIMUM
J3
OR
401D
401
402
403
404
405
406
407
408
409
410
411
W
413
W
L10
- G +
B
PULSE
PULSÉ
PULSACIÓN
L9
PROTECTION PCB
CI PROTECTION
PCB DE PROTECCIÓN
REMOTE RECEPTACLE
PRISE À DISTANCE
RECEPTÁCULO REMOTO
A
B
C
D
E
F
4
1
2
3
6
5
J22
J23
1
2
3
4
5
7
6
8
N.A.
1
2
3
4
5
7
6
8
1
2
3
4
5
7
6
8
J1
1
2
3
4
5
6
7
8
9
10
11
12
1
2
269
270
271
229A
6
12
5
13
4
14
7
15
233
R 222
W 221
X2
232
CB1
15A
265
266
262
263
213
214
R7A
R7B
229
L13
233
233A
0
CR4
263
R7C
R7D
218A
271A
269
271
268
229A
229
216A
R8A
J20
260
233A
J2
231E
J12
1
2
3
5
6
4
115VAC
260
235
236
233A
237
S
T2
F
L2
SPARK GAP
ÉCLATEUR
ABERTURA
DE CHISPA
L3
C6
L4 -L13
201
204
W209
R210
T1 SECONDARY
THERMOSTAT
T1 SECONDAIRE
THERMOSTAT
TERMOSTATO
SECUNDARIO
DEL T1
ARC STARTER AS'BLY
ENSEMBLE DÉMARREUR D'ARC
ENSAMBLE DE ARRANCADOR DE
ARCO
COMPONENT VALUE UNITS:
UNIDADES DE VALOR DE COMPONENTES:
RESISTORS: OHMS/WATTS
RESISTORES: OHMS/WATTS
CAPACITORES: MFD/VOLTIOS
CAPACITORS: MFD/VOLTS
UNITÉS DE VALEUR DES COMPOSANTS:
RÉSISTANCES: OHMS/WATTS
CONDENSATEURS: MFD/VOLTS
R6
284
FRONT
ELECTRODE
ÉLECTRODE AVANT
ELECTRODO FRONTAL
REAR
ELECTRODE
ÉLECTRODE ARRIÈRE
ELECTRODO POSTERIOR
231A
F
T3
D1
L2,L3
262
263
233A
E
C7
R5
236B
R
213
T1 PRIMARY
THERMOSTAT
T1 PRIMAIRE
THERMOSTAT
TERMOSTATO
PRIMARIO DEL T1
231D
L11
N.B.
460 V
CONNECT STRAP TO HIGH (H4) (AS SHOWN)
CONNECTER LA BRIDE SUR HAUT (H4)
(COMME ILLUSTRÉ)
SUJETADOR DE CONEXIÓN A ALTO (H4)
(COMO SE MUESTRA)
230 V
CONNECT STRAP TO MID (H3)
CONNECTER LA BRIDE SUR MOYEN (H3)
SUJETADOR DE CONEXIÓN A MEDIO (H3)
208 V
CONNECT STRAP TO LOW (H2)
CONNECTER LA BRIDE SUR BAS (H2)
SUJETADOR DE CONEXIÓN A BAJO(H2)
R5
R6
R7A,R7B,
R7C,R7D,
R8A, R8B
S1
POWER FACTOR CAPACITORS, 50/460
BY-PASS CAPACITORS, .0047
HIGH VOLTAGE CAPACITOR, .0015/12kV
PHASE SHIFT CAPACITOR, 15uF/250VAC
HIGH FREQ PROTECTION CAPACITORS, .22/400
CIRCUIT BREAKER, 15 AMP
12V DC RELAY COIL
FREE WHEELING DIODE
OUTPUT INDUCTOR (CHOKE)
HIGH FREQ INDUCTORS
RF TOROID CHOKES
PHASE SHIFT RESISTOR, 200/100
HOLDING RESISTOR, 50/225
RESISTOR, 5/50
INPUT POWER SWITCH
POLARITY SWITCH
MICROSWITCH ON POLARITY SWITCH
MENU SWITCH
MAIN POWER SCR'S
GAS SOLENOID VALVE, 115VAC
WATER SOLENOID VALVE, 115VAC (OPTIONAL)
MAIN TRANSFORMER
HIGH VOLTAGE TRANSFORMER
HIGH FREQ TRANSFORMER
CONDENSATEURS FACTEUR DE PUISSANCE, 50/460
CAPACITORES DE FACTOR DE POTENCIA, 50/460
CONDENSATEURS DÉRIVATION , .0047
CAPACITORES DE DERIVACIÓN, .0047
CONDENSATEUR HAUTE TENSION, .0015/12kV
CAPACITOR DE ALTO VOLTAJE, .0015/12kV
CONDENSATEUR, DÉPHASAGE, 15Mf/250VCA
CAPACITOR DE CAMBIO DE FASE 15uf/250VCA
CONDENSATEURS DE PROTECTION HF, .22/400
CAPACITORES DE PROTECCIÓN CONTRA ALTA
FRECUENCIA, .22/400
DISJONCTEUR, 15 AMP
INTERRUPTOR AUTOMÁTICO, 15 AMPS
BOBINE RELAI DE 12V CC
BOBINA DE RELEVADOR DE 12V DE DC
DIODE ROUE LIBRE
DIODO DE RUEDA LIBRE
INDUCTEUR DE SORTIE (STARTER)
INDUCTOR DE SALIDA (ESTABILIZADOR)
INDUCTANCES HF
INDUCTORES DE ALTA FRECUENCIA
STARTERS TOROÏDE FRÉQUENCE RADIO
ESTABILIZADORES TOROIDAL RF
RÉSISTANCE DÉPHASAGE, 200/100
RESISTOR DE CAMBIO DE FASE, 200/100
RÉSISTANCE DE MAINTIEN, 50/225
RESISTOR DE SOSTENIMIENTO, 50/225
RÉSISTANCE, 5/50, RESISTORES, 5/50
INTERRUPTEUR DE PUISSANCE D’ENTRÉE
INTERRUPTOR DE ENERGÍA DE ENTRADA
INTERRUPTEUR DE POLARITÉ
INTERRUPTOR DE POLARIDAD
MICRORUPTEUR SUR SÉLECTEUR DE POLARITÉ
S2A
MICROINTERRUPTOR EN EL INTERRUPTOR DE
POLARIDAD
INTERRUPTEUR MENU
S3
INTERRUPTOR DE MENÚ
SCR1,2,3,4 REDRESSEURS DE PUISSANCE PRINCIPAUX
SCR'S DE ALIMENTACIÓN PRINCIPAL
SV1
SOUPAPE SOLÉNOÏDE DE GAZ, 115 VAC
VÁLVULA DE SOLENOIDE DE GAS, 115 VCA
SOUPAPE SOLÉNOÏDE À EAU, 115 VAC
SV2
VÁLVULA DE SOLENOIDE DE AGUA, 115 VCA
T1
TRANSFORMATEUR PRINCIPAL
TRANSFORMADOR PRINCIPAL
TRANSFORMATEUR HAUTE TENSION
T2
TRANSFORMADOR DE ALTO VOLTAJE
TRANSFORMATEUR HAUTE FRÉQUENCE
T3
TRANSFORMADOR DE ALTA FRECUENCIA
S2
SV1
235
J5A
CR4
L1
214
VENTILATEUR
VENTILADOR
C7
C8,C9
GND6
BYPASS/STABILIZER PC BOARD S
CI DÉRIVATION/STABILISATEUR
TARJETA ELECTRONICA DE
C
DERIVACION /
ESTABILIZADOR
C1,C2
C4,C5
CB1
270
FAN
C1,C2
C4,C5
C6
C7
C8,C9
CB1
CR4
D1
L1
L2,L3
L4 -L13
R5
R6
R7A, R7B,
R7C, R7D,
R8A, R8B
S1
S2
S2A
S3
SCR1,2,3,4
SV1
SV2
T1
T2
T3
C6
1
262
G
NC
266A
B
NO
217A
1 2 3 4 5 6 7 8 9 10
J5
POS
S2A
H
A
S2
201
204
W209
R210
8
16
1 2 3 4 5 6 7 8 9 10
W
SPOT
TACHE
PUNTO
L8
N.C.
J3
+ R -
W
J11
1 2 3 4 5 6 7 8 9 10
407
408
409
410
401D
405
406
401B
402
403
411
4 STEP
4 TEMPS
4 PASO
N.C.
R12
R11
R10
N.D.
J7
401C
Return to Master TOC
Return to Section TOC
ADVANCED CONTROL PANEL (OPTIONAL)
PANNEAU DE COMMANDE AVANCÉ (OPTION)
PANEL DE CONTROL AVANZADO (OPCIONAL)
2
10
3
11
F
C
SCR4
G4
252
253
1
9
10
E
D1
F X2
GND6
335
SCR3
220
J10
D
B
G3
X1
78VAC
S2
S2A
OPEN OUVERT ABIERTO
AC A-C, D-E, B-F
DC+ B-D, C-E, A-F, G-H CLOSED FERMÉ CERRADO
DC- B-D, A-E, C-F, G-H CLOSED FERMÉ CERRADO
L1
265A
334
SCR2
217A
217
218
216
S
232
266
333
G4
G2
217
220
POS
218A
265
W
G2
R8B
Y
218
NEG
B
G1
G3
115VAC
F
X4
T1
SCR1
G1
231
231A
253
W
X1
218B
316A
318
313
B
332
1
6
2
7
3
8
4
9
5
216
252
W
+ G -
331
W
B
W
B
W
B
W
B
W
B
L4
X5
63.5VAC
X6
S X3
X7
S
20VAC
F
X8
W209
R210
6
234
F
H4 (460V)
X9
S
201
18VAC
204
F
X10
SV2
2
C9
231
8
S
H2 (208V)
H3 (230V)
A LA TERRE SELON LE CODE
ÉLECTRIQUE NATIONAL
A TIERRA CONFORME EL CÓDIGO
ELÉCTRICO NACIONAL
TO GROUND PER
NATIONAL
ELECTRICAL CODE
NEG
316B
316A
317
B
332
331
W
-
THERMAL
THERMIQUE
TERMAL
335
B
W
+ G
J4
COM
216A
L12
1
2
3
4
5
6
7
8
9
CR4
250
RECONNECT PANEL
PANNEAU DE RECONNEXION
PANEL DE RECONEXIÓN
233B
4
H1
LOW
N.F.
W 221
R 222
J9
10
POST FLOW
ÉCOULEMENT DE POTEA
FLUJO DEL POSTE
334
B
REMOTE
BALANCE
À DISTANCE
ÉQUILIBRE
BALANCEADO REMOTO
+ G -
313A
333
-
+ R
R3
311A
311
312
311A
322
REMOTE
À DISTANCE
REMOTO
316
313C
316C
319
STICK
ÉLECTRODE
VARILLA
R1
1
2
3
4
5
6
7
8
9
10
11
12
1
2
J6
L2 (V)
GROUND
TERRE
TIERRA
251
C2
HIGH
C4
115VAC
C8
A
MID
C5
231A
321
316C
316B
315
314
320
316D
Return to Master TOC
Return to Section TOC
TIG
POST FLOW
ÉCOULEMENT DE POTEA
FLUJO DEL POSTE
+
R2
LOCAL
311
312
313
314
315
316
317
318
319
320
321
322
L6
313B
MAX OUTPUT
RENDEMENT
SALIDA
-
BALANCE
ÉQUILIBRE
BALANCEADO
STICK
ÉLECTRODE
VARILLA
J8
H2
230
R4
1
2
3
4
5
6
N.E.
H3
H4
L1 (U)
233A
DISPLAY
AFFICHAGE
PANTALLA
J13
S1
C1
N.A. LA CONEXIÓN ES DE PIN A PIN ENTRE J23 Y J5.
N.B. CONEXIÓN DE LA INTERFAZ ROBÓTICA.
N.C. REMUEVA EL CONECTOR DE PUENTE EN J3 CUANDO INSTALE LA
TARJETA DE PC TIG OPCIONAL.
N.D. DESCONECTE EL CABLE DEL PUENTE ENTRE EL PIN 1 Y PIN 2 EN J3
PARA DUPLICAR LOS TIEMPOS DE PRE Y POSTFLUJO.
N.E. EL INTERRUPTOR DE PALANCA DE LA PANTALLA SE MUESTRA EN LA
POSICIÓN MÍNIMA DE AMPERIOS.
N.F. ENCHUFES EN RECEPTÁCULO CONMUTADO INFERIOR.
238
MIN. OUTPUT
RENDEMENT
SALIDA
L5
CONTROL PC BOARD
CI DE COMMANDE
TABLEAU DE
TARJETA ELECTRONICA
DE CONTROL
H1
L2 (V)
239
346
343
344
345
346
347
1
2
3
4
5
6
7
8
220A
S3
344
347
345
343
231E
1
2
3
4
J7
N.A. CONNEXION CONTACT-CONTACT ENTRE J23 ET J5
N.B. CONNEXION INTERFACE ROBOTIQUE
N.C. ENLEVER LA FICHE CAVALIER EN J3 QUAND ON INSTALLE LE CI EN
OPTION TIG
N.D. DÉCONNECTER LE CÂBLE DU CAVALIER ENTRE LES CONTACTS 1 ET
2 DANS J3 POUR DOUBLER TEMPS DE PRÉGAZ ET POSTGAZ.
N.E. AFFICHE LA BASCULE ILLUSTRÉE EN POSITION A MINIMUM.
N.F. SE BRANCHE LA PRISE À INTERRUPTEUR INFÉRIEURE.
TIG OPTION PCB
CI OPTION TIG
PCB DE OPCIÓN
TIG
METER
COMPTEUR
MEDIDOR
N.A. CONNECTION IS PIN TO PIN BETWEEN J23 AND J5.
N.B. ROBOTIC INTERFACE CONNECTION.
N.C. REMOVE JUMPER PLUG IN J3 WHEN INSTALLING
TIG OPTION PC BOARD.
N.D. DISCONNECT JUMPER LEAD BETWEEN PIN 1 AND
PIN 2 IN J3 TO DOUBLE PREFLOW & POSTFLOW TIMES.
N.E. DISPLAY TOGGLE SHOWN IN MIN AMP POSITION.
N.F. PLUGS INTO LOWER SWITCHED RECEPTACLE.
236
CONTROL PANEL (VIEWED FROM REAR)
PANNEAU DE COMMANDE (VIEWED FROM REAR)
PANEL DE CONTROL (VISTO DESDE ATRÁS)
L1 (U)
GND6
PRECISION TIG 275 WIRING DIAGRAM
SCHÉMA DE CÂBLAGE DIAGRAMAS DE CABLEADO
(-)
Return to Master TOC
WIRING DIAGRAM - ENTIRE MACHINE - CODE 11158 (G5692)
316D
Return to Section TOC
G-5
ELECTRICAL DIAGRAMS
(+)
Return to Section TOC
G-5
CONNECTOR PIN NUMBERS: NOMBRE DE CONTACTS CONNECTEURS
NÚMEROS DE PINES DE CONECTORES:
EXAMPLE: THIS IS PIN 1
1 2 3
7
0F CONNECTOR J5
EXEMPLE: C'EST LE CONTACT 1
1 2 3
8
WORK DU CONNECTEUR J5
14
8
J5
PIÈCE EJEMPLO: ESTE ES EL PIN 1 DEL
VIEW OF CONNECTOR ON PC BOARD
VUE DES CONNECTEURS SUR CI
TRABAJO CONECTOR J5
VISTA DEL CONECTOR EN LA
TARJETA ELECTRONICA
ELECTRICAL SYMBOLS PER E1537.
285
SYMBOLES ÉLECTRIQUES SELON E1537
SÍMBOLOS ELÉCTRICOS CONFORME A E1537
LEAD COLORING CODE:
CODE DE COULEUR DES CÂBLES:
CÓDIGO DE COLORES DE CABLES:
W-WHITE
R-RED
B-BLACK
BLANC
ROUGE
NOIR
BLANCO
ROJO
NEGRO
Y-YELLOW
B-BLUE
G-GREEN
JAUNE
BLEU
VERT
AMARILLO
AZUL
VERDE
O-ORANGE
NARANJA
CLEVELAND , OHIO
A
G5692PRINT
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
®
PRECISION TIG 275
Return to Master TOC
401B
AMPTROL
A
B
C
D
E
F
404
413
401A
401
A
B
C
D
E
F
TM
B
1 2 3 4 5 6 7 8 9 10
OR
407
401D
401
402
403
404
405
406
407
408
409
410
411
W
413
W
L10
- G +
B
PULSE
PULSÉ
PULSACIÓN
L9
PROTECTION PCB
CI PROTECTION
PCB DE PROTECCIÓN
REMOTE RECEPTACLE
PRISE À DISTANCE
RECEPTÁCULO REMOTO
A
B
C
D
E
F
4
1
2
3
6
5
J22
J23
1
2
3
4
5
7
6
8
N.A.
1
2
3
4
5
7
6
8
1
2
3
4
5
7
6
8
J1
1
2
3
4
5
6
7
8
9
10
11
12
1
2
6
12
5
13
4
14
7
15
265
266
262
263
213
214
R 222
W 221
GND6
C6
NC
C7
0
CR4
263
C8,C9
1
262
266A
265A
X2
C4,C5
R7A
R7B
229
L13
D1
R7C
R7D
218A
271A
269
271
268
270
229A
229
216A
L1
R8A
R6
201
204
W209
R210
VENTILATEUR
VENTILADOR
J20
260
C
TARJETA ELECTRONICA DE
DERIVACIÓN /
ESTABILIZADOR
213
T1 PRIMARY
THERMOSTAT
T1 PRIMAIRE
THERMOSTAT
T1 SECONDARY
THERMOSTAT
T1 SECUNDARIO
THERMOSTAT
233A
J2
SV1
235
J5A
231E
233A
231D
E
L11
N.B.
J12
1
2
3
5
6
4
115VAC
260
235
236
233A
237
T2
F
C7
R5
236B
R
S
L2
SPARK GAP
ÉCLATEUR
ABERTURA
DE CHISPA
L3
C6
ARC STARTER AS'BLY
ENSEMBLE DÉMARREUR D'ARC
ENSAMBLE DE ARRANCADOR DE
ARCO
COMPONENT VALUE UNITS:
UNIDADES DE VALOR DE COMPONENTES:
RESISTORS: OHMS/WATTS
RESISTORES: OHMS/WATTS
CAPACITORES: MFD/VOLTIOS
CAPACITORS: MFD/VOLTS
UNITÉS DE VALEUR DES COMPOSANTS:
RÉSISTANCES: OHMS/WATTS
CONDENSATEURS: MFD/VOLTS
R6
284
FRONT
ELECTRODE
ÉLECTRODE AVANT
ELECTRODO FRONTAL
REAR
ELECTRODE
ÉLECTRODE ARRIÈRE
ELECTRODO POSTERIOR
231A
F
T3
R7A,R7B,
R7C,R7D,
R8A, R8B
S1
460 V
CONNECT STRAP TO LOW (H2)
CONNECTER LA BRIDE SUR BAS (H2)
SUJETADOR DE CONEXIÓN A BAJO (H2)
POWER FACTOR CAPACITORS, 50/460
BY-PASS CAPACITORS, .0047
HIGH VOLTAGE CAPACITOR, .0015/12kV
PHASE SHIFT CAPACITOR, 15uF/250VAC
HIGH FREQ PROTECTION CAPACITORS, .22/400
CIRCUIT BREAKER, 15 AMP
12V DC RELAY COIL
FREE WHEELING DIODE
OUTPUT INDUCTOR (CHOKE)
HIGH FREQ INDUCTORS
RF TOROID CHOKES
PHASE SHIFT RESISTOR, 200/100
HOLDING RESISTOR, 50/225
RESISTOR, 5/50
INPUT POWER SWITCH
POLARITY SWITCH
MICROSWITCH ON POLARITY SWITCH
MENU SWITCH
MAIN POWER SCR'S
GAS SOLENOID VALVE, 115VAC
WATER SOLENOID VALVE, 115VAC (OPTIONAL)
MAIN TRANSFORMER
HIGH VOLTAGE TRANSFORMER
HIGH FREQ TRANSFORMER
CONDENSATEURS FACTEUR DE PUISSANCE, 50/460
CAPACITORES DE FACTOR DE POTENCIA, 50/460
CONDENSATEURS DÉRIVATION , .0047
CAPACITORES DE DERIVACIÓN, .0047
CONDENSATEUR HAUTE TENSION, .0015/12kV
CAPACITOR DE ALTO VOLTAJE, .0015/12kV
CONDENSATEUR, DÉPHASAGE, 15Mf/250VCA
CAPACITOR DE CAMBIO DE FASE 15uf/250VCA
CONDENSATEURS DE PROTECTION HF, .22/400
CAPACITORES DE PROTECCIÓN CONTRA ALTA
FRECUENCIA, .22/400
DISJONCTEUR, 15 AMP
INTERRUPTOR AUTOMÁTICO, 15 AMPS
BOBINE RELAI DE 12V CC
BOBINA DE RELEVADOR DE 12V DE DC
DIODE ROUE LIBRE
DIODO DE RUEDA LIBRE
INDUCTEUR DE SORTIE (STARTER)
INDUCTOR DE SALIDA (ESTABILIZADOR)
INDUCTANCES HF
INDUCTORES DE ALTA FRECUENCIA
STARTERS TOROÏDE FRÉQUENCE RADIO
ESTABILIZADORES TOROIDAL RF
RÉSISTANCE DÉPHASAGE, 200/100
RESISTOR DE CAMBIO DE FASE, 200/100
RÉSISTANCE DE MAINTIEN, 50/225
RESISTOR DE SOSTENIMIENTO, 50/225
RÉSISTANCE, 5/50, RESISTORES, 5/50
INTERRUPTEUR DE PUISSANCE D’ENTRÉE
INTERRUPTOR DE ENERGÍA DE ENTRADA
INTERRUPTEUR DE POLARITÉ
INTERRUPTOR DE POLARIDAD
MICRORUPTEUR SUR SÉLECTEUR DE POLARITÉ
S2A
MICROINTERRUPTOR EN EL INTERRUPTOR DE
POLARIDAD
INTERRUPTEUR MENU
S3
INTERRUPTOR DE MENÚ
SCR1,2,3,4 REDRESSEURS DE PUISSANCE PRINCIPAUX
SCR'S DE ALIMENTACIÓN PRINCIPAL
SV1
SOUPAPE SOLÉNOÏDE DE GAZ, 115 VAC
VÁLVULA DE SOLENOIDE DE GAS, 115 VCA
SOUPAPE SOLÉNOÏDE À EAU, 115 VAC
SV2
VÁLVULA DE SOLENOIDE DE AGUA, 115 VCA
T1
TRANSFORMATEUR PRINCIPAL
TRANSFORMADOR PRINCIPAL
T2
TRANSFORMATEUR HAUTE TENSION
TRANSFORMADOR DE ALTO VOLTAJE
T3
TRANSFORMATEUR HAUTE FRÉQUENCE
TRANSFORMADOR DE ALTA FRECUENCIA
S2
214
BYPASS/STABILIZER PC BOARD S
CI DÉRIVATION/STABILISATEUR
L2,L3
L4 -L13
R5
262
263
GND6
FAN
CB1
CR4
217A
1 2 3 4 5 6 7 8 9 10
J5
B
NO
G
S2
201
204
W209
R210
8
16
1 2 3 4 5 6 7 8 9 10
W
SPOT
TACHE
PUNTO
L8
N.C.
J3
+ R -
W
J11
269
270
271
229A
POS
S2A
H
A
C1,C2
C4,C5
C6
C7
C8,C9
CB1
CR4
D1
L1
L2,L3
L4 -L13
R5
R6
R7A, R7B,
R7C, R7D,
R8A, R8B
S1
S2
S2A
S3
SCR1,2,3,4
SV1
SV2
T1
T2
T3
C1,C2
GND6
J3
R12
408
409
410
401D
405
406
401B
402
403
411
PULSE
PULSÉ
PULSACIÓN
2 STEP
2 TEMPS
2 PASO
10K A-B
MINIMUM
SPOT
TACHE
PUNTO
N.C.
J7
401C
4 STEP
4 TEMPS
4 PASO
2
10
3
11
N.D.
D1
SCR4
G4
252
253
1
9
F
C
78VAC
F X2
266
J10
10
1
3
2
5
4
6
DOWN SLOPE
VERS LE BAS PENTE
ABAJO CUESTA
R11
R10
R9
Return to Master TOC
Return to Section TOC
BACKGROUND
ARRIÈRE PLAN
FONDO
220
E
X1
S2
S2A
OPEN OUVERT ABIERTO
AC A-C, D-E, B-F
DC+ B-D, C-E, A-F, G-H CLOSED FERMÉ CERRADO
DC- B-D, A-E, C-F, G-H CLOSED FERMÉ CERRADO
D
B
X7
S
20VAC
F
X8
232
X4
F
T1
L1
SCR3
F
231
231A
115VAC
S
265
334
335
SCR2
G3
18VAC
X10
SV2
217A
217
218
216
S
R8B
333
G4
G2
217
220
POS
W209
R210
NEG
W
218
218A
G2
X5
63.5VAC
X6
S X3
F
253
B
1
6
2
7
3
8
4
9
5
G1
G1
G3
N.F.
SCR1
218B
W
332
ADVANCED CONTROL PANEL (OPTIONAL)
PANNEAU DE COMMANDE AVANCÉ (OPTION)
PANEL DE CONTROL AVANZADO (OPCIONAL)
FREQ
J4
316A
318
313
B
Y
L7
ON TIME
À L 'HEURE
EL TIEMPO
1
2
3
4
5
6
7
8
9
X1
6
S
H4 (575V)
X9
201
204
2
234
H2 (460V)
A LA TERRE SELON LE CODE
ÉLECTRIQUE NATIONAL
A TIERRA CONFORME EL CÓDIGO
ELÉCTRICO NACIONAL
231
8
H1
COM
252
W
+ G -
331
W
B
W
B
W
B
W
B
W
B
216
NEG
B
332
331
W
-
THERMAL
THERMIQUE
TERMAL
L4
CR4
251
RECONNECT PANEL
PANNEAU DE RECONNEXION
PANEL DE RECONEXIÓN
230
B
W
+ G
J9
250
LOW
216A
231A
316B
316A
311A
311
312
316
317
+ G -
POST FLOW
ÉCOULEMENT DE POTEA
FLUJO DEL POSTE
W 221
R 222
L12
10
335
B
REMOTE
BALANCE
À DISTANCE
ÉQUILIBRE
BALANCEADO REMOTO
334
-
+ R
R3
313A
333
STICK
ÉLECTRODE
VARILLA
POST FLOW
ÉCOULEMENT DE POTEA
FLUJO DEL POSTE
R1
REMOTE
À DISTANCE
REMOTO
311A
322
TIG
319
R2
LOCAL
313B
MAX OUTPUT
RENDEMENT
SALIDA
1
2
3
4
5
6
7
8
9
10
11
12
1
2
J6
TO GROUND PER
NATIONAL
ELECTRICAL CODE
C1
C9
233
233B
4
C2
L2 (V)
GROUND
TERRE
TIERRA
233A
316C
316B
315
314
320
316C
313C
Return to Master TOC
STICK
ÉLECTRODE
VARILLA
311
312
313
314
315
316
317
318
319
320
321
322
L6
+
Return to Section TOC
BALANCE
ÉQUILIBRE
BALANCEADO
J8
231E
N.E.
321
R4
1
2
3
4
5
6
J13
N.A. LA CONEXIÓN ES DE PIN A PIN ENTRE J23 Y J5.
N.B. CONEXIÓN DE LA INTERFAZ ROBÓTICA.
N.C. REMUEVA EL CONECTOR DE PUENTE EN J3 CUANDO INSTALE LA
TARJETA DE PC TIG OPCIONAL.
N.D. DESCONECTE EL CABLE DEL PUENTE ENTRE EL PIN 1 Y PIN 2 EN J3
PARA DUPLICAR LOS TIEMPOS DE PRE Y POSTFLUJO.
N.E. EL INTERRUPTOR DE PALANCA DE LA PANTALLA SE MUESTRA EN LA
POSICIÓN MÍNIMA DE AMPERIOS.
N.F. ENCHUFES EN RECEPTÁCULO CONMUTADO INFERIOR.
238
DISPLAY
AFFICHAGE
PANTALLA
-
MIN. OUTPUT
RENDEMENT
SALIDA
L5
CONTROL PC BOARD
CI DE COMMANDE
TABLEAU DE
TARJETA ELECTRONICA
DE CONTROL
HIGH
C4
A
115VAC
C8
CB1
15A
H2
MID
C5
232
S1
H4
L1 (U)
575 V
CONNECT STRAP TO HIGH (H4) (AS SHOWN)
CONNECTER LA BRIDE SUR HAUT (H4)
(COMME ILLUSTRÉ)
SUJETADOR DE CONEXIÓN A ALTO (H4)
(COMO SE MUESTRA)
H1
L2 (V)
239
346
343
344
345
346
347
1
2
3
4
5
6
7
8
220A
J7
S2
344
347
345
343
1
2
3
4
N.A. CONNEXION CONTACT-CONTACT ENTRE J23 ET J5
N.B. CONNEXION INTERFACE ROBOTIQUE
N.C. ENLEVER LA FICHE CAVALIER EN J3 QUAND ON INSTALLE LE CI EN
OPTION TIG
N.D. DÉCONNECTER LE CÂBLE DU CAVALIER ENTRE LES CONTACTS 1 ET
2 DANS J3 POUR DOUBLER TEMPS DE PRÉGAZ ET POSTGAZ.
N.E. AFFICHE LA BASCULE ILLUSTRÉE EN POSITION A MINIMUM.
N.F. SE BRANCHE LA PRISE À INTERRUPTEUR INFÉRIEURE.
TIG OPTION PCB
CI OPTION TIG
PCB DE OPCIÓN
TIG
METER
COMPTEUR
MEDIDOR
N.A. CONNECTION IS PIN TO PIN BETWEEN J23 AND J5.
N.B. ROBOTIC INTERFACE CONNECTION.
N.C. REMOVE JUMPER PLUG IN J3 WHEN INSTALLING
TIG OPTION PC BOARD.
N.D. DISCONNECT JUMPER LEAD BETWEEN PIN 1 AND
PIN 2 IN J3 TO DOUBLE PREFLOW & POSTFLOW TIMES.
N.E. DISPLAY TOGGLE SHOWN IN MIN AMP POSITION.
N.F. PLUGS INTO LOWER SWITCHED RECEPTACLE.
236
CONTROL PANEL (VIEWED FROM REAR)
PANNEAU DE COMMANDE (VIEWED FROM REAR)
PANEL DE CONTROL (VISTO DESDE ATRÁS)
L1 (U)
233A
PRECISION TIG 275 WIRING DIAGRAM
SCHÉMA DE CÂBLAGE DIAGRAMAS DE CABLEADO
(-)
Return to Master TOC
WIRING DIAGRAM - ENTIRE MACHINE - CODE 11159 (G5692-1)
316D
Return to Section TOC
G-6
ELECTRICAL DIAGRAMS
(+)
Return to Section TOC
G-6
CONNECTOR PIN NUMBERS: NOMBRE DE CONTACTS CONNECTEURS
NÚMEROS DE PINES DE CONECTORES:
EXAMPLE: THIS IS PIN 1
1 2 3
7
0F CONNECTOR J5
EXEMPLE: C'EST LE CONTACT 1
1 2 3
8
DU
CONNECTEUR
J5
WORK
14
8
J5
PIÈCE EJEMPLO: ESTE ES EL PIN 1 DEL
VIEW OF CONNECTOR ON PC BOARD
VUE DES CONNECTEURS SUR CI
TRABAJO CONECTOR J5
VISTA DEL CONECTOR EN LA
TARJETA ELECTRONICA
ELECTRICAL SYMBOLS PER E1537.
285
SYMBOLES ÉLECTRIQUES SELON E1537
SÍMBOLOS ELÉCTRICOS CONFORME A E1537
LEAD COLORING CODE:
CODE DE COULEUR DES CÂBLES:
CÓDIGO DE COLORES DE CABLES:
W-WHITE
R-RED
B-BLACK
BLANC
ROUGE
NOIR
BLANCO
ROJO
NEGRO
Y-YELLOW
B-BLUE
G-GREEN
JAUNE
BLEU
VERT
AMARILLO
AZUL
VERDE
O-ORANGE
NARANJA
CLEVELAND , OHIO
A
G5692-1PRINT
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
®
PRECISION TIG 275
SCHEMATIC - ENTIRE MACHINE - BELOW CODE 11000 (G4075)
IN(-)
1
2
3
4
5
6
306
303
IN(+)
205mV BETWEEN
IN(+) & IN(-) IS
205A OR 20.5V
1
2
3
4
5
6
METER
301
301
302
303
304
304A
306
304B
304B
302
+5V
DECIMAL PT. IN
IN (+)
COM
DECMAL PT.OUT
IN (-)
TOROID
1J8
2J8
3J8
4J8
5J8
6J8
1J4
5J4
2J4
4J4
9J4
6J4
10J4
7J4
3J4
8J4
(VIEWED FROM REAR)
R1
313A
MIN
OUTPUT
311
312
+10V
314
320
+1.5V
322
316
317
318
321
315
R4
10K
313B
CW
311A
R2
BALANCE
SHUNT (-)
PRESET (0 - 10V)
MIN OUTPUT (0 - 1.5V)
BALANCE (0 - 10V)
+15V
REMOTE (+15V)
POSTFLOW (0 - 15V)
DISPLAY MIN A (+15V)
DISPLAY VOLT (+15V)
319
STICK (+15V)
313
COM
10K
1J9
2J9
4J9
10J9
6J11
MICRO SWITCH ON POLARITY SWITCH
12J11
1J11
9J11
MICRO SWITCH ON POLARITY SWITCH
12J9
6J9
7J9
8J9
11J9
265
266
252
253
VOLT FEEDBACK, ELECTRODE
VOLT FEEDBACK, WORK
9J9
3J9
115VAC IN DC STICK
255
CR2
316B
POST FLOW R3
316C
253
315
STICK
B
B
W
B
W
B
W
334
333
332
THERMAL
(YELLOW)
GAS
(GREEN)
REMOTE
(GREEN)
W
335
LED LIGHTS
331 B
331 W
6J10
332 B
332 W
B
333
333 W
7J10
334 B
334 W
9J10
335 B
335 W
10J10
223
BACKGND FILTER CAP., POS
3J11
11J11
10J11
2J11
1J10
271
BACKGND FILTER CAP., NEG
BYPASS/STABILIZER
PCB
BACKGND RESISTOR
R7
20/100
271A
BACKGND AC OUT (63.5VAC) IN DC TIG
BACKGND AC IN (63.5VAC)
2J10
286
(SCHEMATIC S22530)
D2
BACKGND DIODE
268
8J10
DC TIG BACKGROUND
CIRCUIT
1J7
3J7
2J7
5J7
4J7
6J7
4J10
5J10
PT375 ONLY
63.5V
267
269
BACKGND RECTIFIER
HOLDING RESISTOR
R1
DOWN SLOPE
405
10K
403
ADVANCED CONTROL 6J12
PCB
3J12
407
10K
401B
B
TRIGGER
(SHOWN PULSE ON)
ON TIME (1-15V)
DOWNSLOPE
(SHOWN IN 2-STEP)
W
R11
CW
401
2-STEP
411
4-STEP
OFF
404
ON
2J1
3J1
5J1
6J1
7J1
8J1
9J1
10J1
4J1
1J1
11J1
12J1
409
404
401
411
W
10K
PULSE
(GREEN)
410
PULSE ON (15V)
+15V
2-STEP (15V)
PULSE LED
J2
236
235
GAS (115VAC)
4J12
115VAC IN
2J12
FAN (115VAC)
MOVE THIS PLUG FROM
J5 TO J5A FOR ROBOTIC INTERFACE
REMOTE
RECEPTACLE
U
4J22
A
260
235
233A
WHEN ADVANCED CONTROL
PCB IS NOT INSTALLED
5J11
1J22
2J23
2J22
3J23
WIPER
B
D
3J22
4J23
MIN
5J23
D
W
E
6J22
7J23
E
7J5
5J22
1J23
F
1J5
6J5
16J11
8J5
7J11
F
TOROID
TM
OPTIONAL AMPTROL REMOTE
CONTROL AND ARC START SWITCH
PROTECTION
PCB
(SCHEMATIC M16115)
4J5
5J5
TOROID
230/460/575
REAR
ELECTRODE
SV1
115 V
RECEPTACLE
(TOP)
13J11
TOP FAN
(115VAC)
TOROID
260
COOLER, +12VDC IN TIG WELDING
262
COOLER, COMMON
263
COOLER RELAY
(12VDC)
233B
262
231F
BOTTOM FAN
(115VAC)
260A
PLUGGED TO
COOLER RECEPTACLE
C8
.22/400V
14J11
TSTAT
4J11
TSTAT
8J11
15J11
CONTROL PCB
209
X7
210
X8
201
X9
20VAC
CONTROL BOARD SUPPLY
20VAC
TRIGGER CIRCUIT
204
T1
X10
C9
.22/400V
X3
115VAC
X4
231
234
263
ELECTRICAL SYMBOLS PER E1537
232
233
CR4
FAN
FAN
CB1
115V/15A
COOLER
RECEPTACLE
(BOTTOM)
T1
105VAC
LEAD COLORING CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
214
212
213
215
220V 2A
RECEPTACLE
SV2
(115VAC)
SECONDARY TSTAT
PRIMARY TSTAT
(OF MAIN TRANSFORMER T1)
OPTIONAL
WATER
SOLENOID
KIT
COMPONENT VALUE
UNITS:
CAPACITORS:
MFD/VOLTS
RESISTORS:
OHMS/WATTS
CB2
X14
PRECISION TIG 275 ONLY
( SCHEMATIC G3908-X)
LEAD #250 CONNECTS TO THE "MID" TERMINAL
ON THE RECONNECT PANEL, ALONG WITH CORRECT
LEAD FROM THE MAIN TRANSFORMER (T1)
460/575
LEAD #250 CONNECTS TO THE "LOW" TERMINAL
ON THE RECONNECT PANEL, ALONG WITH CORRECT
LEAD FROM THE MAIN TRANSFORMER (T1)
233A
(TIG WELDING)
231A
PRECISION
TIG 375 ONLY
C
C
LEAD #250 CONNECTS TO THE H5 LEAD OF
THE MAIN TRANSFORMER (T1)
T3
HI-FREQ CIRCUIT
2 3 4
B
3J5
L3
(115VAC)
DISCONNECT FOR
DOUBLE PRE/POST FLOW
220/380/415
HIGH FREQ.
TRANSFORMER
SPARK
GAP
12.5 OHM TYP.
ARC FORCE TRIMMER
J3 1
LEAD #250 CONNECTS TO "HIGH" TERMINAL ON
RECONNECT PANEL, ALONG WITH CORRECT LEAD
FROM MAIN TRANSFORMER (T1)
.0015/12KV
GAS
SOLENOID
R
2J5
14.5 KOHMS
TYP.
TYP.
C6
208/230/460
(STICK WELDING)
PRESENT ONLY ON
PRECISION TIG 375
239
N
B
12.5 OHM TYP.
F
MAX
A
S
C7
15/250 5.5 OHMS
238
231E
2J5A
3J5A
4J5A
5J5A
7J5A
1J5A
6J5A
8J5A
237
236B
233A
HOT START TRIMMER
ADVANCED CONTROL PANEL (OPTIONAL ON PT275)
L2
R5
DIP SWITCH
408
FREQ. (.08 - 15V)
(ADVANCED FEATURES
SELECTION)
402
403
405
406
407
BACK GROUND
401A
(SCHEMATIC G4039-X)
(OPTIONAL ON PT275)
TOROID
406
HI-FREQ (115VAC)
WORK
FRONT
ELECTRODE
3/25
T2
200/100
231E
R12
R10
R9
CW
10K
TOROID
CW
HI-FREQ INTENSITY
R13
HIGH VOLTAGE
TRANSFORMER
231D
CW
NOTE A:
LEAD #250 FROM POWER FACTOR CAPACITORS
CONNECTS ACCORDING TO THE INPUT VOLTAGE
50/100
401D
T1
X6
268
BACKGND TRIAC
CURRENT LIMITING RESISTOR
220A
220C
220B
X5
267
5/50
R8
3J10
240
ON TIME
401C
402
250
SEE NOTE A
PT275: OPTIONAL, C1=C2=50/460
C3 NOT PRESENT
TOROID
FREQUENCY
PRECISION TIG 375
ONLY
PT375: STANDARD, C1=C2=C3=60/460
TOROID
(SHOWN IN STICK)
331
C3
319
MODE SWITCH
AUTO BALANCE
(GREEN)
W
C2
POWER FACTOR
CAPACITORS
POLARITY
SWITCH
S2
231B
CONTROL PANEL
Return to Master TOC
252
MICRO SWITCH
N.O.
212
N.C.
CR3
SCHE. S24206-X
L2
C1
DC
266
227A
313
DC+
BYPASS PCB
TIG
DISPLAY SWITCH
Return to Master TOC
226
AC
L1A
H1
AC
DC- +
231A
231B
VOLT
STICK
(RED)
CONNECTOR PIN NUMBERS:
EXAMPLE: THIS PIN IN
CONNECTOR J11 IS "6J11"
1 2 3
8
220V/5A
50/60HZ MACHINES ONLY
9
PRECISION TIG 375
ONLY
16
LATCH
VIEW OF CONNECTOR ON PC BOARD
AUX. WINDINGS OF
MAIN TRANSFORMER T1
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02
EN-170
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
"X" INFO
XB-UF
DO NOT SCALE THIS DRAWING
Chg. Sheet No.
3-8-2002A
DESIGN INFORMATION
REFERENCE:
DRAWN BY: TN
ENGINEER: TN
APPROVED:
SUPERSEDING:
EQUIPMENT TYPE:
SUBJECT:
SCALE: NONE
PRECISION TIG
MACHINE SCHEMATIC
DATE: 01-29-02 DRAWING No.:
G 4075
SOLID EDGE
Return to Section TOC
R14
270
A
10K
DC-
CLOSED
IN DC
8/300
AC
BOOST
231C
10K
313A
PULSE
CR2
265
L1
L2A
RECONNECT
PANEL
AC
321
MIN A
B
258
+
DC
DC-
AC
CR3
OCV BOOST
RECTIFIER
CR3
DC
BOOST CR3
CW
DC+
DC-
228
225A
225
C5
LOW
H2
H1
X2
256
POWER SWITCH
HIGH
MID
H3
223
L1
224
115VAC IN AC STICK
1J12
5J12
CR2
316A
H4
X1
50/60HZ MACHINE ONLY
.0047/ 3KV
X13
227
316
MAIN
TRANSFORMER
T1 H5
SHUNT
400A/200mV
OUTPUT
INDUCTOR
TOROID
5J9
318
Return to Master TOC
Return to Section TOC
LOCAL
(SHOWN IN REMOTE)
50HZ MACHINE ONLY
SCR2
PT375 ONLY
STICK OCV BOOST CIRCUIT,
PRESENT ONLY ON PRECISION TIG 375
257
317
+
BYPASS ASSEMBLY
C4
R 222(-)
W 221(+)
313C
REMOTE
FREE WHEELING DIODE SCR3
G3
217
218
W 221
R 222
SCR1
MAIN
RECTIFIER
-
220A
D1
TOROID
SHUNT (+)
SCR4
TOROID
10K
CW
216
G4
G1
G2
220
X
X
1J6
2J6
TOROID
CW
SCR1 GATE
G1
SCR2 GATE
G2
SCR3 GATE
G3
SCR4 GATE
G4
SCR1,SCR2 CATHODE 218
SCR3 CATHODE
217
SCR4 CATHODE
216
SCR3,SCR4 ANODE 220
215
TOROID
MAX
OUTPUT
Return to Section TOC
G-7
ELECTRICAL DIAGRAMS
238A
Return to Master TOC
Return to Section TOC
G-7
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
COM
9J9
3J9
IC chip
controller
317
316
B
331
THERMAL
(YELLOW)
GAS
(GREEN)
REMOTE
(GREEN)
B
W
B
W
B
W
334
333
332
335
LED LIGHTS
ON TIME
9J10
5v
opto
triac
4J10
10J10
opto
triac
5J10
opto
triac
10K
BACK GROUND
W
408
B
FREQ. (.08 - 15V)
PULSE
(GREEN)
R11
401
TRIGGER
(SHOWN IN 2-STEP)
W
409
404
401
411
W
10K
410
flashes with
pulse frequency
DOWNSLOPE
PULSE ON (15V)
+15V
2-STEP (15V)
PULSE LED
413
W
MOVE THIS PLUG FROM
J5 TO J5A FOR ROBOTIC INTERFACE
B
1J22
2J23
MAX
C
2J22
3J23
WIPER
R
4J23
MIN
W
2J5A
3J5A
4J5A
5J5A
7J5A
1J5A
6J5A
8J5A
(bottom behind fan)
5J23
D
E
7J5
F
1J5
6J5
5J22
1J23
PROTECTION
PCB
TOROID
8J5
T2
L2
260
S
C7
5.5 OHMS
TYP.
opto
12.5 OHM TYP.
14.5 KOHMS
TYP.
4J11
8J11
16J11
to thermo
led & CPU
7J11
15J11
CONTROL PCB
( SCHEMATIC G4762-X)
NOTE A:
LEAD #250 FROM POWER FACTOR CAPACITORS
CONNECTS ACCORDING TO THE INPUT VOLTAGE
5KV
239
TOP FAN
(115VAC)
c.c. w
intake
COOLER, COMMON
LEAD #250 CONNECTS TO THE H5 LEAD OF
THE MAIN TRANSFORMER (T1)
233A
(TIG WELDING)
outside of right side box
COOLER RELAY
(12VDC)
233B
115 V
RECEPTACLE
(TOP of plug)
"ON" with input power sw.
262
CR4
FAN
BOTTOM FAN
(115VAC)
c.w.
exhaust
260A
262
263
TSTAT
263
PLUGGED TO
COOLER RECEPTACLE
C8
.22/400V
210
X8
201
X9
204
X10
wounded into
primary
215
N.C.
N.C.
lead
mounted
SECONDARY TSTAT
PRIMARY TSTAT
(OF MAIN TRANSFORMER T1)
TOP FAN
X4
T1
ELECTRICAL SYMBOLS PER E1537
C9
(top rear) .22/400V
212
213
T1
115VAC
105VAC
LEAD COLOR CODE:
CB2
B-BLACK OR GRAY
G-GREEN
O-ORANGE
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
X14
214
X7
230/460/575
LEAD #250 CONNECTS TO THE "MID" TERMINAL
ON THE RECONNECT PANEL, ALONG WITH CORRECT
LEAD FROM THE MAIN TRANSFORMER (T1)
460/575
LEAD #250 CONNECTS TO THE "LOW" TERMINAL
ON THE RECONNECT PANEL, ALONG WITH CORRECT
LEAD FROM THE MAIN TRANSFORMER (T1)
X3
231
220V 2A
RECEPTACLE
Make sure that the rear EXTERNAL
baffle is inplace and not damaged.
209
232
233
234
PRECISION TIG 275 ONLY
TSTAT
CB1
115V/15A
COOLER
RECEPTACLE
(BOTTOM of plug)
"ON" with output
231F
FAN
260
COOLER, +12VDC IN TIG WELDING
220/380/415
(right side)
115V common
231A
PRECISION
TIG 375 ONLY
TOROID
LEAD #250 CONNECTS TO "HIGH" TERMINAL ON
RECONNECT PANEL, ALONG WITH CORRECT LEAD
FROM MAIN TRANSFORMER (T1)
REAR
ELECTRODE
SV1
208/230/460
115V common
T3
HI-FREQ CIRCUIT
Fans "ON" @
15A in stick mode
2A in tig mode
"ON" 8 minutes after
weld stops
20VAC
TRIGGER CIRCUIT
(right front)
(STICK WELDING)
HIGH FREQ.
TRANSFORMER
.015"
(115VAC)
20VAC
CONTROL BOARD SUPPLY
WORK
FRONT
ELECTRODE
C6
GAS
SOLENOID
inside side box right
com
com +12
50/100W
base front
PRESENT ONLY ON
PRECISION TIG 375
SPARK
GAP
12.5 OHM TYP.
L3
not used: see
menu options
14J11
T1
X6
.0015/12KV
115V common
235
233A
+8
238
237
15/250V
Dip Switches select:
a. re-start enable
b.ramp down to zero
c. see IM for details
and more.
d.most old options
on menu feature now.
driver
X5
63.5V
236B
233A
10 pin molex
To & From
IC chip
250
SEE NOTE A
bottom right in RF section
(SCHEMATIC S22530)
BACKGND
RESISTORS
R13
3/25W
(right side in box)
board mounted parts
2 3 4
(SCHEMATIC M16115)
K870 foot pedal jumper
to enable Pot (R1) max output
limiter fearure. Jumper not used
in Robotic molex position J5A
HIGH VOLTAGE
TRANSFORMER
R5
236
235
GAS (115VAC)
2J12
5J11
PRECISION TIG 375
ONLY
BYPASS/STABILIZER
PCB
HI-FREQ INTENSITY
(bottom right side)
F
DISCONNECT FOR
DOUBLE PRE/POST FLOW
C3
PT375: STANDARD, C1=C2=C3=60/460V
269
10 pin molex
13J11
7J23
6J22
OPTIONAL AMPTROL REMOTE
CONTROL AND ARC START SWITCH
3J5
4J5
E
TOROID
B
5J5
3J22
TM
2J5
C
D
F
A
HI-FREQ (115VAC)
115VAC IN
WHEN ADVANCED CONTROL
PCB IS NOT INSTALLED
in reconnect area
POWER FACTOR
CAPACITORS
POLARITY
SWITCH
S2
front
253
C2
R1
+5 LED +15 LED
J3 1
C1
+
DC
HOLDING RESISTOR
200/100W
FAN (115VAC)
ARC FORCE TRIMMER
4J22
A
N
B
1J20
2J20
DC-
N.C.
min current range:
375=2 to 65A
275=2 to 55A
4J12
HOT START TRIMMER
ADVANCED CONTROL PANEL (OPTIONAL ON PT275)
REMOTE
RECEPTACLE
J2
2J1
3J1
5J1
6J1
7J1
8J1
9J1
10J1
4J1
1J1
11J1
12J1
ON TIME (1-15V)
CW
411
404
413
402
403
405
406
407
DC+
229
6J12
3J12
(SCHEMATIC G4760-X)
(OPTIONAL ON PT275)
TOROID
AC
PT375 use ONLY
max current range:
375=340A
275=420A
ADVANCED CONTROL
PCB
407
4-STEP
U
1J7
3J7
2J7
5J7
4J7
6J7
ac
212
DC-
AC
252
BACKGND
RECTIFIER
TOROID
min
406
SPOT
(RED)
B
R12
R10
R9
SPOT
405
10K
min
2-STEP
EN-170
11
L2
MICRO SWITCH
N.O.near power switch
PT275: OPTIONAL, C1=C2=50/460V
C3 NOT PRESENT
375 ONLY
OCV clamp
3J10
CW
401A
Return to Master TOC
8J10
DIP SWITCH
401B
403
OFF
BACKGND AC OUT
BACKGND AC IN
DOWN SLOPE
CW
10K
10K
2J10
271A
10J11
2J11
opto
triac
271
229A
BACKGND FILTER CAP., NEG
401D
402
PULSE
7J10
(ADVANCED FEATURES
SELECTION)
Return to Master TOC
401C
CW
min
1J10
TOROID
FREQUENCY
275 = 5/50W 4 ea
375 = 25/25W 4 ea
upper section near lift bale
BACKGND FILTER CAP., POS
3J11
11J11
6J10
H1
AC
266
R8A
331 B
stick
331 W
332 B
auto
332 W
B
333
remote W
333
334 B
gas
334 W
335 B
thermo W
335
SCHE. S24206-X
L1A
275 ONLY
current limiting resistors
to main rectifier
left front lower
BYPASS PCB
RECONNECT
PANEL
375 ONLY
TOROID
(SHOWN IN STICK)
W
231B 115V common
BACKGROUND CIRCUIT
ENABLED IN BOTH TIG
& STICK, AC & DC
R
319
MODE SWITCH
AUTO BALANCE
(GREEN)
W
220B
R7B
large cap and
resistor filter
313
STICK
DISPLAY SWITCH
B
226
227A
CR3
CONTROL PANEL
STICK
(RED)
R14
231C
TIG
315
VOLT
8/300W
AC
BOOST
115VAC
R7C
316D
316C
265
CLOSED
IN DC
10K
313A
A
CR2
115VAC
321
MIN A
DC
BOOST CR3
CW
POST FLOW R3
L2A
H1
238A
316A
316B
opto
triac
+
DC
DC-
AC
L1
LOW
CR3
OCV BOOST
RECTIFIER
258
257
DC+
DCSets weld tables
& CR2 ,CR3 control
CR2
R7D
LOCAL
(SHOWN IN REMOTE)
CR3
MID
X13
75vac
(375 only)
228
218B
REMOTE
225A
225
255
CR2
either is ref
to 231A
318
Return to Master TOC
313C
256
115VAC IN
DC STICK
opto
triac
H3
H2
X1
223
224
115VAC IN
AC STICK
POWER SWITCH
HIGH
C5
L1
X2
TOROID
1J12
5J12
H4
PT375 ONLY
OUTPUT
INDUCTOR
middle section
AC & DC STICK OCV BOOST CIRCUIT,
PRESENT ONLY ON PRECISION TIG 375
right front lower
5J9
.0047/ 3KV
H5
turns off SCR's
SV2
(115VAC)
OPTIONAL
WATER
SOLENOID
KIT
220V/5A
50/60HZ MACHINES ONLY
LABELS:
COMMON
PRECISION TIG 375
ONLY
FRAME GROUND
EARTH GROUND
AUX. WINDINGS OF
MAIN TRANSFORMER T1
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
1 2
7
6
12
LATCH
VIEW OF CONNECTOR ON PC BOARD
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
DESIGN INFORMATION
THE INFORMATION ON THIS
PRINT IS FOR REFERENCE
DRAWN BY: bburkhart
ONLY. COMPONENTS AND
CIRCUITRY MAY BE DIFFERENT ENGINEER: burkhart
FROM AN ACTUAL MACHINE.
APPROVED:
-
SCALE:
NONE
EQUIPMENT TYPE:
IF PRINTED
@ A1 SIZE
SUBJECT:
NONE
UNITS:
MATERIAL
DISPOSITION:
NA
PRECISION TIG
MACHINE SCHEMATIC
APPROVAL
DATE:
7-27-2007
PROJECT
NUMBER:
CRM38261
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
REFERENCE:
G4075
G5691
DOCUMENT
REVISION:
A
SOLID EDGE
STICK (+15V)
313
12J9
6J9
7J9
8J9
11J9
VOLT FEEDBACK, WORK
T1
in reconnect area
215
319
10K
VOLT FEEDBACK, ELECTRODE
1J11
9J11
scaling
PT375 = 86 vac
PT275 =75 vac
to X2
SHUNT
400A/200mV
upper left
BYPASS ASSEMBLY
C4
MAIN
TRANSFORMER
center of base mounted on its side
231A
231B
DISPLAY VOLT (+15V)
MICRO SWITCH ON POLARITY SWITCH
50/60HZ MACHINE
ONLY
SCR2
5/50W
R2
BALANCE
DISPLAY MIN A (+15V)
12J11
SCR3
R 222(-)
W 221(+)
265
266
252
253
220A
CW
+15V
REMOTE (+15V)
POSTFLOW (0 - 15V)
MICRO SWITCH ON POLARITY SWITCH
+
R7A
313B
BALANCE (0 - 10V)
IC chip
controller
4J9
10J9
6J11
R8B
10K
+1.5V
MIN OUTPUT (0 - 1.5V)
-
216A
217A
1J9
2J9
5/50W
PRESET (0 - 10V)
218A
220A
+10V
240
322
316
317
318
321
315
R4
W 221
R 222
268
270
313A
MIN
OUTPUT
SHUNT (-)
SCR1
MAIN
RECTIFIER
very top of welder
50HZ MACHINE ONLY
D1
TOROID
311
312
10K
CW
SHUNT (+)
1J6
2J6
right heat-sink
SCR4
G3
217
218
TOROID
amp
left heat-sink
Free Wheeling diode
X
X
218A
R1
J8 (6pin)
not used
216
G4
G1
G2
220
SCR1 GATE
G1
SCR2 GATE
G2
SCR3 GATE
G3
SCR4 GATE
G4
SCR1,SCR2 CATHODE 218
SCR3 CATHODE
217
SCR4 CATHODE
216
SCR3,SCR4 ANODE 220
230
346
Menu Switch hold to get to TIG options
lift TIG, upslope
Menu Switch hold to get to Stick options
tig hot start levels, micro start
arc force levels
pre flow/after flow time extended
TOROID
hot start levels
see IM for details and more
CW
311A
Return to Section TOC
SCR drive
ckts
&
snubbers
Caliberation: see new control bd. instructions
314
320
Return to Section TOC
1J4
5J4
2J4
4J4
9J4
6J4
10J4
7J4
3J4
8J4
231E
316D
TOROID
1J13
2J13
3J13
4J13
5J13
6J13
7J13
8J13
231E
J7
Meter shows
preset & actual
344
347
345
343
GND
Data
Clock
Menu Switch
+5
223
METER
BOARD
1
2
3
4
343
344
345
346
347
227
S3
MENU
SWITCH
TOROID
menu options( jumper IN)
no menu options ( jumper out)
220B
CHANGE DETAIL: RELEASED FROM X A.02
ENGINEERING CONTROLLED
MANUFACTURER: No
Push & hold
at power up = defaults
231D
Return to Master TOC
SCHEMATIC - ENTIRE MACHINE - ABOVE CODE 11000 (G5691)
MAX
OUTPUT
Return to Section TOC
G-8
ELECTRICAL DIAGRAMS
G5691
Return to Section TOC
G-8
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-9
SCHEMATIC - CONTROL PC BOARD - BELOW CODE 11000 (G3908 PAGE 1)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-9
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-10
SCHEMATIC - CONTROL PC BOARD - BELOW CODE 11000 (G3908 PAGE 2)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-10
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-11
SCHEMATIC - CONTROL PC BOARD - BELOW CODE 11000 (G3908 PAGE 3)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-11
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
PC BOARD ASSEMBLY-CONTROL - BELOW CODE 11000 (G3909-2)
CHANGE DETAIL: ADDED C178 AND REVISED DZ14 PART NUMBER
REVISED MANUFACTURE AS, IDENTIFICATION CODE AND SCHEMATICREFERENCE PART NUMBERS
ADDED SOLDER AND SEALANT NOTE FOR C178 TOASSEMBLY
ENGINEERING CONTROLLED
MANUFACTURER: No
1
3
SOLDER CAPACITOR (C178) TOR108AS SHOWN.
COVER WITH E2861SEALANT.
N.D.
N.D.
N.B.
1.20
N.D.
Return to Master TOC
.20
0
0
.20
J4
J5
XXXXXX
XXXXX
N.D.
N.D.
XX
J5A
XX
XX
R7
X
XX
X
X
X
X
XX
J9
X
XXX X XX
XX
J10
R352
R353
C159
D15
X6
X5
R304
X
X
XXX
TRI2
N.C.
C82
C99
C98
N.C.
TRI3
R218
R263
C112
R264
R305
C134
TP9
C163
XX
TP10
X
X
X
X
X
N.C., N.D.
C135
TP11
TP12
X
N.F.
J12
J11
XXX X XXX
XXX X XX
C81
TRI4
R138
OCI2
R181
OCI3
OCI4
R217
OCI5
R262
D71
D70
TP8
R362
R348
R349
R363
D86
X
X
R140
C80
TP4
XXXX
D87
XX
D69
D68
C133
N.D.
R139
TP7
R340
R341
R342
R343
R344
R345
R346
R347
D85
C155
R338
R339
D84
C154
DZ20
C153
DZ19
DZ18
DZ16
R337
C152
C149
R326
R327
R328
R329
R330
R331
R332
R334
R333
Q28
R323
C146
R324
C148
XX
X X
X X
X X
X X
X X
X X
X X
X X
OCI8
TRI1
R180
C79
R179
X
X
X
DZ17
R335
C150
R46
R137
C95
D50
C96
C132
X15
R178
XXXX
R350
R300
R301
R302
C129
C130
R297
R298
R299
C128
R294
R293
R336
C151
D14
X9
C111
R215
R216
R260
R261
C97
R303
X18
Q27
C127
R290
DZ12
X
X
X
X
X
J3
C94
C39
C37
D25
D35
X8
X17
R214
R257
R258
R259
C110
R291
R292
C126
R250
DZ11
R213
C109
C108
R254
R255
R253
XX
X
X
X
X
XXX
C78
R177
C131
R256
Y1
Q26
R287
R288
R289
R284
R285
R286
R282
C107
C125
C77
DZ13
X11
R171
R172
X16
R252
R251
R283
C124
C122
C147
R281
DZ23
C145
R319
C93
Q23
D49
OCI1
R136
R295
R296
R1
C17
R39
C16
R38
R37
C57
J2
R206
R207
C106
DZ10
J8
X
R212
D55
D83
C158
X
D58
D59
D65
C123
J7
J6
XX
C157
DZ21
R176
R211
C92
D47
R135
L2
XX
XX
X4
X7
X14
C143
D54
R173
R174
R208
C91
R209
R210
X
X
X
X
X
X
X
D48
R88
G3909-2
PRECISION TIG CONTROL
L1
XX
R277
R278
R279
R315
R316
R317
R318
R321
R361
D46
C162
XX
DZ9
R248
X
X
X
X
X
X
X
C62
D27
C40
C53
X
X
C52
R110
R111
R109
C64
R134
R175
XXX
D26
C38
C51
C161
XX
R132
R133
C61
R249
C120
C178
C50
DZ5
C160
N.D.
C105
R275
R276
R314
X
X
X
X
X
D34
XXX
R44
R45
R83
R84
R85
R86
R87
R108
R359
C63
C60
C59
DZ15
D82
C141
C90
R274
R312
C144
R313
C156
C36
Q21
R130
R131
Q20
R320
R322
R325
D80
D81
C165
D67
R6
DZ22
R280
OCI7
R104
C58
X
X
X
X
XXX
C121
D73
D72
R268
R309
D79
R351
XXX
XXX
D89
R357
R246
R247
R356
C104
R245
R270
R271
R272
R273
C119
R311
R358
X19
Q24
D90
C139
C138
R307
R308
DZ14
C117
X
X
R306
Q18
C76
R205
R170
C75
C89
C88
C103
R244
C102
R269
R266
C137
X
X
R204
Q25
C118
TP6
D64
C87
C86
R4
R267
D66
R239
R240
X
X
Q17
R128
C74
C73
R42
R79
R107
R80
R81
R82
R105
R106
C49
R77
R78
D23
D31
R101
R102
R103
Q19
R169
D11
D22
C23
C22
R43
C21
R75
R76
D21
R13
D13
D12
C20
DZ25
R72
D20
R3
D42
R168
D63
R202
DZ4
C35
C33
X10
D62
C18
C19
R73
R74
C34
R129
R127
C56
R125
R167
C85
C100
DZ7
C116
C136
X
XXXX
TP5
C71
D88
X
X
C14
C6
R2
D10
R40
R41
C15
D24
C48
R99
R100
R126
R123
R124
R163
R164
C72
R203
R165
R166
R5
R197
R198
R199
R200
R201
C115
TP3
TP1
TP2
C114
C113
X
XXXX
D5
R26
C12
R161
R162
C70
D61
C84
R265
R97
R98
R122
D41
R119
R160
Q16
C55
DZ6
D51
C69
R158
C83
R67
C32
C47
R95
R96
C46
X13
X12
R117
R118
R159
D19
C31
R64
R65
D2
DZ24
X3
R34
R35
R36
R68
R69
R70
R71
D30
R121
R92
OCI6
XXXXXXXXX
DZ2
X2
R94
D40
Q22
C68
R93
C45
R310
C142
C164
R116
R114
C54
R115
R157
R234
R235
R236
R237
R238
R192
R193
R194
R195
R196
R229
R230
R231
R232
R233
R187
R188
R189
R190
R191
R224
R225
R226
R227
R228
R182
R183
R184
R185
R186
R219
R220
R221
R222
R223
R91
D29
R120
R153
R154
R155
R156
R149
R150
R151
R152
C67
D28
R112
R113
D39
D38
R145
R146
R147
R148
C66
D37
R141
R142
R143
R144
C65
D36
C42
R89
T2
T1
R57
C43
R90
C140
Q3
C41
R355
R61
Q13
Q15
C25
D17
R63
R62
R60
C29
C30
C28
C44
Q9
R30
R31
R32
R66
Q8
D7
Q14
R58
R59
C27
C26
Q12
R29
C13
C5
C4
R12
R33
R28
R11
D6
C11
R25
D18
R54
D16
Q7
D4
C101
R241
R242
R354
R364
R243
Q11
R24
R23
D3
DZ8
Q10
R50
C3
R27
R10
D1
R9
C2
C10
R20
R21
R22
R55
C24
R56
X1
Q6
C7
R14
C8
R15
R47
R48
R49
Q5
C1
R16
R17
R18
C9
R19
R51
R52
R53
DZ3
Q4
DZ1
Q2
Q1
R8
D60
Return to Section TOC
16.80
10.68
Return to Master TOC
Return to Section TOC
N.F.
6.00
5.80
XX X
N.C., N.D.
N.F.
N.C., N.D.
N.F.
N.D.
6.00
N.E.
N.C., N.D.
N.C.
12.00
17.80
18.00
N.A.
N.A.
ITEM REQD
1
2
3
PART NO.
DESCRIPTION
1
SEE BLANK INFO. P.C. BOARD BLANK REF.
SEALANT
5 OZ.
E2861
S19300-7
2
PCB SUPPORT
NOTES:
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. SEE E2454
BEFORE HANDLING.
N.B. KEEP THIS AREA FREE OF ENCAPSULATION MATERIAL (‡ .50 MIN.) BOTH SIDES OF
BOARD.
N.C. SQUEEZE COMPONENTS TOGETHER BEFORE APPLYING ITEM 2 AND / OR
ENCAPSULATION MATERIAL.
N.D. APPLY ITEM 2 ON COMPONENT SIDE ONLY, AS SHOWN.
N.E. APPLY ITEM 2 ON BOTH SIDES OF BOARD AS SHOWN, EXCEPT TOP SURFACE OF
TRIMMER.
N.F. KEEP TOP SURFACE OF TRIMMER FREE OF ENCAPSULATION MATERIAL INCLUDING RTV.
ENCAPSULATE WITH E1844
MAKE PER E1911-ROHS
TEST PER E3937-C
Return to Master TOC
SCHEMATIC REFERENCE G3908-2H1
Return to Section TOC
ITEM
R20, R40, R41, R44,
R55, R60, R75, R76,
R80, R90, R107, R136,
R176, R210, R213,
R214, R241, R275,
R282, R283, R287,
R288, R291, R319,
R323, R324, R325,
R329, R330, R331,
R355, R359, R361
R23, R62, R63, R78,
R92, R103, R104,
R105, R129, R140,
R161, R179, R202,
R206, R207, R208,
R239, R243, R257,
R263, R267, R273,
R274, R279, R305,
R312, R314, R315,
R320, R364
R27, R43
R28
R30, R35, R36, R66
R37, R335, R342,
R344, R345, R347
R39, R79
R42, R128, R164,
R169, R215, R216,
R245, R260, R261,
R339
R45, R85, R86, R108,
R171
R57, R69
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
MANUFACTURED AS:
G3 9 0 9 - 2 H 1
PART NUMBER IDENTIFICATION CODE
REFERENCES
C1, C7, C178
C2, C3, C5, C17, C21,
C25, C28, C33, C36,
C41, C46, C48, C50,
C54, C55, C57, C61,
C69, C70, C71, C76,
C77, C78, C85, C86,
C89, C90, C94, C103,
C105, C106, C109,
C111, C122, C123,
C124, C125, C126,
C129, C130, C139,
C148, C149, C157,
C158, C165
C4, C8, C9, C11, C12,
C26, C27, C29, C32,
C42, C43, C44, C47,
C56, C65, C66, C67,
C68, C83, C87, C92,
C101
C6, C16, C20, C35,
C59, C63, C100, C118,
C143, C155
C10, C24, C58
C13, C18, C19, C30,
C31, C34, C37, C38,
C40, C45, C62, C64,
C72, C73, C74, C75,
C79, C80, C88, C91,
C104, C107, C112,
C128, C134, C142,
C144, C145, C146,
C147, C150, C151,
C152, C153, C154,
C156, C159
C14, C127
C15, C141, C164
C22, C51
C23, C39, C52
C49, C60
C53
C81, C82, C98, C99,
C117, C131, C133,
C135, C136, C137,
C140, C160, C161,
C162, C163
C84
C93, C108
C95, C96, C97
C102, C138
C110
C113, C114, C115,
C116
C119, C120
C121
C132
D1, D4, D7, D16, D17,
D18, D20, D21, D23,
D28, D34, D36, D37,
D38, D39, D90
D2, D3, D5, D6, D10,
D11, D12, D13, D14,
D15, D19, D22, D25,
D26, D27, D29, D30,
D31, D35, D40, D41,
D42, D51, D54, D55,
D58, D59, D60, D61,
D64, D65, D66, D67,
D72, D73, D79, D80,
D81, D82, D83, D84,
D85, D86, D87, D88,
D89
D24, D62, D63
D46, D47, D48, D49,
D50
D68, D69, D70, D71
DZ1, DZ3, DZ9, DZ14
DZ2, DZ5, DZ20
DZ4, DZ11, DZ12, DZ13
DZ6, DZ10
DZ7, DZ8
DZ15, DZ16, DZ17,
DZ18, DZ19, DZ21,
DZ22
DZ23, DZ24, DZ25
J2, J3
J4, J10
J5, J5A
J6
J7, J8, J12
J9
J11
L1, L2
QTY
3
PART NUMBER DESCRIPTION
S16668-8
CAPACITOR,CEMO,330pF,100V,5%
46
S16668-11
CAPACITOR,CEMO,0.1, 50V,10%
22
S16668-6
CAPACITOR,CEMO,4700pF,50V,10%
10
S13490-42
CAPACITOR,TAEL,1.0,35V,10%
3
S16668-3
CAPACITOR,CEMO,100pF, 100V,5%
37
S16668-5
CAPACITOR,CEMO,.022,50V,20%
2
3
2
3
2
1
S13490-25
S13490-181
T11577-54
S13490-183
S16668-7
S13490-92
CAPACITOR,TAEL,4.7,35V 10%
CAPACITOR,ALEL,22,63V,20%
CAPACITOR,CD,750PF,1000V,10%
CAPACITOR,ALEL,120MF,50V,20%
CAPACITOR,CEMO,820pF,50V,5%
CAPACITOR,ALEL,3300, 50V,+30/-10%
15
T11577-58K
CAPACITOR,CD,.0047,3000V,20%
1
2
3
2
1
S13490-40
S16668-1
T11577-46K
S16668-9
S16668-4
CAPACITOR,TAEL,2.7,50V,10%
CAPACITOR,CEMO,22pF, 100V,5%
CAPACITOR,CD,.05,600V,+80/-20%
CAPACITOR,CEMO,150pF, 100V,5%
CAPACITOR,CEMO, 2700pF, 50V,5%
4
S13490-81
CAPACITOR,PEF,0.1MF,400V,10%,RADIAL
2
1
1
S16668-2
S13490-19
S13490-186
CAPACITOR,CEMO,47pF, 100V,5%
CAPACITOR,TAEL,1.8,20V,10%
CAPACITOR,ALEL,1800,160V,20%
16
T12705-34
DIODE,AXLDS,1A,400V,FR,1N4936
46
3
T12199-1
T12705-23
R59, R173, R252, R259
R64, R65, R73, R74,
R93, R94, R114, R131,
R135, R170, R205,
R258, R270, R292,
R295
R71, R83, R87, R118,
R168, R248, R249,
R256, R277, R280
DIODE,AXLDS,1A,400V
DIODE,SCHOTTKY,AXLDS,1A,30V,1N5818
5
T12705-14
DIODE,AXLDS,3A,200V,1N5402
4
4
3
4
2
2
T12199-2
T12702-29
T12702-53
T12702-27
T12702-19
T12702-23
DIODE,AXLDS,1A,1000V
ZENER DIODE,1W,15V,5%,1N4744A
ZENER DIODE,1W,3.3V,5%,1N4728A
ZENER DIODE,1W,10V,5%,1N4740A
ZENER DIODE,1W,12V,5%,1N4742A
ZENER DIODE,5W,15V,5%,1N5352B
7
T12702-52
ZENER DIODE,1W,5.1V,5%,1N4733A
3
2
2
2
1
3
1
1
2
T12702-45
S21134-10
S24020-10
S24020-8
S24020-2G
S24020-6
S24020-12
S24020-16
T12218-9
ZENER DIODE,1W,18V,5%,1N4746A
CONNECTOR,MOLEX,MINI,BLIND,F,10-PIN
CONNECTOR,MOLEX,MINI,PCB,10-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,2-PIN,GOLD
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,12-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,16-PIN,TIN
CHOKE,RF,390UH,5%, 225MA,CONFORMAL
OCI1, OCI2, OCI5, OCI8
4
S15000-16
OPTOCOUPLER,TRIAC,DRIVER,ZVC,3083
OCI3, OCI4
OCI6, OCI7
Q1, Q4, Q18
Q2, Q3, Q5, Q6, Q7,
Q8, Q9, Q12, Q13,
Q14, Q15, Q16, Q17,
Q19, Q20, Q21, Q22,
Q23, Q24, Q26, Q27,
Q28
Q10, Q11
Q25
R1, R3, R5
R2
R4, R7
R6
R8, R16, R120, R122,
R172, R317, R356
R9, R91, R116, R117,
R350
R10, R98, R177, R278,
R336
R11, R17, R21, R22,
R24, R29, R31, R32,
R33, R34, R38, R46,
R56, R61, R68, R70,
R84, R96, R97, R99,
R106, R109, R115,
R119, R123, R126,
R127, R130, R132,
R133, R157, R159,
R160, R163, R175,
R203, R204, R209,
R212, R240, R246,
R247, R250, R253,
R254, R255, R289,
R290, R293, R294,
R296, R297, R298,
R299, R300, R302,
R321, R332, R352,
R353, R354, R358
R12, R25, R26, R58,
R67, R89, R95, R125,
R134, R158, R211,
R242, R251, R281
R13, R88
R14, R18, R141, R142,
R143, R144, R145,
R146, R147, R148,
R149, R150, R151,
R152, R153, R154,
R155, R156
R15, R19, R47, R48,
R49, R50, R51, R52,
R53, R54, R308, R311
2
2
3
S15000-31
S15000-10
T12704-69
OPTOCOUPLER,TRIAC,DRV,RANDOM,800V
OPTOCOUPLER,PHOTO-Q,70V,CNY17-3
TRANSISTOR,PNP,TO226,0.5A, 40V,2N4403
22
T12704-68
TRANSISTOR,NPN,TO226,0.5A,40V,2N4401
2
1
3
1
2
1
T12704-54
T12704-73
S16296-3
T10812-41
T10812-73
S16296-5
TRANSISTOR,NMF,TO220,15A,60V,(SS)
TRANSISTOR,NMF,4-PIN DIP,1A,100V,IRFD110(SS)
TRIMMER,MT,1/2W,500, 10%,LINEAR
TRIMMER,ST,1/2W,10K, 10%,LINEAR
TRIMMER,ST,1/2W,2K, 10%,LINEAR
TRIMMER,MT,1/2W,10K, 10%,LINEAR
7
S19400-1000
RESISTOR,MF,1/4W,100,1%
5
S19400-3322
RESISTOR,MF,1/4W,33.2K,1%
5
S19400-4750
RESISTOR,MF,1/4W,475,1%
N.A.
N.A.
N.A.
N.A.
N.A.
62
S19400-1002
RESISTOR,MF,1/4W,10.0K,1%
14
S19400-2212
RESISTOR,MF,1/4W,22.1K,1%
REQ'D PART NO.
DESCRIPTION
33
S19400-4751
RESISTOR,MF,1/4W,4.75K,1%
30
S19400-1001
RESISTOR,MF,1/4W,1.00K,1%
2
1
4
S19400-2213
S19400-3921
S19400-1372
RESISTOR,MF,1/4W,221K,1%
RESISTOR,MF,1/4W,3.92K,1%
RESISTOR,MF,1/4W,13.7K,1%
6
S19400-2000
RESISTOR,MF,1/4W,200,1%
2
S19400-3011
RESISTOR,MF,1/4W,3.01K,1%
10
S19400-4752
RESISTOR,MF,1/4W,47.5K ,1%
5
S19400-2002
2
S19400-2210
RESISTOR,MF,1/4W,221,1%
4
S19400-3321
RESISTOR,MF,1/4W,3.32K,1%
S19400-1003
RESISTOR,MF,1/4W,100K,1%
15
RESISTOR,MF,1/4W,20.0K,1%
10
S19400-1004
RESISTOR,MF,1/4W,1.00M,1%
R72, R101, R102, R276
4
S19400-26R7
RESISTOR,MF,1/4W,26.7,1%
R77, R110, R111
R81, R313
R82, R316, R357
R100, R271, R334,
R337, R340, R341
R112
R113
R121, R124, R244,
R318
R137, R138, R181,
R217, R262, R304
R139, R180, R218,
R264
R162, R333, R338
R165
R166
R167, R174, R284,
R285, R301, R326,
R327
R178
R182, R183, R184,
R185, R186, R187,
R188, R189, R190,
R191, R192, R193,
R194, R195, R196,
R197, R198, R199,
R200, R201, R219,
R220, R221, R222,
R223, R224, R225,
R226, R227, R228,
R229, R230, R231,
R232, R233, R234,
R235, R236, R237,
R238
R265, R266, R306,
R351
R268, R309, R343,
R346
R269, R307
R272
R286, R328
R303
R310
R322
R348, R349, R362,
R363
T1, T2
TP1, TP3, TP5, TP6
TP2
TP4, TP7, TP9, TP10,
TP11, TP12
TP8
TRI1, TRI2
TRI3, TRI4
X1
X2, X11
X3
X4, X10, X14
X5
X6, X9
X7, X12, X13, X16
X8
X15
X17
X18
X19
Y1
3
2
3
S19400-2001
S19400-9091
S19400-3012
RESISTOR,MF,1/4W,2.00K,1%
RESISTOR,MF,1/4W,9.09K,1%
RESISTOR,MF,1/4W,30.1K,1%
6
S19400-5110
RESISTOR,MF,1/4W,511,1%
1
1
S19400-9092
S19400-2211
RESISTOR,MF,1/4W,90.9K,1%
RESISTOR,MF,1/4W,2.21K,1%
4
S19400-7681
RESISTOR,MF,1/4W,7.68K,1%
6
S19400-1211
RESISTOR,MF,1/4W,1.21K,1%
4
S19400-2670
RESISTOR,MF,1/4W,267,1%
3
1
1
S19400-3320
S19400-3323
S19400-5621
RESISTOR,MF,1/4W,332,1%
RESISTOR,MF,1/4W,332K,1%
RESISTOR,MF,1/4W,5.62K,1%
7
S19400-1501
RESISTOR,MF,1/4W,1.50K,1%
1
T14648-24
RESISTOR,WW,5W,0.5,5%,SQ
40
S19400-68R1
RESISTOR,MF,1/4W,68.1,1%
4
S18380-1
THERMISTOR,PTC,56 OHMS,90MA
4
S19400-2490
RESISTOR,MF,1/4W,249,1%
2
1
2
1
1
1
S19400-2673
S19400-3922
S19400-2802
S18380-3
S19400-6810
S19400-3570
RESISTOR,MF,1/4W,267K,1%
RESISTOR,MF,1/4W,39.2K,1%
RESISTOR,MF,1/4W,28.0K,1%
THERMISTOR,PTC,.08-0.19 OHMS,1.85A
RESISTOR,MF,1/4W,681,1%
RESISTOR,MF,1/4W,357,1%
4
S19400-20R0
RESISTOR,MF,1/4W,20.0,1%
2
4
1
T12737-2
T13640-25
T13640-16
TRANSFORMER,PULSE,3-WINDING,1:1:1
MOV,130VRMS,90J,20MM
MOV,150VRMS,80J,20MM
6
T13640-18
MOV,320VRMS,150J,20MM
1
2
2
1
2
1
3
1
2
4
1
1
1
1
1
1
T13640-14
S18395-27
S15161-27
S15018-15
S15018-4
S15128-10
S15018-6
S18395-8
S18395-3
S15128-4
S15128-18
S25431-2
M15102-4
M15102-3
S15128-16
S16665-2
MOV,150VRMS,13J,7MM
TRIAC,T220,8A,800V WITH S18104-3HS
TRIAC,T220,8A,800V
IC,CMOS,GATE,NAND,2-INPUT,QUAD,SCHM(SS)
IC,CMOS,INVERTER,SCHMITT, HEX,4584(SS)
VOLTAGE REF,ADJ, PRECISION,431I
IC,CMOS,SWITCH,ANALOG,QUAD, 4066(SS)
REGULATOR,HEAT-SINKASBLY,S15128-6,S18104-3
REGULATOR,HEAT-SINKASBLY,S15128-5,S18104-3
OP-AMP,QUAD, GEN-PURPOSE,224N
OP-AMP,QUAD, HIGH-PERF,33074
ROM ASSEMBLY (SS)
IC,ARRAY,DRIVER,PERIPHERAL,NPN,DARL
IC,CMOS,UNDERVOLT-SENSING,RESET,MCU(SS)
IC,OP-AMP,QUAD,HIGH-PERF,1014
CRYSTAL,QUARTZ,4.0000MHZ,HC-18/U
UNLESS OTHERWISE SPECIFIED:
CAPACITANCE = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
P.C. BOARD BLANK REFERENCE INFORMATION
BUY BLANK COMPLETE AS G3909-H (4 LAYER BOARD PER E3281)
2
T14648-4
RESISTOR,WW,5W,40,5%,SQ
18
S19400-47R5
RESISTOR,MF,1/4W,47.5,1%
12
S19400-10R0
RESISTOR,MF,1/4W,10.0,1%
(MAKES 2 BOARDS PER PANEL, SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION)
FOR PARTS ORDERS:
INCLUDE (1)S25597
PRINT PARTS ORDERS
INSTRUCTION SHEET.
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
FEI
REFERENCE:
G3909-1
SCALE:
-
1:1
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
PRECISION TIG
CONTROL P.C. BOARD ASSEMBLY
APPROVAL
DATE:
3/29/2007
PROJECT
NUMBER:
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
G3909-2
CRM36844
DOCUMENT
REVISION:
C
SOLID EDGE
Return to Master TOC
G-12
ELECTRICAL DIAGRAMS
G3909-2
Return to Section TOC
G-12
STRP
NOTE:
®
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-13
SCHEMATIC - CONTROL PC BOARD - ABOVE CODE 11000 (G4762 PAGE 1)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-13
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-14
SCHEMATIC - CONTROL PC BOARD - ABOVE CODE 11000 (G4762 PAGE 2)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-14
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-15
SCHEMATIC - CONTROL PC BOARD - ABOVE CODE 11000 (G4762 PAGE 3)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-15
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-16
SCHEMATIC - CONTROL PC BOARD - ABOVE CODE 11000 (G4762 PAGE 4)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-16
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-17
SCHEMATIC - CONTROL PC BOARD - ABOVE CODE 11000 (G4762 PAGE 5)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-17
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
RELEASED FROM X A.02
C H A NGE DETAIL:
E N G IN E E R IN G C O N T R O LLE D
M A N U F A C T U R E R : No
ITEM
1
2 (TRI1,
3 (TRI1,
4 (TRI1,
5 (TRI1,
6
7
8
9
0
.20
N.C.,N.D.
N.D.
N.F.
N.D.
N.F.
J8
J9
X5,
X5,
X5,
X5,
X9)*
X9)*
X9)*
X9)*
XXX
J11
N.C., N.D.
5
X5
R 46
X
X
T R I2
R 140
C80
C81
C99
R 263
C 112
N.D.
R 264
X
D 7, D91, D92, D93, D94,
D 95
D 46, D47, D 48, D49, D50
D 62, D63
D 68, D69, D 70, D71
D Z1, DZ3, D Z9, DZ29
D Z4, DZ12, DZ13, D Z26,
D Z27, DZ28
D Z5, DZ20
D Z6, DZ10
D Z7, DZ8, D Z14
D Z15, DZ16, DZ17, DZ18,
D Z19
D Z23, DZ24, DZ25
J2, J3
J4, J10
J5, J13, J5A
J6
J7, J8, J12
J9
J11
J14
L1, L2
O CI1, O C I2, O CI5, O CI8
O CI3, O C I4
O CI6, O C I7
Q 1, Q 4, Q 18
N.C.
T R I3
R 218
R 305
C 134
N.C.
C82
C98
TP9
R 13 8
TP10
D 2, D10, D11, D12, D13,
D 14, D19, D 22, D25, D26,
D 31, D35, D 40, D41, D42,
D 51, D54, D 55, D58, D59,
D 60, D61, D 64, D65, D66,
D 67, D72, D 73, D79, D80,
D 81, D82, D 83, D84, D85,
D 86, D87, D 89, D96
R 139
TP4
C 163
N.D.
X
X
X
X
J12
T R I4
O C I3
O C I2
R 21 7
TP8
X X X X
X
X
X
O C I8
R 26 2
O C I5
O C I4
R 18 1
XXXX
TP7
X X
X X
X X
X X
X X
X X
X X
X X
L2
D 85
XX
D87
D 71
R 304
XXX X XXX
N.C.
D 70
D 69
D 68
R 36 2
R 34 8
R 34 9
R 36 3
12.00
T R I1
R 13 7
D 50
C 95
C 13 1
X
X
X
D 86
XXX X XX
N.H.
R 34 0
R 34 1
R 34 2
R 34 3
R 34 4
R 34 5
R 34 6
R 34 7
C 15 5
R 33 8
R 33 9
XX
D Z20
C 15 3
D Z19
D Z16
J10
C152
XX
R 215
R 216
R 260
R 261
XXXX
C97
C96
R 30 0
R 30 1
R 30 2
R 35 3
R 35 2
C 12 9
R 296
R 298
C 13 0
R 297
C 15 9
C151
D 14
X9
R 38 2
C 22
X
X
X
X
X
R 35 0
R 259
X
X
X
X
XXX
O C I1
R 180
R 179
C79
4
REFERENCES
C 1, C7, C178, C179
C 2, C5, C17, C21, C25,
C 28, C36, C 41, C46, C50,
C 57, C61, C 69, C70, C71,
C 76, C77, C 78, C85, C86,
C 89, C90, C 103, C105,
C 106, C122, C123, C124,
C 125, C129, C130, C139,
C 148, C149, C157, C158,
C 165, C167, C168, C169,
C 171, C172, C173, C176,
C 177
C 6, C16, C20, C35, C59,
C 100, C118, C143, C155
C 8, C9, C11, C26, C27,
C 32, C42, C 44, C56, C65,
C 66, C67, C 68, C83, C87,
C 92, C101
C 10, C24, C 58
C 14, C15, C 141
C 18, C19, C 37, C38, C62,
C 72, C73, C 74, C75, C79,
C 80, C88, C 91, C104,
C 107, C112, C128, C134,
C 142, C144, C145, C146,
C 147, C150, C151, C152,
C 153, C154, C156, C159,
C 170
C 22, C51
C 23, C52
C 53
C 60
C 81, C82, C 98, C99,
C 117, C131, C133, C135,
C 136, C137, C140, C160,
C 161, C162, C163
C 84
C 95, C96, C 97
C 102, C138
C 113, C114, C115, C116
C 119, C120
C 121
C 132
C 175
D 1, D16, D17, D18, D20,
D 21, D28, D 36, D37, D38,
D 39, D90
D26
G4763-1
XXX
XXX
3
P R E C ISION TIG C O N T R O L
L1
R 214
R 295
XX
C38
C53
C132
R 213
C 12 8
R 294
R 97
D 25
X8
X 17
X 21
R 177
Q 27
R 336
R 33 7
R 335
XXX X XX
N.E.
D49
DZ1 7
C 15 0
9
D48
D Z13
R 98
R 25 3
R 25 4
D Z29
XX
D46
D47
C78
C 168
Q 16
D Z12
Q 26
R 25 0
C 16 9
R 28 6
R 32 8
R 32 9
R 33 0
R 33 1
R 33 2
R 33 4
R 33 3
C 14 9
R 28 7
R 28 8
R 28 9
C 12 4
XX
C77
R 293
R 100
D Z18
X 11
D59
C 125
R 299
C 14 8
R 28 2
X
R 32 3
C 14 6
Q 28
C 12 2
C 14 7
R 28 1
D Z23
X
R67
C32
R 291
R 292
R 135
R 136
J3
X4
C15
R 17 1
R 17 2
X 16
R 20 6
R 20 7
J2
X
D Z15
X
D19
D55
X
X
X
X
X
X
X
XXX
2
16.80
N.C., N.D.
C 135
TP11
X
T P 12
N.F.
X X X
C 13 3
X
R 275
D83
R29
D7
R 212
R 252
R 251
C 107
R 394
D58
D65
DZ1 0
R 396
C37
C 16 2
C 157
R 321
R 175
C91
R 209
R 210
C 106
R 390
D54
R 173
R 176
X
X
X
X
X
X
X
R 389
R 134
C23
R 365
X
X
R 110
R 111
R 109
C 16 1
J7
X
R 279
R 316
R 317
R 318
R 32 5
R 314
X
6.00
R 280
C 87
C 88
X 20
X 14
X
C 121
R 359
C62
C 123
C 14 5
R5
J6
XX
C 120
DZ9
R 133
C51
DZ5
D94
R 132
C61
C76
X
X
X
X
X
X
X
X
XXX X
R 31 9
D 80
C 143
R7
R 248
R 249
C85
R 277
R 278
R 276
C 105
C57
XX
R 16 8
C 90
C 10 4
R 26 8
D 73
R 30 9
XX
D82
C86
R 315
D67
R 274
R 312
C 144
R 313
C 156
D96
C 173
R 388
R 361
R 130
R 131
C60
Q 20
R87
R 108
C 178
C50
Q 21
C58
C59
R 411
D95
R 410
C5
C36
R 381
C 179
R44
R45
R83
R84
R85
R66
R42
R79
R77
R78
N.D.
R13
D35
R43
C21
C 16 0
J5 A
D81
R 358
C75
R 357
R 246
R 247
D21
D31
R 104
R 129
R 419
C 165
C16
Q 17
D13
C20
D11
D22
R75
R76
Q 18
R3
Q 19
R 170
R6
D20
R 103
R 127
R73
DZ2 5
R 401
C6
R2
C18
C19
R74
DZ4
R72
C35
R 101
R 102
D89
Q 25
R 407
DZ2 7
R 392
D64
C 14 1
XX
R38
R 402
R 391
R 205
R 204
R 421
DZ2 6
D10
R40
C17
R41
R 422
D12
D2
DZ2 4
R 418
R 403
R39
R 128
C74
R 35 6
X 13
R 26 7
D 90
D 72
XX
XX
XXX
O C I7
R 31 0
C 14 2
XX
XXX
R 372
D42
R 211
R 245
R 270
R 271
R 272
R 273
C 119
R 311
R 417
C 177
R 423
J14
XXX X XX
C 172
C89
XX
J13
R 398
R 377
Q 23
R 169
C73
XX
R 420
R 416
C 15 8
XXXXX
R 351
D 79
XX
C 14 0
X
X
R 41 4
C 13 8
R 30 7
R 30 8
C 13 9
Q 29
R 413
R 412
X
X
X
X
X
X
X
X 19
Q 13
C 10 1
R 24 1
R 24 2
R 36 4
R 24 3
D 66
X
X
C56
R 125
C 103
C102
R 269
X
X
X
X
X
X
X
R 167
C92
R 166
R4
Q 24
J5
D63
D Z8
R 24 0
R 306
XX
XXXXXX
.20
0
X
X
R 202
R 244
O C I6
D Z14
TP6
C71
R 124
R 163
R 164
C72
R 203
R 165
D62
R 409
D92
R 266
C 13 7
C 11 6
R 23 4
R 23 5
R 23 6
R 23 7
R 23 8
XX
X
XXXX
R 265
C 13 6
TP3
TP2
R 23 9
D Z7
J4
C 11 5
R 22 9
R 23 0
R 23 1
R 23 2
R 23 3
R 22 4
R 22 5
R 22 6
R 22 7
R 22 8
C 11 4
TP1
XX
Q 12
X 12
R 38 0
R 37 8
R 37 9
R 197
R 198
R 199
R 20 0
R 20 1
R 192
R 193
R 194
R 195
R 196
R 18 7
R 18 8
R 18 9
R 190
R 191
C 17 0
C 68
C 67
C 66
R 14 5
R 14 6
R 14 7
R 14 8
R 14 1
R 14 2
R 14 3
R 14 4
R 18 2
R 18 3
R 18 4
R 18 5
R 18 6
R 21 9
R 22 0
R 22 1
R 22 2
R 22 3
C 11 3
TP5
N.C.,N.D.
Return to Master TOC
X
XXXX
XXXXXXXXX
D61
R 159
R 384
R 383
R 385
C 167
R 122
C70
R 161
R 162
R 375
C84
R 374
R 376
R 405
R 387
R 123
DZ6
R 160
R 373
R 126
D41
R 158
X
X
C46
R 119
R 118
D60
R 369
R 120
R92
R 117
D51
Q 22
DZ2 8
R 386
R 112
D40
C69
C83
C 176
R 406
C 171
R 408
D28
R 121
R56
C1 4
D39
D38
R 400
D93
D91
R 404
R 395
C28
C44
R91
R 116
R 367
R55
C24
C 11 8
T2
D37
R57
C42
R 15 3
R 15 4
R 15 5
R 15 6
T1
D36
R58
R 368
R 366
R22
C41
Q4
C 175
R59
C27
D 18
C25
Q3
Q5
R 415
X2
X1
R54
C 11 7
D16
Q7
C11
R25
D17
Q 11
Q6
R50
C 65
R19
R51
R52
R53
R24
R 37 1
C 26
Q1
D1
C2
R21
Q2
Q 10
R9
R16
C9
C 10 0
R14
C8
R15
R47
R48
R49
DZ1
R18
C10
R20
R17
R8
R 14 9
R 15 0
R 15 1
R 15 2
Return to Master TOC
C1
C7
DZ3
N.D.
N.C.
R 17 8
N.F.
10.68
6.00
5.80
N.K.
R 30 3
N.J.
N.B.
C 52
6
D 84
N.G.
C 15 4
8
1.20
Return to Section TOC
TR!2,
TRI2,
TRI2,
TRI2,
QTY
1
4
4
A S RE Q
4
2
5.0 O Z
1
1
PART NUMBER
G 4763-A
CF 000003
E 106A -13
E 1868
S 18104-3
S 19300-7
E 2861
S 26860-1
S 26861-1
DESCRIPTION
P C B O A RD B LA N K
6-32 X .375 R O UN D HE A D M A CHINE S CRE W
# 6 LO C K W A S HE R
TH E RM O JO INT CO M P O UND
HE A T S INK ,A LUM INUM ,E XTRU DE D,F O R 1 TO -220
S U P P O RT,P CB ,S NA P =IN ,063,W HT
S E A LA NT
P S O C S O F TW A R E
P S O C S O F TW A R E
RE F E R TO E LE CTR O N IC CO M P O NE NT DA TA B A S E F O R S P E CIF ICA TIO NS O N ITE M S LIS TE D B E LO W
R 32 0
R 32 2
Return to Master TOC
PC BOARD ASSEMBLY-CONTROL - ABOVE CODE 11000 (G4763-1)
1
Return to Section TOC
G-18
ELECTRICAL DIAGRAMS
G4763-1
Return to Section TOC
G-18
N.C., N.D.
N.C., N.D.
17.80
18.00
N.A.
N.A.
N.K.,N.L.
NOTES:
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. SEE E2454
BEFORE HANDLING.
N.B. KEEP THIS AREA FREE OF ENCAPSULATION MATERIAL (‡ .50 MIN.) BOTH SIDES OF
BOARD.
N.C. SQUEEZE COMPONENTS TOGETHER BEFORE APPLYING ITEM 7 AND / OR
ENCAPSULATION MATERIAL.
N.D. APPLY ITEM 7 ON COMPONENT SIDE ONLY, AS SHOWN.
N.E. APPLY ITEM 7 ON BOTH SIDES OF BOARD AS SHOWN, EXCEPT TOP SURFACE OF
TRIMMER. MAXIMUM ITEM 7 HEIGHT NEAR CONNECTOR J2 IS .50 INCHES.
N.F. KEEP TOP SURFACE FREE OF ENCAPSULATION MATERIAL INCLUDING RTV.
N.G. PROGRAM X20 WITH ITEM 8 AND LABEL X20 WITH PART NO. OF ITEM 8.
N.H. PROGRAM X21 WITH ITEM 9 AND LABEL X21 WITH PART NO. OF ITEM 9.
N.J. COVER WITH TAPE AFTER PROGRAMMING.
N.K. APPLY ITEM 7 ON COMPONENT SIDE ONLY, AS SHOWN. MAXIMUM ITEM 7 HEIGHT IS .50
INCHES.
N.L. APPLY ITEM 7 TO CONNECTOR’S PLASTIC MOUNTING PINS ON NON-COMPONENT SIDE.
Q 2, Q 3, Q 5, Q 6, Q 7, Q 12,
Q 13, Q 16, Q 17, Q 19,
Q 20, Q 21, Q 22, Q 23,
Q 24, Q 26, Q 27, Q 28, Q 29
Q 10, Q 11
Q 25
R2
R 3, R5
R 4, R7
R6
R 8, R16, R120, R122,
R 172, R317, R356, R369,
R 376, R380, R402
R 9, R91, R116, R117,
R 350
R 13
R 14, R18, R 141, R142,
R 143, R144, R145, R146,
R 147, R148, R149, R150,
R 151, R152, R153, R154,
R 155, R156, R390, R398,
R 413, R420, R421, R422,
R 423
QTY
4
PART NUMBER DESCRIPTION
S 16668-8
CA P A CITO R,CE M O ,330pF ,100V ,5%
45
S 16668-11
CA P A CITO R,CE M O ,0.1, 50V ,10%
9
S 13490-42
CA P A CITO R,TA E L,1.0,35V ,10%
17
S 16668-6
CA P A CITO R,CE M O ,4700pF ,50V ,10%
3
3
S 16668-3
S 13490-181
CA P A CITO R,CE M O ,100pF , 100V ,5%
CA P A CITO R,A LE L,22,63V ,20%
31
S 16668-5
CA P A CITO R,CE M O ,.022,50V ,20%
2
2
1
1
T11577-54
S 13490-183
S 13490-92
S 16668-7
CA P A CITO R,CD,750P F ,1000V ,10%
CA P A CITO R,A LE L,120M F ,50V ,20%
CA P A CITO R,A LE L,3300, 50V ,+30/-10%
CA P A CITO R,CE M O ,820pF ,50V ,5%
15
T11577-52K
CA P A CITO R,CD,.0047/.005,1400V ,20%
1
3
2
4
2
1
1
1
S 13490-40
T11577-46K
S 16668-9
S 13490-81
S 16668-2
S 13490-19
S 13490-186
S 16668-1
CA P A CITO R,TA E L,2.7,50V ,10%
CA P A CITO R,CD,.05,600V ,+80/-20%
CA P A CITO R,CE M O ,150pF , 100V ,5%
CA P A CITO R,P E F ,0.1M F ,400V ,10%,RA DIA L
CA P A CITO R,CE M O ,47pF , 100V ,5%
CA P A CITO R,TA E L,1.8,20V ,10%
CA P A CITO R,A LE L,1800,160V ,20%
CA P A CITO R,CE M O ,22pF , 100V ,5%
12
T12705-34
DIO D E ,A XLD S ,1A ,400V ,F R,1N4936
39
T12199-1
DIO D E ,A XLD S ,1A ,400V
6
T12705-64
DIO D E ,S CHO TTK Y ,A XLDS ,0.2A ,30V ,B A T42
5
2
4
4
T12705-14
T12705-23
T12199-2
T12702-29
DIO D E ,A XLD S ,3A ,200V ,1N5402
DIO D E ,S CHO TTK Y ,A XLDS ,1A ,30V ,1N5818
DIO D E ,A XLD S ,1A ,1000V
ZE NE R DIO D E ,1W ,15V ,5%,1N 4744A
2
2
3
T12702-53
T12702-19
T12702-23
ZE NE R DIO D E ,1W ,3.3V ,5%,1N 4728A
ZE NE R DIO D E ,1W ,12V ,5%,1N 4742A
ZE NE R DIO D E ,5W ,15V ,5%,1N 5352B
3
2
2
3
1
3
1
1
1
2
4
2
2
3
T12702-45
S 21134-10
S 24020-10
S 24020-8
S 24020-2G
S 24020-6
S 24020-12
S 24020-16
S 18248-4
T12218-9
S 15000-16
S 15000-31
S 15000-10
T12704-69
ZE NE R DIO D E ,1W ,18V ,5%,1N 4746A
CO NNE CTO R,M O LE X,M INI,B LIND ,F ,10-P IN
CO NNE CTO R,M O LE X,M INI,P C B ,10-P IN,TIN
CO NNE CTO R,M O LE X,M INI,P C B ,8-P IN ,TIN
CO NNE CTO R,M O LE X,M INI,P C B ,2-P IN ,G O LD
CO NNE CTO R,M O LE X,M INI,P C B ,6-P IN ,TIN
CO NNE CTO R,M O LE X,M INI,P C B ,12-P IN,TIN
CO NNE CTO R,M O LE X,M INI,P C B ,16-P IN,TIN
CO NNE CTO R,M O LE X,M INI,P C B ,4-P IN
CH O K E ,RF ,390UH ,5%, 225M A ,CO NF O R M A L
O P TO CO UP LE R,TRIA C,DRIV E R,ZV C,3083
O P TO CO UP LE R,TRIA C,DRV ,R A NDO M ,800V
O P TO CO UP LE R,P HO TO -Q ,70V ,CNY 17-3
TR A NS IS TO R,P NP ,TO 226,0.5A , 40V ,2N4403
19
T12704-68
TR A NS IS TO R,NP N,TO 226,0.5A ,40V ,2N4401
2
1
1
2
2
1
T12704-54
T12704-73
T10812-41
S 16296-3
T10812-73
S 16296-5
TR A NS IS TO R,NM F ,TO 220,15A ,60V ,(S S )
TR A NS IS TO R,NM F ,4-P IN DIP ,1A ,100V ,IRF D110(S S )
TR IM M E R,S T,1/2W ,10K , 10%,LIN E A R
TR IM M E R,M T,1/2W ,500, 10%,LIN E A R
TR IM M E R,S T,1/2W ,2K , 10%,LINE A R
TR IM M E R,M T,1/2W ,10K , 10%,LIN E A R
11
S 19400-1000
RE S IS TO R ,M F ,1/4W ,100,1%
5
S 19400-3322
RE S IS TO R ,M F ,1/4W ,33.2K ,1%
25
S 19400-47R5
RE S IS TO R ,M F ,1/4W ,47.5,1%
6
5
1
T12702-27
T12702-52
T14648-4
ZE NE R DIO D E ,1W ,10V ,5%,1N 4740A
ZE NE R DIO D E ,1W ,5.1V ,5%,1N 4733A
N.A.
N.A.
N.A.
RE S IS TO R ,W W ,5W ,40,5%,S Q
N.A.
N.A.
N.A.
N.A.
R 15, R19, R47, R48, R49,
R 50, R51, R52, R53, R54,
R 308, R311
R 17, R20, R21, R22, R29,
R 40, R41, R44, R55, R56,
R 58, R75, R76, R136,
R 176, R210, R213, R214,
R 241, R275, R282, R287,
R 288, R291, R319, R323,
R 325, R329, R330, R331,
R 359, R366, R375, R378,
R 379, R383, R404, R406,
R 407, R408, R409, R412,
R 418
R 24, R39, R46, R84, R97,
R 109, R119, R123, R126,
R 127, R130, R132, R133,
R 159, R160, R163, R175,
R 203, R204, R209, R212,
R 240, R246, R247, R250,
R 253, R289, R293, R294,
R 296, R297, R299, R300,
R 302, R321, R332, R352,
R 353, R358, R384, R386,
R 394, R403, R4
R 25, R67, R125, R134,
R 158, R211, R242, R251,
R 281, R392, R419
R 38, R254, R298, R313,
R 387, R411, R415
R 42, R128, R164, R169,
R 215, R216, R245, R260,
R 261, R339
R 43
R 45, R66, R85, R108,
R 171
R 57, R371
R 59, R252, R259, R377,
R 389
R 72, R101, R102, R276
R 73, R74, R131, R135,
R 170, R205, R270, R292,
R 295
R 77, R385
R 78
R 79
R 83, R87, R118, R168,
R 248, R249, R277, R280
R 92, R103, R104, R129,
R 140, R161, R179, R202,
R 206, R207, R239, R243,
R 263, R267, R273, R274,
R 279, R305, R312, R314,
R 315, R320, R364, R388,
R 396, R400, R405, R410
R 98, R177, R278, R336,
R 395
R 100, R271, R334, R337,
R 340, R341
R 110, R111
R 112
R 121, R124, R244, R318
R 137, R138, R181, R217,
R 262, R304
R 139, R180, R218, R264
R 162, R173, R333, R338,
R 372, R373, R374
R 165
R 166
R 167, R301
R 178
R 182, R183, R184, R185,
R 186, R187, R188, R189,
R 190, R191, R192, R193,
R 194, R195, R196, R197,
R 198, R199, R200, R201,
R 219, R220, R221, R222,
R 223, R224, R225, R226,
R 227, R228, R229, R230,
R 231, R232, R233, R234,
R 235, R236, R237, R238
R 265, R266, R306, R351
R 268, R309, R343, R346
R 269, R307
R 272
R 286, R328
R 303
R 310
R 316
R 322
R 335, R342, R344, R345,
R 347, R365, R381
R 348, R349, R362, R363
R 357
R 361, R367, R368
R 382
R 391
R 401
R 414
T1, T2
TP 1, TP 3, TP 5, TP 6
TP 2
TP 4, TP 7, TP 9, TP 10,
TP 11, TP 12
TP 8
TRI1, TR I2, TR I3, TR I4
X1
X2
X4, X14
X5
X8, X12, X13, X16
X9
X11
X17
X19
X20, X21
REVISION CONTROL
12
S 19400-10R 0
RE S IS TO R ,M F ,1/4W ,10.0,1%
43
S 19400-4751
RE S IS TO R ,M F ,1/4W ,4.75K ,1%
45
S 19400-1002
RE S IS TO R ,M F ,1/4W ,10.0K ,1%
11
S 19400-2212
RE S IS TO R ,M F ,1/4W ,22.1K ,1%
7
S 19400-9091
RE S IS TO R ,M F ,1/4W ,9.09K ,1%
10
S 19400-4752
RE S IS TO R ,M F ,1/4W ,47.5K ,1%
S 19400-2213
RE S IS TO R ,M F ,1/4W ,221K ,1%
1
5
S 19400-2002
5
S 19400-3321
2
S 19400-2210
RE S IS TO R ,M F ,1/4W ,20.0K ,1%
RE S IS TO R ,M F ,1/4W ,221,1%
RE S IS TO R ,M F ,1/4W ,3.32K ,1%
4
S 19400-26R 7
RE S IS TO R ,M F ,1/4W ,26.7,1%
9
S 19400-1003
RE S IS TO R ,M F ,1/4W ,100K ,1%
2
1
1
8
S 19400-6811
S 19400-3921
S 19400-3011
S 19400-1004
RE S IS TO R ,M F ,1/4W ,6.81K ,1%
RE S IS TO R ,M F ,1/4W ,3.92K ,1%
RE S IS TO R ,M F ,1/4W ,3.01K ,1%
28
S 19400-1001
RE S IS TO R ,M F ,1/4W ,1.00K ,1%
RE S IS TO R ,M F ,1/4W ,1.00M ,1%
5
S 19400-4750
RE S IS TO R ,M F ,1/4W ,475,1%
6
S 19400-5110
RE S IS TO R ,M F ,1/4W ,511,1%
2
1
4
S 19400-2001
S 19400-9092
S 19400-7681
RE S IS TO R ,M F ,1/4W ,2.00K ,1%
RE S IS TO R ,M F ,1/4W ,90.9K ,1%
RE S IS TO R ,M F ,1/4W ,7.68K ,1%
4
S 19400-2670
RE S IS TO R ,M F ,1/4W ,267,1%
1
1
2
1
S 19400-3323
S 19400-5621
S 19400-1501
T14648-24
RE S IS TO R ,M F ,1/4W ,332K ,1%
RE S IS TO R ,M F ,1/4W ,5.62K ,1%
RE S IS TO R ,M F ,1/4W ,1.50K ,1%
RE S IS TO R ,W W ,5W ,0.5,5%,S Q
40
S 19400-68R 1
RE S IS TO R ,M F ,1/4W ,68.1,1%
4
4
2
1
2
1
1
1
1
S 18380-1
S 19400-2490
S 19400-2673
S 19400-3922
S 19400-2802
S 18380-3
S 19400-6810
S 19400-3012
S 19400-3570
THE R M IS TO R,P TC,56 O HM S ,90M A
RE S IS TO R ,M F ,1/4W ,249,1%
RE S IS TO R ,M F ,1/4W ,267K ,1%
RE S IS TO R ,M F ,1/4W ,39.2K ,1%
RE S IS TO R ,M F ,1/4W ,28.0K ,1%
THE R M IS TO R,P TC,.08-0.19 O HM S ,1.85A
RE S IS TO R ,M F ,1/4W ,681,1%
RE S IS TO R ,M F ,1/4W ,30.1K ,1%
RE S IS TO R ,M F ,1/4W ,357,1%
4
1
3
1
1
1
1
2
4
1
S 19400-20R 0
S 19400-1502
S 19400-2211
S 19400-1500
S 19400-5622
T10812-79
S 18380-5
T12737-2
T13640-25
T13640-16
RE S IS TO R ,M F ,1/4W ,20.0,1%
RE S IS TO R ,M F ,1/4W ,15K ,1%
RE S IS TO R ,M F ,1/4W ,2.21K ,1%
RE S IS TO R ,M F ,1/4W ,150,1%
RE S IS TO R ,M F ,1/4W ,56.2K ,1%
TRIM M E R,S T,1/2W ,100, 10%,LINE A R
THE R M IS TO R,P TC,0.5-1.17 O HM S ,0.5A
TRA N S F O RM E R ,P ULS E ,3-W IND ING ,1:1:1
M O V ,130V RM S ,90J,20M M
M O V ,150V RM S ,80J,20M M
1
4
1
1
2
1
4
1
1
1
1
2
T13640-11K
S 15161-27
S 17900-24
S 17900-8
S 15018-6
S 15128-6
S 15128-18
S 15128-15
S 15018-4
M 15102-4
S 15128-16
S 25073-9
M O V ,150V RM S ,45J,14M M
TRIA C,TO 220,8A ,800V
IC,CM O S ,G A TE ,NA ND,2-IN P UT,Q U A D,S C HM (S S )
IC,CM O S ,INV E RTE R ,S CH M ITT,H E X,HC14A (S S )
IC,CM O S ,S W ITCH ,A NA LO G ,Q UA D , 4066(S S )
IC,V O LT R E G ,F IXE D,3-T,(+),1A ,15V ,TO 220
O P -A M P ,Q U A D, H IG H-P E RF ,33074
IC,V O LT R E G ,A D J,3-T,(+),3A ,350,TO 220
IC,CM O S ,INV E RTE R ,S CH M ITT, HE X,4584(S S )
IC,A R RA Y ,DRIV E R ,P E R IP HE RA L,N P N,D A RL
IC,O P -A M P ,Q UA D ,HIG H -P E RF ,1014
IC,CM O S ,P S O C ,8-B IT,C Y 8C 27443,DIP -28(S S )
6
7
7
6
S 19400-1211
S 19400-3320
S 19400-2000
T13640-18
RE S IS TO R ,M F ,1/4W ,1.21K ,1%
RE S IS TO R ,M F ,1/4W ,332,1%
RE S IS TO R ,M F ,1/4W ,200,1%
M O V ,320V RM S ,150J,20M M
UNLESS OTHERWISE SPECIFIED:
CAPACITANCE = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
G4763-1A1
PART NO. IDENTIFICATION
CODE
TEST PER E4298-C
COAT WITH E1844 AND E3668
SCHEMATIC REFERENCE: G4762-1A1
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253
BUY BLANK COMPLETE
( 2 BOARDS PER PANEL)
FOR PARTS ORDERS:
4 LAYER BOARD BLANK PANEL
SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION.
INCLUDE (1) S25597PRINT PARTS ORDERS
INSTRUCTION SHEET.
THIS DOCUMEN T CON TAINS PROPRIETARY
INFORMATION O
PROPRIETARY & CONFIDENTIAL:
TO O THER PARTIES OR USED FOR AN
Y PURPOSE WITHOU
U N LE S S O TH E R W IS E S P E C IF IE D TO LE R A N C E
DESIG N INF OR MATIO N
M ANUF ACTURING TO LERANC E P ER E 2056
REFERENCE:
ON AL L A NGLES IS ± .5 OF A DE GREE
MATER IAL T O LE RA NCE (" t") T O AG REE
W ITH PUB LIS HE D STAN DA RDS.
SCA LE:
ON 2 PLA CE DE CIMA LS IS ± .02
O N 3 PLACE DEC IM ALS IS ± .002
DO NOT SCAL E THI S DR AWING
NOTE:
®
DRAWN BY:
ENGI NEER:
APPR O V E D :
JB
TNguyen
-
G3909
1:1
EQUIPM ENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
WNED BY LINCOLN G LOBAL, INC. AND MA
Y NOT BE DUPLICATED, COM
T THE EXPRESS WRIT
TEN PERMISSION OF LINCOLN GL
OBAL, INC.
PRECISION TIG
CONTROL P.C. BOARD ASSEMBLY
APPROVAL
DATE:
7-27-2007
PROJECT
NUMBER:
PAGE
DOCUMENT
NUMBER:
CRM38261
MUNICATED
1
1 O F ___
___
G4763-1
DOCUMENT
REVISION:
A
S O LID E D G E
Return to Master TOC
Return to Section TOC
MAKE DETAIL
MANUFACTURE PER E1911
STRP
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
PRECISION TIG 275
Return to Master TOC
G-19
ELECTRICAL DIAGRAMS
SCHEMATIC-PROTECTION P.C. BOARD (M16115)
M 16115
Return to Section TOC
G-19
1
L4
J23
J22
.39mH
5
C4
.0047
3000V
L5
J23
J22
.39mH
4
C5
Return to Master TOC
Return to Section TOC
2
.0047
3000V
L1
3
J23
J22
.39mH
1
C1
.0047
3000V
L2
4
J23
J22
.39mH
2
C2
.0047
3000V
L6
5
J23
J22
.39mH
6
C6
.0047
Return to Master TOC
Return to Section TOC
3000V
L3
7
8
J23
J22
.39mH
3
C3
J23
.0047
3000V
GENERAL INFORMATION
LAST NO. USED
R- _
ELECTRICAL SYMBOLS PER E1537
CAPACITORS =
MFD ( .022/50V
RESISTORS = Ohms (
DIODES =
1A, 400V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
C- _
LABELS
(UNLESS OTHERWISE SPECIFIED)
SUPPLY
Return to Master TOC
Return to Section TOC
COMMON CONNECTION
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
FRAME CONNECTION
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
EARTH GROUND CONNECTION
NUMBER.
THIS SHEET CONTAINS PROPRIETARY INFORMATION
OWNED BY
THE LINCOLN ELECTRIC CO.
AND IS
NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF
THE LINCOLN ELECTRIC CO.
NOTE:
®
VOLTAGE NET
POWER SUPPLY SOURCE POINT
NOTES :
N.A.
D- _
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLE SIZES PER E2056
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE DECIMALS IS .002
ON ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE (" ")t TO AGREE
WITH PUBLISHED STANDARDS.
5-29-90SPA
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
SCALE
DR MK/DRS
NONE
DATE 1-12-90
EQUIP.
SQARE WAVE TIG 350
TYPE
SUBJECT
PROTECTION P.C. BOARD SCHEMATIC
SHT.
CHK GM/BS
REF.
SUP'S'D'G
NO.
M 16115
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
PRECISION TIG 275
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-20
PC BOARD ASSEMBLY-PROTECTION (M16062-1)
-1
Return to Master TOC
ITEM
Return to Section TOC
G-20
ELECTRICAL DIAGRAMS
REQ'D
®
IDENTIFICATION
C1, C2, C3, C4, C5, C6
6
T11577-58
.0047/3000 V
L1, L2, L3, L4, L5, L6
6
T12218-9F
.39 mH
J22
1
S18248-6
HEADER
J23
1
S18248-8
HEADER
1
1
L8081-B
P.C. BD BLANK
CAPACITORS = MFD/VOLTS
NOTE:
PART NO.
M16062-1
M16062
-1
9-28-2001M
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
PRECISION TIG 275
Return to Master TOC
Return to Section TOC
G-21
G-21
ELECTRICAL DIAGRAMS
SCHEMATIC-BYPASS / STABILIZER P.C. BOARD (S22530-1) (CODE 10806 & 10807)
ARC STABILIZER CAPACITOR
C9
ARC STABILIZER
15
RESISTOR
10
250V
R1
Return to Master TOC
Return to Section TOC
5W
CONNECTION MADE THROUGH
CONNECTION MADE THROUGH
HOLE WITH SOLDER PAD
HOLE WITH SOLDER PAD
C1
C2
.05
600V
.05
600V
C3
.05
600V
C4
.05
600V
160J
160J
320V
C5
C6
C7
C8
600V
600V
600V
600V
.05
.05
.05
.05
Graphic
Return to Master TOC
Return to Section TOC
TP2
320V
Graphic
GND
GND CONNECTION MADE THROUGH SOLDER PAD
AND SCREW TO STEEL STANDOFF ON MACHINE
S22530-1B0
Rev A
NOTES :
N.A.
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED
CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE
Return to Master TOC
Return to Section TOC
TP1
BOARD.
LABELS
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS =
MFD ( .022/50V
THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS
RESISTORS = Ohms (
OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER.
DIODES =
1A, 400V
1/4W
SUPPLY
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
VOLTAGE NET
POWER SUPPLY SOURCE POINT
FRAME CONNECTION
EARTH GROUND CONNECTION
COMMON CONNECTION
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
Return to Master TOC
Return to Master TOC
Return to Master TOC
XXX
XXX
Return to Section TOC
XXXXXXXXXXX
XXXXXXXXXXX
XXX
Return to Section TOC
PC BOARD ASSEMBLY-BYPASS / STABILIZER (L10121-1) (CODE 10806 & 10807)
L10121-1
Return to Master TOC
ITEM
Return to Section TOC
G-22
ELECTRICAL DIAGRAMS
XXXXXXXXXXX
Return to Section TOC
G-22
NOTE:
®
REQ'D
BYPASS
STABILIZER
L10121-1
Rev B
PART NO.
IDENTIFICATION
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
PRECISION TIG 275
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
SCHEMATIC-BYPASS AND CE P. C. BOARD (S24206) (CODE 10893)
LINE 1 (U)
LINE 2 (V)
B1
C3
B2
C4
2.2
2.2
275V
275V
C1
C2
.0047
.0047
440V
440V
FRAME GROUND
FILE NAME: S24206_1AA
THE LINCOLN ELECTRIC CO.
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY
NOTES :
N.A.
SINCE COMPONENTS OR CIRCUITRY ON
CIRCUIT BOARD
MAY CHANGE
THE INTERCHANGEABILITY
THIS DIAGRAM MAY NOT
OR CIRCUITRY OF
Return to Master TOC
Return to Section TOC
G-23
ELECTRICAL DIAGRAMS
S 24206
Return to Section TOC
G-23
ELECTRICAL SYMBOLS PER E1537
WITHOUT AFFECTING
BOARD.
SHOW THE EXACT COMPONENTS
CONTROLS HAVING A COMMON
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2
CODE NUMBER.
Ch'ge.Sht.No.
XA
3-20-98
CAPACITORS =
MFD ( .022/50V
RESISTORS = Ohms (
DIODES =
1A, 400V
1/4W
SUPPLY
UNLESS OTHERWISE SPECIFIED)
WITH PUBLISHED STANDARDS
(UNLESS OTHERWISE SPECIFIED)
EARTH GROUND CONNECTION
EQUIP.
TYPE
CLEVELAND, OHIO U.S.A.
SCALE
APM
FRAME CONNECTION
COMMON CONNECTION
THE LINCOLN ELECTRIC CO.
DR.
VOLTAGE NET
POWER SUPPLY SOURCE POINT
UNLESS OTHERWISE SPECIFIED)
ON ALL ANGLES IS + .5 OF A DEGREE
MATERIAL TOLERANCE ("t") TO AGREE
THE LINCOLN ELECTRIC CO.
LABELS
GENERAL INFORMATION
A PRINTED
OF A COMPLETE
AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION O F
DATE
SUBJECT
NONE
9/29/97
CHK.
SUP'S'D'G.
SCHEMATIC, BYPASS
SHT.
NO.
S 24206
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
Return to Master TOC
Return to Master TOC
Return to Master TOC
SSAPYB
Return to Master TOC
Return to Section TOC
x
xx xx
x
x
x
x
x
x
xxxx
x
x
x
x
x
x
1-28801L
Return to Section TOC
PC BOARD ASSEMBLY-BYPASS AND CE (L10882-1) (CODE 10893)
L10882-1
Return to Section TOC
G-24
ELECTRICAL DIAGRAMS
BYPASS
Return to Section TOC
G-24
xxx x
xx
x xx x
xx
ITEM
REQ'D
IDENTIFICATION
PART NO.
xx xx
x
x
xx x x
xx
x
x
x
x
x
x
x
x
x
xx xx
x x x
L
10882-1
3-20-98
BOTTOM VIEW
NOTE:
®
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-25
SCHEMATIC - TIG OPTION P.C. BOARD - BELOW CODE 11000 (G4039 PAGE 1)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-25
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-26
SCHEMATIC - TIG OPTION P.C. BOARD - BELOW CODE 11000 (G4039 PAGE 2)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-26
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
PC BOARD ASSEMBLY - TIG OPTION P.C. BOARD - BELOW CODE 11000 (G4040-2)
REVISED MANUFACTURER SPECIFICATION
C H A NGE DETAIL:
E N G IN E E R IN G C O N T R O LLE D
M A N U F A C T U R E R : Yes
ITEM
1
2
QTY PART NUMB ER
DESCRIPTION
1
G 4040-F
P C B O A RD B LA N K
1
S 25409-1
S O F TW A RE CP LD (X3)
RE F E R TO E LE CTR O NIC C O M P O NE NT DA TA B A S E F O R S P E CIF ICA TIO NS O N ITE M S LIS TE D B E LO W
REFERENCES
QTY PART NUMB ER
DESCRIPTION
C1, C2, C4, C5, C7, C9, C10, C14, C 15, C16, C17, C 18,
C19, C21, C 22, C23, C24, C26, C 27, C28, C29, C 30, C31,
44
S 25020-3S M T
CA P A CITO R ,S M D,CE R A M IC ,0.1M F ,50V ,10%,X7R ,S 0805
C32, C33, C 34, C38, C39, C40, C 41, C42, C43, C 44, C45,
C47, C49, C 50, C51, C52, C53, C 54, C55, C56, C 57
C3, C8, C58
3
S 25020-2S M T
CA P A CITO R ,S M D,CE R A M IC ,0.022M F ,50V ,10%,X7R,S 0805
C6, C20
2
S 25020-5S M T
CA P A CITO R ,S M D,CE R A M IC ,2700pF ,50V ,5%,X7R,S 0805
C11, C12, C 13, C35, C36, C37, C 46, C48
8
S 25020-24S M T
CA P A CITO R ,S M D,CE R A M IC ,1.0M F ,25V ,10% ,X7R ,S 1206
C59
1
S 25020-12S M T
CA P A CITO R ,S M D,CE R A M IC ,100pF ,100V ,5%,CO G ,S 0805
D1
1
S 25040-2S M T
DIO DE ,S M D,1A ,400V ,DO -214B A /A C
D2, D3, D8, D10
4
S 25049-4S M T
DIO DE ,S M D,S CHO TTK Y ,DUA L,0.200A ,30V ,S O T-23
D4, D5, D6, D7, D9
5
S 25040-5S M T
DIO DE ,S M D,D UA L,0.200A ,70V ,UF R
DZ1
1
S 25046-1S M T
ZE NE R DIO D E ,S M D,0.5W ,5.1V , 5%,S O D123
DZ2, DZ3
2
S 25046-4S M T
ZE NE R DIO D E ,S M D,0.5W ,12V ,5%,S O D-123
N .D. J1
1
S 24020-12
CO NNE CTO R,M O LE X,M INI,P CB ,12-P IN,TIN
N .D. J2, J3
2
S 21135-10
CO NNE CTO R,M O LE X,M INI,B LIND,F ,10-P IN
LE D1, LE D2
2
S 25080-2S M T
LE D,S M D ,G RE E N,CLE A R,S 1206
Q 1, Q 5
2
S 25051-4S M T
TRA N S IS TO R,S M D ,NM F ,S O T-23,0.115A ,60V ,7002LT1(S S )
Q 2, Q 3, Q 4, Q 6, Q 7
5
S 25050-1S M T
TRA N S IS TO R,S M D ,NP N,0.5A ,40V ,S O T-23,M M B T4401LT1
R1, R13, R26, R 66, R87, R93, R105, R126, R 163, R164,
13
S 25000-4751S M T RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,4.75K ,1%,S 0805
R165, R 166, R167
R2, R3, R4, R5, R8, R12, R43, R 47, R68, R88, R 90, R108,
19
S 25000-1001S M T RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,1.00K ,1%,S 0805
R109, R 112, R122, R 145, R146, R 147, R160
REVISION CONTROL
G4040-2F0
PART NO. IDENTIFICATION
CODE
TEST PER E3937-AC
COAT WITH E1844 AND E3668 (1 COAT EACH)
SCHEMATIC REFERENCE: G4039-2F0
B UY DETAIL
Return to Master TOC
1
N.E.
N.B.
2.75
R 133
R 138
2.60
C6
R 19
D1
R 18
X2
C5
R 17
C 13
C 12
C 11
D Z2
R 64
C20
R 61
X9
X8
C37
LE D 2
R 104
R 105
R 120
R 149
R 147
HOT S T ART
TP1
C 56
N.F.
R 151
R 156
C 57
R 153
R 157
R 154
R 158
R 155
R 124
C 52
R 152
R 123
C 51
C53
R 150
R 122
R 118
R 148
R 121
C33
R 145
C36
R 102
C 50
R 117
R 144
R 146
C 55
R 63
R 62
R 82
R 83
R 75
R 98
R 142
C 54
C35
R 101
R 103
R 99
X7
R 143
R 141
R 139
R 140
R 137
X 12
R 136
X 11
R 134
R 135
TP4
R 119
R 116
R 89
R 100
C 49
R 114
R 1 15
N .A .
N .A .
N .A .
N .A .
N .A .
N .A .
R 88
R 87
C 34
D9
C45
C48
R 113
R 67
R 159
Q6
C43
X 10
R 132
D10
0 .20
C46
R 111
R 130
R 129
C 47
C 44
R 112
C 42
C 41
D8
R 110
R 127
R 128
Q5
R 125
R 96
R 92
C 40
R 131
R 126
D Z3
.20
0
R 109
C31
Q4
R 79
C 32
R 97
C 38
Q3
R 107
C39
R 90
Return to Master TOC
R 108
R 106
R 80
R 74
R 72
R 68
R 66
C 30
LE D 1
C 29
D7
R 73
R 71
R 94
R 95
R 93
R 76
TP3
C 24
TP2
R 86
C 26
R 70
R 166
R 167
C58
C23
C22
X3
R 91
D6
X6
Q7
R 69
R 45
R 65
R 58
R 84
R 81
C27
R 77
R55
C21
D5
R 57
D4
R 59
R 56
R 60
C 19
R 53
R 54
R 85
R 52
C 10
R 46
Q2
R44
C28
C 18
R 41
Q1
C9
X5
R 50
R 40
R 78
R 35
R 36
R 34
R 33
R 32
R 49
C17
C16
R 39
D3
R 13
X 13
R 162
D Z1
R 161
R 168
C3
R 163
C59
C1
R 160
R 165
R 20
R 27
R5
C15
R 38
R 51
C14
R 47
R 48
R 37
R 16
R 12
C4
R 26
R 42
R 43
D2
R 14
R 11
R 10
C2
R 25
R 24
R9
J1
R8
R6
R3
X1
JI
R7
R 15
C8
C7
R2
R1
R4
R 22
S1
R 23
R 21
1 2 3 4 5 6 7 8
ADVANCED CONTROL
R 31
O
N
R 30
N.G.
G 4 0 4 0 -2
R 164
P R E C IS IO N T IG
3.30
R 28
3.50
Return to Section TOC
MAK E DETAIL
MANUFACTURE PER E1911-ROHS
BUY BLANK COMPLETE
(6 BOARDS PER PANEL)
4 LAYER BOARD BLANK PANEL
SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION.
R 29
Return to Section TOC
BUY PER E3867
ARC FORCE
44
S 25000-1002S M T
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,10.0K ,1%,S 0805
1
10
8
3
2
1
3
5
5
1
3
3
4
1
2
1
3
3
2
1
8
5
5
3
2
1
2
1
2
1
1
1
6
1
1
2
1
S 25058-1S M T
S 25000-5110S M T
S 25000-4750S M T
S 25000-1372S M T
S 25000-10R0S M T
S 25000-1501S M T
S 25000-2212S M T
S 25000-2002S M T
S 25000-1211S M T
S 25000-2211S M T
S 25000-3323S M T
S 25000-4752S M T
S 25000-3320S M T
S 25000-4753S M T
S 25000-1000S M T
S 25000-47R5S M T
S 25000-3321S M T
S 25000-1821S M T
S 25000-6811S M T
S 25000-3922S M T
S 25000-1003S M T
S 25000-7501S M T
S 25000-2671S M T
S 25000-1822S M T
S 25001-1210S M T
S 25000-3570S M T
S 25000-2000S M T
S 25000-6810S M T
T10812-41
S 25000-1652S M T
S 19869-8
S 15128-11S M T
S 15128-4S M T
S 25070-12S M T
S 25067-1S M T
S 15018-6S M T
S 25057-2S M T
TRIM M E R,S M D,S T,1/4W ,10K ,10%,LINE A R
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,511O HM S ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,475O HM S ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,13.7K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,10.0O HM S ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,1.50K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,22.1K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,20.0K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,1.21K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,2.21K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,332K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,47.5K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,332O HM S ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,475K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,100O HM S ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,47.5O HM S ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,3.32K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,1.82K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,6.81K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,39.2K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,100K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,7.50K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,2.67K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,18.2K ,1%,S 0805
RE S IS TO R,S M D ,121O H M S ,1/4W ,1206,1%,TR
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,357O HM S ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,200O HM S ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,681O HM S ,1%,S 0805
TRIM M E R,S T,1/2W ,10K , 10%,LIN E A R
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,16.5K ,1%,S 0805
S W ITCH ,DIP ,S P S T,8-CIRC UITS ????S E T_S W ITC H_P O S ITIO N S ????
IC,S M D,C O M P A R A TO R,Q UA D ,2901D
O P -A M P ,S M D,Q UA D , G E N -P URP O S E ,224D
IC,S M D,C M O S ,CP LD ,CY 37192,160-TQ F P (S S )
IC,B IP O LA R,TIM E R,S O IC -14
IC,S M D,C M O S ,S W ITCH ,A NA LO G ,Q UA D, 4066B D (S S )
P O T,S M D,DIG ITA L,10K ,1-C HNL,S O IC -8
J2, J3MOUNTED
ON BACK OF BOARD
UNLESS OTHERWISE SPECIFIED:
CAPACITANCE = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
5.50
5.30
NOTES:
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. SEE E2454
BEFORE HANDLING.
N.B. PROGRAM X3 WITH ITEM 2.
Return to Master TOC
N.D.
N.E.
N.F.
N.G.
Return to Section TOC
R6, R10, R14, R 16, R17, R18, R21, R 28, R29, R32, R 33,
R48, R52, R 53, R56, R61, R63, R 64, R65, R89, R 92, R101,
R102, R 103, R104, R 107, R116, R 120, R123, R128, R130,
R135, R 137, R138, R 139, R140, R 141, R143, R151, R152,
R153, R 154, R155, R 157
R7
R9, R34, R37, R 38, R50, R67, R127, R131, R 132, R133
R11, R42, R 49, R51, R111, R 134, R161, R162
R15, R79, R 81
R19, R57
R20
R22, R142, R144
R23, R62, R 86, R136, R158
R24, R44, R 91, R110, R121
R25
R27, R46, R 75
R30, R31, R 168
R35, R36, R 106, R124
R39
R40, R45
R41
R54, R69, R 77
R55, R82, R 125
R58, R84
R59
R60, R70, R 73, R74, R78, R83, R 113, R150
R71, R76, R 94, R97, R118
R72, R80, R 95, R96, R117
R85, R119, R129
R98, R99
R100
R114, R 115
R148
R149, R 159
R156
S1
X1
X2, X5, X6, X8, X11, X13
X3
X7
X9, X12
X10
DO NOT COAT WITH ENCAPSULATION MATERIAL.
KEEP MOUNTING HOLES FREE OF ENCAPSULATION MATERIAL. (5 PLACES)
KEEP TOP SURFACE OF TRIMMERS FREE OF ENCAPSULATION MATERIAL. (2 PLACES)
KEEP TOP SURFACE OF DIP SWITCH FREE OF ENCAPSULATION MATERIAL.
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMB LY ARE TO B E RoHS COMPLIANT PER E4253.
THIS DOCUMEN T CON TAINS PROPRIETARY
INFORMATION O
PROPRIETARY & CONFIDENTIAL:
TO O THER PARTIES OR USED FOR AN
Y PURPOSE WITHOU
U N LE S S O TH E R W IS E S P E C IF IE D TO LE R A N C E
DESIG N INF OR MATIO N
M ANUF ACTURING TO LERANC E P ER E 2056
REFERENCE:
ON AL L A NGLES IS ± .5 OF A DE GREE
MATER IAL T O LE RA NCE (" t") T O AG REE
W ITH PUB LIS HE D STAN DA RDS.
SCA LE:
ON 2 PLA CE DE CIMA LS IS ± .02
NOTE:
®
O N 3 PLACE DEC IM ALS IS ± .002
DRAWN BY:
DO NOT SCAL E THI S DR AWING
APPR O V E D :
ENGI NEER:
FEI
-
G4040-1
1:1
SUBJECT:
MATERIAL
DISPOSITION:
UF
WNED BY LINCOLN G LOBAL, INC. AND MA
Y NOT BE DUPLICATED, COM
T THE EXPRESS WRIT
TEN PERMISSION OF LINCOLN GL
OBAL, INC.
INDUSTRIAL TIG
ADVANCED CONTROL PC BOARD ASSEMBLY
EQUIPM ENT TYPE:
APPROVAL
DATE:
3/16/2
007
PROJECT
NUMBER:
CRM34409
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
MUNICATED
1
1 O F ___
P A G E ___
DOCUMENT
NUMBER:
G4040 -2
DOCUMENT
REVISION:
B
S O LID E D G E
Return to Master TOC
G-27
ELECTRICAL DIAGRAMS
G4040-2
Return to Section TOC
G-27
STRP
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-28
SCHEMATIC - TIG OPTION P.C. BOARD - ABOVE CODE 11000 (G4760 PAGE 1)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-28
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-29
SCHEMATIC - TIG OPTION P.C. BOARD - ABOVE CODE 11000 (G4760 PAGE 2)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-29
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
Return to Master TOC
ELECTRICAL DIAGRAMS
G-30
SCHEMATIC - TIG OPTION P.C. BOARD - ABOVE CODE 11000 (G4760 PAGE 3)
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-30
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
®
PRECISION TIG 275
C6
R 18
C5
R 45
R 46
R 88
C35
J3
R 68
R 86
R 92
R 101
R 61
R 54
R 173
X
LE D 1
TP5
R 71
R 55
R 69
C62
R 39
R 67
C 30
R 17
R 11
X2
R 87
TP2
C 29
C 11
R 13
R 26
X6
R 108
R 82
R 83
R 84
R 122
R 178
R 59
C27
R 70
R 72
R 147
R 140
R 66
TP4
R 124
X9
X8
D 12
C37
C 49
R 117
R 1 48
R 118
R 102
R 104
C 56
R 103
R 120
C 51
LE D 2
R 158
R 150
R 149
HOT START
C 52
R 152
X
R 156
R 89
N.J.
N.H.
X
X
X
X
X
X
D9
TP1
R 151
R 157
N.F.
R 119
R 155
R 154
C 57
R 153
J2, J3 MOUNTED
ON BACK OF BOARD
R 159
ARC FORCE
NOTES:
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. SEE E2454
BEFORE HANDLING.
N.B. PROGRAM X14 WITH ITEM 2 AND LABEL X14 WITH PART NUMBER OF ITEM 2.
N.C. APPLY ITEM 3 TO COMPONENT SIDE OF BOARD AS SHOWN.
N.D. DO NOT COAT WITH ENCAPSULATION MATERIAL.
N.E. KEEP MOUNTING HOLES FREE OF ENCAPSULATION MATERIAL. (5 PLACES)
N.F. KEEP TOP SURFACE OF TRIMMERS FREE OF ENCAPSULATION MATERIAL. (2 PLACES)
N.G. KEEP TOP SURFACE OF DIP SWITCH FREE OF ENCAPSULATION MATERIAL.
N.H. APPLY ITEM 3 AROUND BASE OF J2 & J3 ON BACK SIDE OF BOARD. LIMIT HEIGHT TO
.125 +0/-.0625 INCHES.
N.J. APPLY ITEM 3 TO CONNECTOR’S PLASTIC MOUNTING PINS.
5.30
5.50
REVISION CONTROL
G4761-1A0
PART NO. IDENTIFICATION
CODE
TEST PER E4298-AC
COAT WITH E1844 AND E3668
SCHEMATIC REFERENCE: G4760-1A0
N.A.
MAK E DETAIL
4 LAYER BOARD BLANK PANEL
SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION.
Return to Master TOC
Return to Section TOC
MANUFACTURE PER E1911
BUY BLANK COMPLETE
(6 BOARDS PER PANEL)
QTY
PART NUMB ER
DESCRIPTION
36
S 25020-3S M T
CA P A CITO R ,S M D,CE R A M IC,0.1M F ,50V ,10%,X7R ,S 0805
5
1
4
1
4
1
1
S 25020-2S M T
S 25020-5S M T
S 25020-27S M T
S 25020-9S M T
S 25020-24S M T
S 25020-14S M T
S 25040-2S M T
CA P A CITO R ,S M D,CE R A M IC,0.022M F ,50V ,10%,X7R,S 0805
CA P A CITO R ,S M D,CE R A M IC,2700pF ,50V ,5%,X7R,S 0805
CA P A CITO R ,S M D,CE R ,0.1M F ,50V ,-20%+80%,Z5U,S 0805
CA P A CITO R ,S M D,CE R A M IC,47pF ,50V ,5%,CO G ,S 0805
CA P A CITO R ,S M D,CE R A M IC,1.0M F ,25V ,10% ,X7R ,S 1206
CA P A CITO R ,S M D,CE R A M IC,330pF ,100V ,5%,CO G ,S 0805
DIO DE ,S M D,1A ,400V ,DO -214B A /A C
6
S 25040-5S M T
DIO DE ,S M D,D UA L,0.200A ,70V ,UF R
7
{
2
1
1
1
2
1
1
2
1
5
1
S 25049-4S M T
S 25046-1S M T
S 25046-4S M T
S 25046-3S M T
S 24020-12
S 21135-10
S 24020-2
S 24020-4
S 25080-2S M T
S 15000-34S M T
S 25050-1S M T
S 25051-4S M T
S 25000-2211S M T RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,2.21K ,1%,S 0805
48
S 25000-1002S M T RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,10.0K ,1%,S 0805
1
3
S 25058-1S M T
TRIM M E R,S M D,S T,1/4W ,10K ,10%,LIN E A R
S 25000-6810S M T RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,681O HM S ,1%,S 0805
6
5
S 25000-3320S M T RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,332O HM S ,1%,S 0805
S 25000-1000S M T RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,100O HM S ,1%,S 0805
1
1
3
3
4
2
3
S 25000-1372S M T
S 25000-1501S M T
S 25000-2212S M T
S 25000-2002S M T
S 25000-1211S M T
S 25000-3323S M T
S 25000-4752S M T
ON AL L A NGLES IS ± .5 OF A DE GREE
MATER IAL T O LE RA NCE (" t") T O AG REE
W ITH PUB LIS HE D STAN DA RDS.
SCA LE:
DO NOT SCAL E THI S DR AWING
NOTE:
®
ENGI NEER:
APPR O V E D :
Jbarto
T Nguyen
-
F ILM ,1/10W ,13.7K ,1%,S 0805
F ILM ,1/10W ,1.50K ,1%,S 0805
F ILM ,1/10W ,22.1K ,1%,S 0805
F ILM ,1/10W ,20.0K ,1%,S 0805
F ILM ,1/10W ,1.21K ,1%,S 0805
F ILM ,1/10W ,332K ,1%,S 0805
F ILM ,1/10W ,47.5K ,1%,S 0805
12
S 25000-5110S M T RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,511O HM S ,1%,S 0805
9
S 25000-4751S M T RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,4.75K ,1%,S 0805
5
S 25000-47R 5S M T RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,47.5O HM S ,1%,S 0805
19
S 25000-1001S M T RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,1.00K ,1%,S 0805
5
S 25000-4750S M T RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,475O HM S ,1%,S 0805
2
2
2
3
1
2
2
1
2
2
2
2
2
1
1
1
3
1
2
2
1
1
2
S 25000-3321S M T
S 25000-1821S M T
S 25000-10R 0S M T
S 25000-1003S M T
S 25000-3162S M T
S 25000-7501S M T
S 25000-2671S M T
S 25084-2S M T
S 25001-1210S M T
S 25000-9091S M T
S 25000-2000S M T
S 25000-1822S M T
T10812-41
S 25000-1652S M T
S 19869-8
S 15128-11S M T
S 15128-28S M T
S 25067-1S M T
S 15128-4S M T
S 15018-6S M T
S 25057-2S M T
S 25073-12S M T
S 25065-3S M T
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,3.32K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,1.82K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,10.0O HM S ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,100K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,31.6K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,7.50K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,2.67K ,1%,S 0805
THE R M IS TO R,S M D,P TC,0.35./1.4O H M S ,2.0A
RE S IS TO R,S M D ,121O H M S ,1/4W ,1206,1%,TR
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,9.09K ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,200O HM S ,1%,S 0805
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,18.2K ,1%,S 0805
TRIM M E R,S T,1/2W ,10K , 10%,LINE A R
RE S IS TO R,S M D ,M E TA L F ILM ,1/10W ,16.5K ,1%,S 0805
S W ITCH ,DIP ,S P S T,8-CIRC UITS ????S E T_S W ITC H_P O S ITIO N S ????
IC,S M D,C O M P A R A TO R,Q UA D,2901D
IC,O P -A M P ,S M T,Q U A D,HIG H -P E RF ,33074A D T
IC,B IP O LA R,TIM E R,S O IC -14
O P -A M P ,S M D,Q UA D , G E N-P URP O S E ,224D
IC,S M D,C M O S ,S W ITCH ,A NA LO G ,Q U A D, 4066B D (S S )
P O T,S M D,DIG ITA L,10K ,1-CH NL,S O IC-8
IC,S M D,C M O S ,P S O C,8-B IT,CY 8C27643,TF N49(S S )
IC,S M D,C M O S ,INV E RTE R,S CH M ITT,HE X,V HC 14(S S )
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253
REFERENCE:
DRAWN BY:
RE S IS TO R,S M D ,M E TA L
RE S IS TO R,S M D ,M E TA L
RE S IS TO R,S M D ,M E TA L
RE S IS TO R,S M D ,M E TA L
RE S IS TO R,S M D ,M E TA L
RE S IS TO R,S M D ,M E TA L
RE S IS TO R,S M D ,M E TA L
UNLESS OTHERWISE SPECIFIED:
CAPACITANCE = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
U N LE S S O TH E R W IS E S P E C IF IE D TO LE R A N C E
DESIG N INF OR MATIO N
M ANUF ACTURING TO LERANC E P ER E 2056
ON 2 PLA CE DE CIMA LS IS ± .02
ZE NE R DIO D E ,S M D,0.5W ,5.1V , 5%,S O D123
ZE NE R DIO D E ,S M D,0.5W ,12V ,5%,S O D-123
ZE NE R DIO D E ,S M D,0.5W ,18V , 5%,S O D123
CO NNE CTO R,M O LE X,M INI,P CB ,12-P IN,TIN
CO NNE CTO R,M O LE X,M INI,B LIN D,F ,10-P IN
CO NNE CTO R,M O LE X,M INI,P CB ,2-P IN,TIN
CO NNE CTO R,M O LE X,M INI,P CB ,4-P IN,TIN
LE D,S M D ,G RE E N,CLE A R,S 1206
IC,S M D,O P TO C O UP LE R,HM A 124
TRA N S IS TO R,S M D ,NP N,0.5A ,40V ,S O T-23,M M B T4401LT1
TRA N S IS TO R,S M D ,NM F ,S O T-23,0.115A ,60V ,7002LT1(S S )
7
THIS DOCUMEN T CON TAINS PROPRIETARY
INFORMATION O
PROPRIETARY & CONFIDENTIAL:
TO O THER PARTIES OR USED FOR AN
Y PURPOSE WITHOU
O N 3 PLACE DEC IM ALS IS ± .002
DIO DE ,S M D,S CHO TTK Y ,DUA L,0.200A ,30V ,S O T-23
G4040
1:1
SUBJECT:
MATERIAL
DISPOSITION:
NA
WNED BY LINCOLN G LOBAL, INC. AND MA
Y NOT BE DUPLICATED, COM
T THE EXPRESS WRIT
TEN PERMISSION OF LINCOLN GL
OBAL, INC.
INDUSTRIAL TIG
ADVANCED CONTROL PC BOARD ASSEMBLY
EQUIPM ENT TYPE:
APPROVAL
DATE:
3/5/2007
PROJECT
NUMBER:
CRM38259
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
PAGE
DOCUMENT
NUMBER:
MUNICATED
1
1 O F ___
___
G4761-1
DOCUMENT
REVISION:
A
S O LID E D G E
C66
C4
R 10
R 181
C65
D Z5
R 180
R 57
R 179
C64
R 58
R 41
R 76
R 52
R 75
R 25
X1
R 29
R 21
R 27
C15
R 28
R 73
R 145
R 146
R 138
R 135
R 60
R 74
R 95
C26
C33
X 12
R 143
R 141
R 139
X 11
R 136
C 48
R 94
R 142
R 111
R 144
2.60
C 63
R 105
R 116
R 137
R 132
R 130
N.B.
D Z4
R 107
X 13
R 166
C58
R 167
R 114
2
C 50
C 10
C9
R 123
D5
C36
R99
C 55
C 54
D6
R 85
C 28
R 64
R 115
X7
C20
C45
C43
R 127
R 128
R 129
D8
D4
R 98
X 14
R 172
R 126
R 110
D Z3
Q5
D 14
R6
X
D 11
R 30
R 22
R 112
R 106
R 20
X 16
Q6
D 13
C7
R 16
J20
C 34
C 19
R 14
R 15
R 32
R 31
C1
R 121
Q3
D 10
R 24
X 15
C 53
X
Q8
R 65
C3
R 77
R 38
C12
R 37
R 51
XX
D7
D3
R 33
R9
XX
J1
R 23
R 36
R 50
C18
R 34
R 42
R 174
R 35
R 96
O C I1
C8
R 43
R 44
R 182
R 49
C17
R8
R 97
D1
C14
XX
D2
C 38
C 32
0 .20
Q2
X 10
R2
R5
R3
R 47
R 183
R 12
R 169
R 91
C60
C39
R 109
C31
R 125
.20
0
XX
Q7
R 170
R 171
J2
X
R 90
Return to Master TOC
N.J.
R 177
R 176
R 48
R1
R4
C 46
J1,J20,J21
R7
DESCRIPTION
P C B O A RD B LA N K
P S O C S O F TW A R E (X14)
S E A LA NT
R E F E R TO E LE CTRO NIC CO M P O NE NT DA TA B A S E F O R S P E C IF ICA TIO NS O N ITE M S LIS TE D B E LO W
{
N.E.
ADVANCED CONTROL
XX
J21
S1
X
C2
X X
1 2 3 4 5 6 7 8
R 134
O
N
R 133
N.G.
D Z1
P R E C IS IO N T IG
G 4 7 6 1 -1
R 175
2.75
PART NUMB ER
1
G 4761-A
1
S 26859-1
A S R E Q E 2861
REFERENCES
C1, C2, C4, C5, C7, C10,
C12, C14, C15, C17, C18,
C19, C20, C26, C29, C30,
C31, C32, C33, C34, C38,
C39, C43, C45, C49, C50,
C51, C52, C53, C54, C55,
C56, C57, C62, C63, C65
C3, C8, C58, C 64, C66
C6
C9, C27, C 28, C46
C11
C35, C36, C37, C48
C60
D1
D2, D3, D4, D5, D6, D7,
D8
D9, D10, D 11, D12, D13,
D14
DZ1, DZ5
DZ3
DZ4
J1
J2, J3
J20
J21
LE D1, LE D2
O C I1
Q 2, Q 3, Q 6, Q 7, Q 8
Q5
R1, R2, R3, R4, R5, R8,
R25
R6, R10, R 13, R14, R16,
R17, R18, R21, R26, R28,
R29, R32, R33, R48, R52,
R58, R59, R61, R65, R72,
R82, R84, R85, R89, R92,
R101, R 102, R103, R104,
R116, R 120, R123, R128,
R130, R 135, R137, R138,
R139, R 140, R141, R143,
R151, R 152, R153, R154,
R155, R 157,
R7
R9, R148, R175
R11, R35, R36, R106,
R111, R 124
R12, R45, R169, R170,
R171
R15
R20
R22, R142, R144
R23, R136, R158
R24, R44, R110, R178
R27, R46
R30, R31, R70
R34, R37, R38, R50, R67,
R75, R76, R127, R131,
R132, R 133, R181
R39, R60, R66, R87,
R105, R 126, R166, R167,
R177
R41, R172, R176, R 182,
R183
R42, R43, R47, R64, R68,
R71, R83, R88, R90, R91,
R107, R 109, R112, R121,
R145, R 146, R147, R174,
R179
R49, R51, R77, R134,
R180
R54, R69
R55, R125
R57, R97
R73, R74, R150
R86
R94, R118
R95, R117
R96
R98, R99
R108, R 122
R114, R 115
R119, R 129
R149, R 159
R156
S1
X1
X2, X6, X11
X7
X8, X13
X9, X12
X10
X14
X15, X16
N.C.
1
QTY
1
2
3
N.D.
R 131
Return to Master TOC
ITEM
RELEASED A.01 FROM "X"
C H A NGE DETAIL:
E N G IN E E R IN G C O N T R O LLE D
M A N U F A C T U R E R : No
Return to Master TOC
Return to Section TOC
PC BOARD ASSEMBLY - TIG OPTION P.C. BOARD - ABOVE CODE 11000 (G4761-1)
3.50
3.30
Return to Section TOC
G-31
ELECTRICAL DIAGRAMS
G4761-1
Return to Section TOC
G-31
STRP
PRECISION TIG 275
Return to Master TOC
SVM ERROR REPORTING FORM
We need to know if there are errors in our manuals. We also value any suggestions as to
additional tests or procedures that would make this SVM a better tool for you.
If you discover new or different “Problems or Symptoms” that are not covered in the three column troubleshooting chart, please share this information with us. Please include the
machine’s code number and how the problem was resolved.
Return to Master TOC
Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
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Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 01/99