Lincoln Electric IM609-B manual

Square W a v e TIG 275 OPERA T OR’S MANU AL IM609-B May , 2001 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with saf ety in mind. Howe ver , your ov erall saf ety can be increased by proper installation ... and thoughtful operation on y our par t. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHO[...]

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

ii SAFETY ii ARC RA YS can b urn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b . Use suitab le clothing made from durable flame-resistant material to protect you[...]

FOR ELECTRICALL Y powered equipment. 8.a. T ur n off input pow er using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U .S. National Electrical Code, all local codes and the manuf acturer’ s recommendations. 8.c. Ground the equipment in accordance with the U .S. National Ele[...]

iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ P our votre propre protection lire et obser v er toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté P our Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Les circ[...]

Thank You f or selecting a QU ALITY product by Lincoln Electric. We w ant you to take pride in operating this Lincoln Electric Company product ••• as much pride as we hav e in br inging this product to y ou! Read this Operators Man ual completely bef ore attempting to use this equipment. Sav e this manual and keep it handy f or quick ref eren[...]

vi vi T ABLE OF CONTENTS P age Installation .......................................................................................................Section A T echnical Specifications .................................................................................A-1, A-2 Select Suitable Location ....................................................[...]

A-1 INST ALLA TION SQU ARE W A VE TIG 275 A-1 TECHNICAL SPECIFICA TIONS - Square W ave TIG 275 (K1617-1, and -2) For A C/DC Stic k, DC TIG and Balanced A C TIG W elding at 275A 40% Duty Cycle w/o Optional K1620-1 P ower F actor Capacitors Based on the 1996 U .S. National Electrical Code For Unbalanced A C TIG W elding above 180A, 255A 40% Duty Cycl[...]

A-2 INST ALLA TION SQU ARE W A VE TIG 275 A-2 TECHNICAL SPECIFICA TIONS - Square W ave TIG 275 (K1618-1) For A C/DC Stic k, DC TIG and Balanced A C TIG W elding at 275A 40% Duty Cycle w/o Optional K1620-1 P ower F actor Capacitors Based on the 1996 U .S. National Electrical Code For Unbalanced A C TIG W elding above 180A, 255A 40% Duty Cycle, Maxim[...]

A-3 INST ALLA TION SQU ARE W A VE TIG 275 A-3 ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • T urn the input power OFF at the disconnect switch or fuse bo x before w orking on this equipment. • Do not touch electrically hot parts. • Always connect the Square W ave TIG 275 grounding screw (located on [...]

A-4 INST ALLA TION SQU ARE W A VE TIG 275 A-4 2. K eep the work and electrode leads as shor t as pos- sible and as close together as possib le. Lengths should not e xceed 25 ft (7.6m). T ape the leads together when practical. 3. Be sure the torch and work cable rubber cov er ings are free of cuts and crac ks that allow high frequen- cy leakage. Cab[...]

A-5 INST ALLA TION SQU ARE W A VE TIG 275 A-5 Fuse the input circuit with the recommended super lag fuses or dela y type 1 circuit breakers . Choose an input and grounding wire size according to local or national codes or ref er to the T echnical Specifications page at the beginning of this section. Using fuses or circuit breakers smaller than reco[...]

A-6 INST ALLA TION SQU ARE W A VE TIG 275 A-6 575V 460V WARNING: Powered by high voltage which can kill. Turn off all input Connect the input power leads to the input terminals, L1 (U) and L2 (V), at the right below. Connect the input power leads with the hardware provided. Completely tighten all fasteners. Connect a grounding lead to the ground st[...]

A-7 INST ALLA TION SQU ARE W A VE TIG 275 A-7 Designations on the reconnect panel LO W , MID , and HIGH correspond to the nameplated input voltages of a triple voltage welder . Dual voltage welders use only LO W and HIGH. EXAMPLE: On a 208/230/460 volt welder , LOW is 208V , MID is 230V , and HIGH is 460V . 3. Mak e sure all connections are tight. [...]

A-8 INST ALLA TION SQU ARE W A VE TIG 275 A-8 TIG T ORCH CONNECTION The T wist-Mate connection allows fast and reliab le TIG torch attachment to the electrode terminal of the Square Wa ve TIG 275 welding power supply . T wist- Mate TIG adapters are made of brass, combining high electrical conductivity with mechanical strength. They are av ailable i[...]

A-9 INST ALLA TION SQU ARE W A VE TIG 275 A-9 TWIST -MA TE AD APTER FOR LA-9 and LA-17 TIG T ORCH The T wist-Mate connection allows fast and reliab le TIG torch connections to the electrode terminal of the Square Wa ve TIG 275. The T wist-Mate adapter , strain relief boot and retaining compound needed to connect an LA-9 or LA-17 torch (or any equiv[...]

A-10 INST ALLA TION SQU ARE W A VE TIG 275 A-10 4. Hold the TIG adapter , with cables and hoses installed, fir mly in place b y secur ing it into the T wist- Mate receptacle on the pow er source or into a padded vise. Apply a thin film of lubricant to the boot’ s lead in chamfer area. Also apply lubr icant to the lead in chamf er and 2" diam[...]

B-1 OPERA TION B-1 SQU ARE W A VE TIG 275 ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from w ork and ground. • Alwa ys wear dr y insulating glo ves . • Read and f ollow “Electric Shock Warnings” in the Saf ety section if welding must be per- f or med under e[...]

B-2 OPERA TION B-2 SQU ARE W A VE TIG 275 2 A GRAPHIC SYMBOLS THA T APPEAR ON THIS MA CHINE OR IN THIS MANU AL & & PO WER SWITCH SYMBOL MEANING ON OUTPUT CONTROL SYMBOL MEANING CURRENT CONTROL (OUTPUT) OFF INPUT PO WER O VER TEMPERA TURE A C W A VE B ALANCE CONTROL SYMBOL MEANING A C W A VE B ALANCE CLEAN (INCREASING POSITIVE POLARITY) PENE[...]

B-3 OPERA TION B-3 SQU ARE W A VE TIG 275 GRAPHIC SYMBOLS THA T APPEAR ON THIS MA CHINE OR IN THIS MANU AL OPTIONAL W A TER SOLENOID CONNECTIONS SYMBOL MEANING W A TER (COOLANT) INPUT OUTPUT CONNECTIONS SYMBOL MEANING WORK CONNECTION ELECTRODE CONNECTION W A TER (COOLANT) OUTPUT ADDITIONAL SYMBOLS SYMBOL MEANING REMO TE CONTROL DO NO T SWITCH WHILE[...]

B-4 OPERA TION B-4 GENERAL DESCRIPTION The Square Wa ve TIG 275 is a constant current, single range square wa ve A C/DC TIG (GT A W) arc welding power source with b uilt-in high frequency stabilization. It also has stick (SMA W) capability . A TIG Pulser Kit, P ower F actor Capacitor Kit, and a W ater Solenoid Kit are av ailable as field installed [...]

B-5 OPERA TION B-5 • DC+/A C/DC- P olar ity Switch allows the w elder to change polarity without reconnecting leads. • Provides e xcellent arc star ting and stability through- out the machines wide current range (5 to 315 Amps) to handle the v ast major ity of TIG welding applica- tions. • Simple output current dial allo ws the user to preset[...]

B-6 OPERA TION B-6 1. Current Control - This knob is used to set the welding current from 5 to 315 amps . Read the complete Operating Instructions section f or more inf or mation on Local and Remote setting of current. 2. A C W ave Balance Contr ol - This knob is activ e in the AC TIG mode only . It is used to set the amount of cleaning and/or pene[...]

B-7 OPERA TION B-7 6. T rimmer P otentiometers - Allows the meters to be calibrated in the field. 7. Digital Ammeter - The ammeter displays actual welding current during a weld cycle and displa ys the peak current f or approximately 5 seconds after welding is complete. Otherwise the machine’ s set current is displa yed. Read the complete Operatin[...]

B-8 OPERA TION B-8 SQU ARE W A VE TIG 275 (1) When used with argon gas. The current ranges sho wn must be reduced when using argon/helium or pure helium shielding gasses. (2) T ungsten electrodes are classified as follows b y the American W elding Society (A WS): Pure ...............E W P 1% Thoriated . .......E W Th-1 2% Thoriated . .......E W Th-[...]

B-9 OPERA TION B-9 8. Set the P ost Flow Time with the post flow knob . P ost flow control knob adjusts the time that the shielding gas flows (and cooling w ater flow , if the optional water solenoid is used) after the w eld cycle. Use shor t post flow times with low currents and small tungstens, use long post flo w times at high output currents wi[...]

B-10 OPERA TION B-10 10. With the torch held saf ely aw ay from e verything, press the Arc Star t Switch and set the gas flow meter . Release the switch. The welder is now ready f or welding. 11. Position the tungsten electrode at the start of the weld at a 65˚ to 75˚ angle with the horizontal so that the electrode is appro ximately 1/8" (4 [...]

B-11 OPERA TION B-11 STICK WELDING 1. T urn the welder “ON”. The digital ammeter/voltmeter will illuminate when the pow er is on. 2. Set the Mode Switch to “STICK”. Set the output cur- rent displa yed on the digital ammeter with the Output Control Knob . No other functions or adjust- ments operate in the Stic k Mode. 3. Select the desired D[...]

C-1 A CCESSORIES C-1 A CCESSORIES INCLUDED WITH MA CHINE K852-50 - T wist Mate Cable Plug f or #2 to #1 W or k Lead. K1622-1 - T wist Mate Adapter Kit for LA9 and LA17 T orches. K1622-2 - T wist Mate Adapter Kit for L W18 and L W20 T orches. OPTIONAL A CCESSORIES K963-1, -2 - Hand Amptrol K870 - F oot Amptrol K814 - Arc Star t Switch K559-2 - Magnu[...]

D-1 MAINTENANCE D-1 SQU ARE W A VE TIG 275 ELECTRIC SHOCK can kill. • Only qualified per sonnel should perform this maintenance. • T urn the input power OFF at the disconnect switch or fuse bo x before w orking on this equipment. • Do not touch electrically hot parts. T o av oid receiving a high frequency shock, k eep the TIG torch and cables[...]

D-2 MAINTENANCE D-2 COMPONENT LOCA TION AND A CCESS Control PC Boar d: Remov e the left case side. Use a 3/8" Nut Dr iv er or other suitable tool. Note: The Case side can be remov ed while roof is in place, as long as the three scre ws which secure the roof to the case side are remov ed. The PC Board is mounted on left divider assembly and can[...]

E-1 TR OUBLESHOO TING E-1 SQU ARE W A VE TIG 275 If f or any reason y ou do not understand the test procedures or are unable to perf or m the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Ser vice F acility f or technical troubleshooting assistance bef ore you proceed. CA UTION This T roubleshooting Guide is provided to help [...]

E-2 TR OUBLESHOO TING E-2 SQU ARE W A VE TIG 275 Obser v e all Safety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unable to perf or m the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Ser vice F acility f or technical troubleshooting assistance bef ore you pr[...]

E-3 TR OUBLESHOO TING E-3 SQU ARE W A VE TIG 275 Obser v e all Safety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unable to perf or m the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Ser vice F acility f or technical troubleshooting assistance bef ore you pr[...]

E-4 TR OUBLESHOO TING E-4 SQU ARE W A VE TIG 275 Obser v e all Safety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unable to perf or m the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Ser vice F acility f or technical troubleshooting assistance bef ore you pr[...]

E-5 TR OUBLESHOO TING E-5 SQU ARE W A VE TIG 275 Obser v e all Safety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unable to perf or m the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Ser vice F acility f or technical troubleshooting assistance bef ore you pr[...]

E-6 TR OUBLESHOO TING E-6 SQU ARE W A VE TIG 275 Obser v e all Safety Guidelines detailed throughout this manual If f or any reason y ou do not understand the test procedures or are unable to perf or m the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Ser vice F acility f or technical troubleshooting assistance bef ore you pr[...]

E-7 TR OUBLESHOO TING E-7 SQU ARE W A VE TIG 275 If f or any reason y ou do not understand the test procedures or are unable to perf or m the tests/repairs saf ely , contact your Local Lincoln A uthorized Field Ser vice F acility f or technical troubleshooting assistance bef ore you proceed. CA UTION PC BO ARD TROUBLESHOO TING PR OCEDURE Bef ore re[...]

F-1 WIRING DIA GRAM F-1 SQU ARE W A VE TIG 275 B 232 R 222 (U) (V) L1 255 254 L1 L2 C1 RECEPTACLE G1 G2 SCR4 246 2 STEP TIG BRASS 115VAC 251 TERMINAL 243 248 H4 POS D FRONT GANG ELECTRICAL SYMBOLS PER E1537. 276 A F J6 C C E J7A ARC STARTER AS'BLY 253 N.A. CONNECTION IS PIN TO PIN BETWEEN 248 A B B R5 236B 208 VOLT CONNECTION NEG H4 (460V) F 2[...]

F-2 WIRING DIA GRAM F-2 SQU ARE W A VE TIG 275 380 VOLT CONNECTION 312 MODE SWITCH STICK 243 248 AT MINIMUM D F 260 N.C. N.A. N.B. 50 B C PRIMARY TOROID THERMOSTAT H5 313 255 217 G3 R 222 (-) G1 C2 F2 DOWNSLOPE CONTROL G A-C, D-E, B-F B-D, C-E, A-F, G-H CONNECTOR PIN NUMBERS: TL1 R6 S2A AC D2 G3 217 275C 275B 4 STEP TIG G-GREEN R-RED O-ORANGE REAR [...]

F-3 WIRING DIA GRAM F-3 SQU ARE W A VE TIG 275 B 232 R1 R2 R3 T3 R 222 POSTFLOW CONTROL POTENTIOMETER 10K PHASE SHIFT RESISTOR 200/100 (U) (V) L1 255 254 L1 L2 C1 RECONNECT PANEL R3 RECEPTACLE G2 R5 SCR4 246 2 STEP TIG BRASS 115VAC 251 TERMINAL 243 248 D2 MAIN TRANSFORMER HI-FREQ TRANSFORMER D1 (+) HIGH VOLTAGE TRANSFORMER SCR1 W 221 B SCR2 VIEW OF[...]

DIMENSION PRINT SQU ARE W A VE TIG 275 20.00 40.65 4.00 24.06 3.57 .71 15.37 28.00 3.57 17.50 A M19118 9.57 19.15 22.89 33.40 27.65 F-4 F-4[...]

Now A vailable...12th Edition The Procedure Handbook of Ar c W elding With ov er 500,000 copies of pre vious editions published since 1933, the Procedure Handbook is considered by man y to be the “ Bible ” of the arc welding industry . This printing will go fast so don ’ t dela y . Place your order now using the coupon belo w . The hardbound [...]

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

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German P ortuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

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