Lincoln Electric SVM141-A manual

SVM141-A November , 1998 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be in- creased by proper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECA[...]

SAFETY i i SQUARE W A VE TIG 275 FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ______________[...]

SAFETY ii ii SQUARE W A VE TIG 275 ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant materia[...]

SQUARE W A VE TIG 275 FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S[...]

SAFETY iv iv SQUARE W A VE TIG 275 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électr[...]

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v SQUARE W A VE TIG 275 Page Safety ...................................................................................................................................................................i-iv Installation ........................................................................................[...]

Section A-1 Section A-1 SQUARE W A VE TIG 275 T ABLE OF CONTENTS - INST ALLA TION SECTION - Installation ............................................................................................................................. Section A T echnical Specifications, Square W ave TIG 275 (K1617-1) ...................................................[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-2 A-2 SQUARE W A VE TIG 275 TECHNICAL SPECIFICA TIONS - Square W ave TIG 275 For all Stick, DC TIG and Balanced AC TIG Welding at 275A 40% Duty Cycle w/o Option[...]

Read this entire installation section before you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this installation. • T urn the input power OFF at the dis- connect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. • Always connect the Squar[...]

1. Keep the welder power supply lines as short as possible and enclose as much of them as possible in rigid metallic conduit or equivalent shielding for a distance of 50 feet (15.2m). There should be good electrical contact between this conduit and the welder case ground. Both ends of the conduit should be connected to a driven ground and the entir[...]

Fuse the input circuit with the recommended super lag fuses or delay type 1 circuit breakers. Choose an input and grounding wire size according to local or national codes or refer to the T echnical Specifications page at the beginning of this section. Using fuses or circuit breakers smaller than recommended may result in “nuisance” tripping fro[...]

USER SUPPLIED CONNECT ORS The Square W ave TIG 275 should be permanently wired into the power system. No plugs or connectors are necessary . OUTPUT CONNECTIONS T o avoid being startled by a high frequency shock, keep the TIG torch and cables in good condition. ELECTRIC SHOCK can kill. • T urn the power switch of the power source “OFF” before [...]

TIG T ORCH CONNECTION The T wist-Mate connection allows fast and reliable TIG torch attachment to the electrode terminal of the Square W ave TIG 275 welding power supply . T wist- Mate TIG adapters are made of brass, combining high electrical conductivity with mechanical strength. They are available in several sizes and styles to accommo- date a wi[...]

INST ALLA TION A-8 A-8 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TWIST -MA TE ADAPTER FOR LA-9 and LA-17 TIG T ORCH The T wist-Mate connection allows fast and reliable TIG torch connections to the e[...]

4. Hold the TIG adapter , with cables and hoses installed, firmly in place by securing it into the T wist-Mate recep- tacle on the power source or into a padded vise. Apply a thin film of lubricant to the boot’s lead in chamfer area. Also apply lubricant to the lead in chamfer and 2” diameter on the TIG adapter . Next align the strain relief bo[...]

NOTES A-10 A-10 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Section B-1 Section B-1 SQUARE W A VE TIG 275 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Precautions ...............................................................................................[...]

OPERA TION B-2 B-2 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work[...]

GENERAL DESCRIPTION The Square W ave TIG 275 is a constant current, single range square wave AC/DC TIG (GT AW) arc welding power source with built-in high frequency stabilization. It also has stick (SMA W) capability . A TIG Pulser Kit, Power Factor Capacitor Kit, and a W ater Solenoid Kit are available as field installed options. The Square W ave [...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-4 B-4 SQUARE W A VE TIG 275 • Provides excellent arc starting and stability through- out the machines wide current range (5 to 315 Amps) to handle the vast majori[...]

OPERA TION B-5 B-5 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1. Current Control - This knob is used to set the welding current from 5 to 315 amps. Read the complete Operating Instructions section fo[...]

8. Digital V oltmeter - This meter displays welding voltage, as measured on the output studs of the Square W ave TIG 275. After welding is complete, the meter displays the welding voltage corre- sponding to the peak welding current and displays this value for approximately 5 seconds. 9. Thermal Protection Light - A yellow light which only lights wh[...]

TIG WELDING SEQUENCE OF OPERA TION (2-Step TIG Mode) 1. Connect an Arc Start Switch or an Amptrol to the Remote Amphenol. 2. T urn the welder , gas supply and water supply (if equipped), on. The digital ammeter/voltmeter dis- plays will illuminate when the power is on. 3. Select the 2-Step TIG Mode with the 2-Step/4-Step TIG/Stick switch. 4. Set th[...]

1 1. Hold the Arc Start Switch down until an arc is established. The arc will start at a low current value that is equal to 25% of the preset current established in Step 4. It will remain at this current as long as the Arc Start Switch is closed. Release the Arc Start Switch. At this point, the Square W ave TIG 275 will quickly ramp up to the prese[...]

STICK WELDING 1. T urn the welder “on”. The digital ammeter/volt - meter will illuminate when the power is on. 2. Set the Mode Switch to “STICK”. Set the output current using the Output Control Knob. No other functions or adjustments operate in the Stick Mode. 3. Select the desired DC+/AC/DC- electrode polarity . 4. Clamp the electrode in t[...]

NOTES B-10 B-10 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Accessories Included with Machine ............................................................................................C-2 Optional Accessories ..................[...]

ACCESSORIES INCLUDED WITH MACHINE K852-50 - T wist Mate Cable Plug for #2 to #1 Work 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 ACCESSORIES Any necessary installation instructions are included for the following accessories: K963-1, -2 - Hand Amptrol K87[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 SQUARE W A VE TIG 275 T ABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ......................................................................................................................... Section D Safety Precautions .............[...]

SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this maintenance. • T urn the input power OFF at the dis- connect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. T o avoid receiving a high frequency shock, keep the TIG torch and cables in good condition. ROUTI[...]

COMPONENT LOCA TION AND ACCESS CONTROL PC BOARD Remove the left case side. Use a 3/8" Nut Driver or other suitable tool. NOTE: The Case side can be removed while roof is in place, as long as the three screws which secure the roof to the case side are removed. The PC Board is mounted on left divider assembly and can be removed with a phillips h[...]

MAINTENANCE D-4 D-4 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 4 3 5 12 11 2 1 9 8 13 10 7 6 SQUARE WAVE TIG 275 FIGURE D.2 - MAJOR COMPONENT LOCA TIONS 1. CASE FRONT (WITH DISPLA Y BOARD) 2. INTERNA[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 SQUARE W A VE TIG 275 T ABLE OF CONTENTS - THEOR Y OF OPERA TION SECTION - Theory of Operation ............................................................................................................. Section E General Description ......[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GENERAL DESCRIPTION The Square W ave TIG 275 machine is a constant cur - rent, single range square wave AC/DC TIG (GT AW) arc welding power source with built-in high frequency s[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFICA TION, CONTROL BOARD AND FEEDBACK The AC output from the main transformer secondary is rectified and controlled through the SCR bridge. Output current is sensed [...]

THEOR Y OF OPERA TION E-4 E-4 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HIGH VOL T AGE / HIGH FREQUENCY CIRCUIT The control board passes the 1 15 V AC voltage to the primary of the high voltage tran[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-5 E-5 SQUARE W A VE TIG 275 FIGURE E.5 – DC WELDING OUTPUT FIGURE E.6 – DC WELDING CURRENT GENERA TION DC WELDING OUTPUT When the polarity switch is [...]

AC WELDING OUTPUT 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 machine’s 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[...]

SCR OPERA TION 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 sig- nal 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 OF[...]

PROTECTIVE CIRCUITS Protective circuits are designed into the Square W ave TIG 275 to sense trouble and shut down the machine before the trouble damages the internal machine com- ponents. Both thermal protection and current overload are included. THERMAL PROTECTION Thermostats protect the machine from excessive oper- ating temperatures. Excessive o[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 SQUARE W A VE TIG 275 T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR SECTION - T roubleshooting & Repair Section ...................................................................................... Section F How to Use T roubleshoo[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW T O USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T urn the input power OFF at the fuse box before working on equipment. Do not touch electrically[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 SQUARE W A VE TIG 275 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason y[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 SQUARE W A VE TIG 275 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason y[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 SQUARE W A VE TIG 275 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason y[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 SQUARE W A VE TIG 275 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason y[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-8 F-8 SQUARE W A VE TIG 275 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason y[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 SQUARE W A VE TIG 275 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason y[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 SQUARE W A VE TIG 275 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-11 F-11 SQUARE W A VE TIG 275 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-12 F-12 SQUARE W A VE TIG 275 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-13 F-13 SQUARE W A VE TIG 275 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 SQUARE W A VE TIG 275 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason[...]

F-15 F-15 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason [...]

F-16 F-16 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason [...]

INST ALLA TION F-17 F-17 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If [...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-18 F-18 SQUARE W A VE TIG 275 HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric f[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 SQUARE W A VE TIG 275 LEADS A TT ACH HERE . 015 Spark Gap RIGHT SIDE VIEW OF MACHINE FIGURE F .1 – SP ARK GAP ASSEMBL Y HIGH FREQUENCY [...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-20 F-20 SQUARE W A VE TIG 275 W ARNING T1 MAIN TRANSFORMER TEST Service and repair should be performed by only Lincoln Electric factory trained p[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-21 F-21 SQUARE W A VE TIG 275 T1 MAIN TRANSFORMER TEST (continued) FIGURE F .2 – PLUG J8 LOCA TION ON CONTROL BOARD S-W TIG 275 CONTROL J8 PIN [...]

TROUBLESHOOTING & REP AIR F-22 F-22 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T1 MAIN TRANSFORMER TEST (continued) 6. If all of the secondary voltages are correct, the T1 transformer is function[...]

TROUBLESHOOTING & REP AIR F-23 F-23 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T1 MAIN TRANSFORMER TEST (continued) T ABLE F .1. T1 TRANSFORMER VOL T AGES TEST POINTS ACCEPT ABLE VOL T AGES SECON[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-24 F-24 SQUARE W A VE TIG 275 W ARNING GAS (W A TER) SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory traine[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-25 F-25 SQUARE W A VE TIG 275 GAS (W A TER) SOLENOID TEST (continued) FIGURE F .3 – GAS SOLENOID LOCA TION GAS SOLENOID CASE BACK LEFT SIDE INT[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-26 F-26 SQUARE W A VE TIG 275 W ARNING ST A TIC SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personne[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-27 F-27 SQUARE W A VE TIG 275 ST A TIC SCR TEST (continued) FIGURE F .4 – PLUG J1 LOCA TION ON CONTROL BOARD S-W TIG 275 CONTROL G3360-[ ] J1 J[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-28 F-28 SQUARE W A VE TIG 275 ST A TIC SCR TEST (continued) 3. Using an analog ohmmeter , test the resis- tance from anode to cathode of SCR1. Re[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-29 F-29 SQUARE W A VE TIG 275 W ARNING ACTIVE SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-30 F-30 SQUARE W A VE TIG 275 ACTIVE SCR TEST (continued) FIGURE F .6 – PLUG J1 LOCA TION ON CONTROL BOARD S-W TIG 275 CONTROL G3360-[ ] J1 J8 [...]

TROUBLESHOOTING & REP AIR F-31 F-31 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ACTIVE SCR TEST (continued) FIGURE F .7 – ACTIVE SCR TEST SETUP R2 SW2 SW1 V R1 6volt Lantern Battery A G C SCR un[...]

TROUBLESHOOTING & REP AIR F-32 F-32 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ACTIVE SCR TEST (continued) FIGURE F .8 – SCR GA TE LOCA TIONS SCR4 CA THODE SCR1 / SCR2 CA THODE SCR3 CA THODE SC[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-33 F-33 SQUARE W A VE TIG 275 This is the typical AC output voltage waveform generated from a properly operating machine. Note that each vertical[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-34 F-34 SQUARE W A VE TIG 275 This is the typical DC (+) output volt- age waveform generated from a prop- erly operating machine. Note that each [...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-35 F-35 SQUARE W A VE TIG 275 This is the typical AC output voltage waveform generated from a properly operating machine. Note that each vertical[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-36 F-36 SQUARE W A VE TIG 275 NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM DC STICK MODE This is the typical DC (+) output volt- age waveform generat[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-37 F-37 SQUARE W A VE TIG 275 TYPICAL OUTPUT VOL T AGE W A VEFORM - MACHINE LOADED AC TIG MODE MACHINE LOADED TO 255 AMPS A T 30 V AC. This is th[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-38 F-38 SQUARE W A VE TIG 275 MACHINE LOADED TO 275 AMPS A T 31 VDC. This is the typical DC (+) output volt- age waveform generated from a prop- [...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-39 F-39 SQUARE W A VE TIG 275 MACHINE LOADED TO 275 AMPS A T 31 VDC. This is the typical AC output voltage waveform generated from a properly ope[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-40 F-40 SQUARE W A VE TIG 275 MACHINE LOADED TO 275 AMPS A T 31 VDC. This is the typical AC output voltage waveform generated from a properly ope[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-41 F-41 SQUARE W A VE TIG 275 This is NOT the typical DC (+) output voltage waveform. One output SCR is not functioning. Note the “gap” in th[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-42 F-42 SQUARE W A VE TIG 275 W ARNING HIGH VOL T AGE TRANSFORMER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln[...]

TROUBLESHOOTING & REP AIR F-43 F-43 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HIGH VOL T AGE TRANSFORMER REMOV AL AND REPLACEMENT (continued) FIGURE F .9 – SECONDAR Y LEADS A T HIGH FREQUENCY [...]

TROUBLESHOOTING & REP AIR F-44 F-44 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HIGH VOL T AGE TRANSFORMER REMOV AL AND REPLACEMENT (continued) FIGURE F .10 – HIGH VOL T AGE TRANSFORMER MOUNTING[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-45 F-45 SQUARE W A VE TIG 275 W ARNING SCR BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Elect[...]

TROUBLESHOOTING & REP AIR F-46 F-46 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .11 – RECEPT ACLE/CIRCUIT BREAKER LEADS CIRCUIT[...]

TROUBLESHOOTING & REP AIR F-47 F-47 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .13 – SCR BRIDGE CONNECTIONS X2 LEAD LOCATION ([...]

TROUBLESHOOTING & REP AIR F-48 F-48 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE Refer to Figures F .1 1 - F .13. 1. [...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-49 F-49 SQUARE W A VE TIG 275 W ARNING POLARITY SWITCH REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric f[...]

TROUBLESHOOTING & REP AIR F-50 F-50 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POLARITY SWITCH REMOV AL AND REPLACEMENT (continued) FIGURE F .14 – NAMEPLA TE REMOV AL SQUARE WA VE TIG 275 REMOT[...]

TROUBLESHOOTING & REP AIR F-51 F-51 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POLARITY SWITCH REMOV AL AND REPLACEMENT (continued) FIGURE F .15 – POLARITY SWITCH CONNECTIONS 253 X1 MICRO SWITC[...]

TROUBLESHOOTING & REP AIR F-52 F-52 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POLARITY SWITCH REMOV AL AND REPLACEMENT (continued) FIGURE F .16 – POLARITY SWITCH WIRING DIAGRAM 232A 21 1A R8 2[...]

TROUBLESHOOTING & REP AIR F-53 F-53 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POLARITY SWITCH REMOV AL AND REPLACEMENT (continued) For Steps 9--17, see Figure F .15 and F .16. 9. W ith the 1/2?[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-54 F-54 SQUARE W A VE TIG 275 W ARNING MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBL Y REMOV AL AND REPLACEMENT Service and repair should be performe[...]

TROUBLESHOOTING & REP AIR F-55 F-55 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .17 – PLUG J8 LOCA TION [...]

TROUBLESHOOTING & REP AIR F-56 F-56 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .18 – TRANSFORMER CONNEC[...]

TROUBLESHOOTING & REP AIR F-57 F-57 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBL Y REMOV AL AND REPLACEMENT (continued) 20. Using the 3/8” wrench, remove[...]

TROUBLESHOOTING & REP AIR F-58 F-58 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBL Y REMOV AL AND REPLACEMENT (continued) Reassembly Procedure Refer to Figur[...]

RETEST AFTER REP AIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could af fect the machine’ s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested. INPUT IDLE AMPS Input V olts/Hertz Maximum Idle Amps Maximum Idle Amps (witho[...]

NOTES F-60 F-60 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

ELECTRICAL DIAGRAMS G-1 G-1 SQUARE W A VE TIG 275 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams Section ..........................................................................................Section G Wiring Diagram (L10747) ................................................................[...]

ELECTRICAL DIAGRAMS G-2 G-2 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W iring Diagram (L10747) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manu[...]

ELECTRICAL DIAGRAMS G-3 G-3 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W iring Diagram (L10747-2) NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this ma[...]

G-4 ELECTRICAL DIAGRAMS SQUARE W A VE TIG 275 Control Board Schematic (G3358-1) X6 10 8 9 221K R209 50V 820p C89 22.1K R212 3.92K R213 10.0K R206 X8 3 2 1 X8 4 5 6 X5 13 12 1N4936 D45 1N4936 D46 1N4936 D44 18.2K R190 39.2K R189 4.75K R208 X6 11 12 13 50V .0047 C96 D43 50V 0.1 C93 D53 Q22 2N4401 50V .0047 C105 10.0K R217 1W 3.3V DZ13 LINE_SYNC PHASE[...]

G-5 ELECTRICAL DIAGRAMS SQUARE W A VE TIG 275 G-5 Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Control Board Schematic (G3358-2) J7A 6 .39mH L6 START PRESET LINE_SYNC OUTPUT_ENABLE PTC- TRI- WORK VOLT. OCI- ELECT.VOLT X- S[...]

G-6 ELECTRICAL DIAGRAMS SQUARE W A VE TIG 275 Display Board Schematic (L10768) N_GND DISP3 2 1 4 9 5 10 7 6 8 3 N_GND DISP1 2 1 4 9 5 10 7 6 8 3 1.00K R57 14 3 Rx Vdd d BANK1 g DATA OUT f CLOCK MC14489 DATA IN h Vss BANK3 BANK4 BANK2 a /ENABLE e c BANK5 b X8 18 9 17 6 5 2 10 19 8 1 13 12 16 20 11 15 4 7 DISP2 2 1 4 9 5 10 7 6 8 3 1000V 750p C26 1N4[...]

ELECTRICAL DIAGRAMS G-7 G-7 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Bypass Board Schematic (S22530) 80J 150V TP1 600V .05 C8 5W 10 R1 250V 15 C9 600V .05 C6 600V .05 C7 600V .05 C5 600V .05 C2 600[...]

ELECTRICAL DIAGRAMS G-8 G-8 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Display Board Layout (L10770-1) DISPLAY L10770-1 ITEM ITEM REQ'D REQ'D PART NO. PART NO. DESCRIPTION DESCRIPTION NOTE:[...]

Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-9 ELECTRICAL DIAGRAMS SQUARE W A VE TIG 275 R215 R117 D9 D17 D12 D13 C38 R114 C39 R125 C54 R18 C19 R63 R197 R186 C79 C72 R182 R211 C100 R196 R205 C84 R181 R195 C74 R179 C75 C9[...]

ELECTRICAL DIAGRAMS G-10 G-10 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Bypass Board Layout (L10121-1) NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level tr[...]

Notes G-11 G-11 SQUARE W A VE TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]