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Lincoln Electric IM936 manual

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Table of contents for the manual

  • Page 1

    PRECISION TIG 375 OPERA T OR’S MANUAL IM936 April, 2007 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 increased by proper installation ... and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THI[...]

  • Page 2

    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. _______________________________________________[...]

  • Page 3

    ii SAFETY ii 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 material to protect your skin[...]

  • Page 4

    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. National Electrical[...]

  • Page 5

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

  • Page 6

    v v T T h h a a n n k k Y Y o o u u for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy fo[...]

  • Page 7

    T ABLE OF CONTENTS Page . Installation ..........................................................................................................Section A T echnical Specifications ........................................................................................A-1,A-2 Safety Precautions .. ...................................................[...]

  • Page 8

    A-1 INST ALLA TION PRECISION TIG 375 A-1 TECHNICAL SPECIFICA TIONS- PRECISION TIG 375 (K2623-1 Export-50/60Hz) V oltage + 10% 220-230/ 380-400/415 Max. Amps With Power Factor Capacitor 1 19/69/63 1 18/68/62 1 10/64/59 97/56/52 88/51/47 73/42/39 48/28/25 .67 min. .8KW Duty Cycle-Applications 40% AC/DC Stick / Balance TIG Unbalance (70% Penetration #[...]

  • Page 9

    A-2 INST ALLA TION PRECISION TIG 375 A-2 Height Width Depth Weight 31.0 in. 22.0 in. 26.0 in. 507 lbs. 787 mm 559 mm 660 mm 230 kgs. PHYSICAL DIMENSIONS 1 ALSO CALLED ‘INVERSE TIME" OR "THERMAL/MAGNETIC " CIRCUIT BREAKERS; CIRCUIT BREAKERS WHICH HA VE A DELA Y IN TRIPPING ACTION THA T DECREASES AS THE MAGNITUDE OF CURRENT INCREASES[...]

  • Page 10

    A-3 INST ALLA TION PRECISION TIG 375 A-3 SAFETY PRECAUTIONS SELECT SUIT ABLE LOCA TION Place the welder where clean cooling air can freely cir- culate in through the top rear vents and out through the bottom rear vents. Dirt, dust or any foreign material that can be drawn into the welder should be kept at a minimum. Failure to observe these precaut[...]

  • Page 11

    INPUT and GROUNDING CONNECTIONS 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. Remove the reconnect panel cover located near the back of the left case side to reveal the reconnect panel. Welder supply line entry provision is in the case rear panel. Entry is throu[...]

  • Page 12

    A-5 INST ALLA TION PRECISION TIG 375 A-5 Recommended Cable Sizes for Combined Lengths of Copper Work and Electrode Cables using 75 o C Wire: Machine Rating 0 to 100 Ft . 101 to 200 Ft 201 to 250 Ft 375A/40% #1 (42.4 mm 2 ) 1/0 (53.5 mm 2 ) 2/0 (67.4 mm 2 ) WORK CABLE CONNECTION A 15’ (2/0) weld cable with clamp is available (K2150-1). Otherwise, [...]

  • Page 13

    A-6 INST ALLA TION PRECISION TIG 375 A-6 TIG TORCH CONNECTION The Precision TIG torch connection box, located on the right side of the machine, provides all the input and output connections for the installation of both air- cooled and water-cooled TIG torches with fittings con- forming to Compressed Gas Association (CGA) stan- dards: Note: The Prec[...]

  • Page 14

    T orch Adapter Air Cooled T orch O UTPUT (front) Panel E LECTODE AND/OR GAS OUTPUT 5/8-18 RH ELECTODE AND COOLANT IN 7/8-14 LH C OOLANT OUT 5/8-18 LH ELECTODE AND/OR GAS OUTPUT 5/8-18 RH INPUT (back) Panel T wo - Cable (PT A-9,-7,-26) One - Cable (PT A-26) One - Cable (PT A-9,-17) K2166-2 (Opt.) K2166-1 (Opt.) S20403-4 (Incl.) 7/8-14 M-LH 5/8-18 M-[...]

  • Page 15

    A-8 INST ALLA TION PRECISION TIG 375 A-8 ROBOTIC INTERF ACE CONNECTION Robotic interface can be made at the Remote Receptacle (See Operation Section B-2). The machine is shipped with the remote receptacle circuit internally connected to receptacle J5 of the Control board for standard Amptrol operation. In order to enable the remote receptacle for r[...]

  • Page 16

    B-1 OPERA TION B-1 PRODUCT DESCRIPTION The Precision TIG 375 is part of a family of industrial arc welding power sources providing constant current, single range square wave AC/DC TIG (GT AW) with patented MicroStart™ II T echnology , Presettable Min. and Max. Output controls, and built-in high frequency stabilization for continuous AC TIG and DC[...]

  • Page 17

    B-2 OPERA TION B-2 RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Precision TIG 375 is recommended for the TIG (GT AW) and Stick (SMAW) welding processes within its output capacity range of 2 amps DC, or 5 amps AC, to 420 amps AC/DC. It is compatible with most Magnum TIG accessories (refer Equipment Limitations), as well as many indu[...]

  • Page 18

    B-3 OPERA TION B-3 1. POWER SWITCH - Input line switch turns input power ON or OFF , as indicated by the on or off sta- tus of the front panel displays. 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 [...]

  • Page 19

    B-4 OPERA TION B-4 • When the Polarity Switch is set to DC (- or +), the TIG mode provides high frequency only for starting. Hi-Freq. turns on after pre-flow time with the arc start switch closure, and turns off when the arc is established. * • Also functions for DC+ polarity to permit "balling" of tungsten for AC TIG welding. 4. AC B[...]

  • Page 20

    B-5 OPERA TION B-5 PRECISION TIG 375 DIGIT AL DISPLA Y DIGIT A L DISPLA Y SELECT SELECT DISPLA Y DISPLA Y SET SET DISPLA Y DISPLA Y 7a MENU BUTTON AND DISPLA Y SWITCH – 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[...]

  • Page 21

    B-6 OPERA TION B-6 PRECISION TIG 375 8. DIGIT AL METER AND DISPLA Y SWITCH – A (3- digit) 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 Outpu[...]

  • Page 22

    B-7 OPERA TION B-7 • In 4-Step position allows welding without continu- ously holding the start switch trigger . The arc start switch functions in the following manner: 1. Closing switch starts preflow , then arc starts at Minimum (Start) setting level (See Item 7). If the trigger is maintained closed after preflow time the output remains at the [...]

  • Page 23

    B-8 OPERA TION B-8 INTERNAL SET UP CONTROLS Precision TIG 375 Advanced Panel has 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 an[...]

  • Page 24

    B-9 OPERA TION B-9 PRECISION TIG 375 ( With DIP Switch #2 ON , As Shi pp ed ) ( With DIP Switch #2 OFF ) FIG. 1 FIGURE B.3[...]

  • Page 25

    B-10 OPERA TION B-10 PRECISION TIG 375 FIGURE B.4 ( With DIP Switch #3 OFF , As Shi pp ed ) ( With DIP Switch #3 ON ) FIG. 2[...]

  • Page 26

    B-11 OPERA TION B-11 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 machine’ s 2-Step trigger mode (See Item 12). The Amptrol is capable of controlling the output of the Precision TIG over the range between t[...]

  • Page 27

    B-12 OPERA TION B-12 PRECISION TIG 375 Max. to Min. Amptrol Min. to Max. Amptrol Setup for TIG Amp trol Weld ing Advanced P anel (If used) Standard C ontrols P ower Switch ON Polarity Switch A C or DC - Mode Switch TIG AC Balance AUTO or Set: More + fo r alum. oxide " Cleaning " w/o "S pitti ng " o r " wettin g " los s[...]

  • Page 28

    B-13 OPERA TION B-13 PRECISION TIG 375 RECOMMENDED ELECTRODE AMPERAGE RANGES - Precision TIG 375 SMA W Process ELECTRODE POLARITY 3/32" 1/8" 5/32" Fleetweld 5P , Fleetweld 5P+ DC+ 40 - 70 75 - 130 90 - 175 Fleetweld 180 DC+ 40 - 80 55 - 1 10 105 - 135 Fleetweld 37 DC+ 70 - 95 100 - 135 145 - 180 Fleetweld 47 DC- 75 - 95 100 - 145 135[...]

  • Page 29

    C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED OPTIONS The basic Precision TIG 375 machine is factory equipped with: • K2621-1 Precision TIG Advanced Control Panel. Provides 2/4-step trigger with adjustable Pulser con- trols and Down slope timer for TIG welding. Also includes adjustable Hot Start and Arc Force internal panel controls[...]

  • Page 30

    D-1 MAINTENANCE D-1 PRECISION TIG 375 ELECTRIC SHOCK can kill. • Only qualified personnel should perform this maintenance. • T urn the input power OFF at the disconnect 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 c[...]

  • Page 31

    D-2 MAINTENANCE D-2 SERVICE PROCEDURES Operation of the Precision TIG should be trouble-free for t he 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: COMPONENT ACCESS The following components are accessible for routin[...]

  • Page 32

    DO NOT use a volt-ohm meter to measure output voltages in TIG mode. The High Frequency Arc Starter voltage can damage the meter . CAUTION E-1 TROUBLESHOOTING E-1 PRECISION TIG 375 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facili[...]

  • Page 33

    E-2 TROUBLESHOOTING E-2 PRECISION TIG 375 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION OUTP[...]

  • Page 34

    E-3 TROUBLESHOOTING E-3 PRECISION TIG 375 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION METE[...]

  • Page 35

    E-4 TROUBLESHOOTING E-4 PRECISION TIG 375 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION HI-F[...]

  • Page 36

    E-5 TROUBLESHOOTING E-5 PRECISION TIG 375 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRES[...]

  • Page 37

    E-6 TROUBLESHOOTING E-6 PRECISION TIG 375 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION STIC[...]

  • Page 38

    E-7 TROUBLESHOOTING E-7 PRECISION TIG 375 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION TIG [...]

  • Page 39

    F-1 WIRING DIAGRAM F-1 PRECISION TIG 375 C A B B 10K A-B F E D C MINIMUM D F A E A B C D E F 319 322 316C 313C 316B 315 316 317 311 312 313 318 313A 313B 8 4 1 2 3 6 5 6 321 12 11 10 9 8 6 5 4 3 1 2 6 5 4 3 2 1 2 3 4 5 7 1 314 320 311A 316A 8 7 6 5 4 3 2 1 J23 J22 7 316C 321 322 313 314 315 316 317 318 319 320 311 312 J8 J9 2 1 W 221 R 222 11 3 10 [...]

  • Page 40

    F-2 DIMENSION PRINT F-2 PRECISION TIG 375 L11660 XB- U F ** L O C A TI O N O F (4) O .2 8 4 B AS E M O U N TI N G H O L ES . 1 2. 77 3 1. 0 0 2 6. 0 0 1. 00 2 4. 00 ** .2 8 3. 47 2 0. 5 0 ** 2 2. 0 0 .3 0 .7 5 3. 44 T O RC H H O L S T E R 2. 1 1 T O R CH B O X 1 1. 00 2. 98[...]

  • Page 41

    NOTES PRECISION TIG 375[...]

  • Page 42

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese 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 P ARA EL [...]

  • Page 43

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. l Keep your hea d out of fu mes. l Use ve ntil atio n or exha ust to remo ve fum es [...]

  • Page 44

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]