square wave tig 275

Square Wave TIG 275

OPERATOR’S MANUAL

IM609-BMay, 2001

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thoughtfuloperation on your part. DO NOTINSTALL, OPERATE OR REPAIRTHIS EQUIPMENT WITHOUTREADING THIS MANUAL ANDTHE SAFETY PRECAUTIONSCONTAINED THROUGHOUT.And, most importantly, think beforeyou act and be careful.

For use with machines having Code Numbers: 10523,10524,10525,10605,10738

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Date of Purchase:Serial Number:Code Number:Model:Where Purchased:

Copyright © 2001 Lincoln Global Inc.

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework 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 weld-

ing arc or when the engine is running. Stopthe engine and allow it to cool before refuel-ing to prevent spilled fuel from vaporizing oncontact with hot engine parts and igniting. Donot spill fuel when filling tank. If fuel is spilled,wipe it up and do not start engine until fumeshave been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in posi-

tion and in good repair.Keep hands, hair, clothing and toolsaway from V-belts, gears, fans and all other moving partswhen starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan. Do

not attempt to override the governor or idlerby pushing on the throttle control rods whilethe engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

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.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-chase 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 theLincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay 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, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem 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 andwork 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 aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

For Diesel Engines: Diesel engine exhaust andsome of its constituents are known to the Stateof California to cause cancer, birth defects, andother reproductive harm.

For Gasoline Engines: The engine exhaust fromthis product contains chemicals known to theState of California to cause cancer, birth defects,or other reproductive harm.

CALIFORNIA PROPOSITION 65 WARNINGS

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

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 bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b. Mar ‘95

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contact cancause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate circuits.This can create fire hazards or overheat lifting chains orcables until they fail.

6.h. Also see item 1.c.

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un plancher met-allique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble desoudage et la machine à souder en bon et sûr état defonc-tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à soud-er parce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peaude soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible dela zone de travail qu’il est pratique de le faire. Si on place lamasse sur la charpente de la construction ou d’autres endroitséloignés de la zone de travail, on augmente le risque de voirpasser le courant de soudage par les chaines de levage,câbles de grue, ou autres circuits. Cela peut provoquer desrisques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voirle code “Code for safety in welding and cutting” CSA StandardW 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can be foundon your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information youhave recorded above.

vv

vivi TABLE OF CONTENTSPage

Installation .......................................................................................................Section ATechnical Specifications.................................................................................A-1, A-2Select Suitable Location ........................................................................................A-3Stacking .................................................................................................................A-3Lifting and Moving .................................................................................................A-3Tilting. ....................................................................................................................A-3Environmental Rating ...........................................................................................A-3Machine Grounding and High Frequency Interference Protection ........................A-3Supply Connections...............................................................................................A-4Input Reconnect Procedures.................................................................................A-5Output Connections...............................................................................................A-7Work Cable Connections.......................................................................................A-7TIG Torch Connections ..........................................................................................A-8Twist-Mate Adapter for LA-9 and LA-17 TIG Torch................................................A-9Twist-Mate Adapter for LW-18 and LW-20 TIG Torch ............................................A-9Stick Electrode Cable Connection .......................................................................A-10Installation of Field Installed Options...................................................................A-10

Operation .........................................................................................................Section BSafety Precautions ...............................................................................................B-1Graphic Symbol Definitions ...................................................................................B-2General Description...............................................................................................B-4Recommended Processes and Equipment ...........................................................B-4Design Features and Advantages .........................................................................B-4Limitations..............................................................................................................B-5Duty Cycle and Time Period..................................................................................B-5Controls and Settings ............................................................................................B-6Welding Operation .................................................................................................B-7Auxiliary Power ....................................................................................................B-10

Accessories.....................................................................................................Section CAccessories Included with Machine ......................................................................C-1Optional Accessories.............................................................................................C-1

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Routine and Periodic Maintenance .......................................................................D-1Overload Protection...............................................................................................D-1Service Procedures...............................................................................................D-1Component Location and Access .........................................................................D-2Spark Gap Adjustment ..........................................................................................D-2

Troubleshooting ..............................................................................................Section ESafety Precautions.................................................................................................E-1How To Use Troubleshooting Guide ......................................................................E-1Troubleshooting Guide...........................................................................................E-2PC Board Troubleshooting.....................................................................................E-7

Wiring Diagrams & Dimension Print .............................................................Section F

Parts List ......................................................................................................P316 Series

Parts List ......................................................................................................P383 Series

A-1INSTALLATION

SQUARE WAVE TIG 275

A-1

TECHNICAL SPECIFICATIONS - Square Wave TIG 275 (K1617-1, and -2)

For AC/DC Stick, DC TIG and Balanced AC TIGWelding at 275A 40% Duty Cycle

w/o Optional K1620-1 Power Factor CapacitorsBased on the 1996 U.S. National Electrical Code

For Unbalanced AC TIG Welding above 180A,255A 40% Duty Cycle, Maximum Penetrationw/o Optional K1620-1 Power Factor Capacitors

Based on the 1996 U.S. National Electrical Code

INPUT - SINGLE PHASE ONLY

RECOMMENDED INPUT WIRE AND FUSE SIZES

Input

Voltage /

phase/

Frequency

208/1/60

230/1/60

460/1/60

575/1/60

Input

Amperes

111

100

50

40

Type 75°C

Copper Ground

Wire in

Conduit AWG

(IEC) Sizes

6 (13.3 mm2)

6 (13.3 mm2)

10 (5.3 mm2)

10 (5.3 mm2)

Fuse

(Super Lag)

or Breaker

Size(1)

125

125

60

50

Type 75°C

Copper Wire in

Conduit AWG

(IEC) Sizes

40°C (104°F) Ambient

4 (21.2 mm2)

4 (21.2 mm2)

8 (8.4 mm2)

10 (5.3 mm2)

Type 75°C

Copper Ground

Wire in

Conduit AWG

(IEC) Sizes

6 (13.3 mm2)

6 (13.3 mm2)

8 (8.4 mm2)

10 (5.3 mm2)

Type 75°C

Copper Wire in

Conduit AWG

(IEC) Sizes


3 (25.0 mm2)

3 (25.0 mm2)

8 (8.4 mm2)

8 (8.4 mm2)

Input

Amperes

130

120

61

49

Height Width Depth WeightPower 24.06 in. 19.15 in. 28.00 in. Approx. 330 lbs.Source 611 mm 486 mm 711 mm 150 kg.

Lift Hook add 3.57” (91 mm)

Power Source 33.40 in. 27.65 in. 40.65 in. Approx. 375 lbs.on 848 mm 702 mm 1033 mm 170 kg.

Undercarriage

PHYSICAL DIMENSIONS

Fuse

(Super Lag)

or Breaker

Size(1)

150

150

70

60

(1) Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of cur-rent increases.

Code Number

105231052510605

Input Current at Input Current at Input Current at Idle Idle Power40% Duty Cycle 60% Duty Cycle 100% Duty Cycle Current Power

DC STICK, DC STICK, DC STICK,DC TIG, UNBALANCED AC TIG DC TIG, UNBALANCED AC TIG DC TIG, UNBALANCED AC TIGBALANCED AC TIG BALANCED AC TIG BALANCED AC TIG

95/86/43 130/120/61 76/69/34 106/97/50 57/52/26 82/75/38 5/4/2 900 WMax.43/35 61/49 34/28 50/41 26/21 38/31 2/1.5 900 WMax.

95/86/43 130/120/61 76/69/34 106/97/50 57/52/26 82/75/38 5/4/2 900 WMax.

StandardVoltage

208/230/460/1/60 (K1617-1)460/575/1/60 (K1617-2)

208/230/460/1/60 (K1617-1)

RATED OUTPUT & ADDITIONAL OUTPUT CAPACITYDuty Cycle Amps Volts at Rated Amperes Current Range Auxiliary Power

40% Duty Cycle AC/DC Stick 275 A 31.0 V 5-315 Amps 115 Volts AC, 10 AmpsNEMA Class II (40) AC/DC TIG 255 A 16.1 V Grounded NEMA-5-15R

Receptacle and 60% Duty Cycle AC/DC Stick 225 A 29.0 V MAX O.C.V. 10 Amp Circuit Breaker

AC/DC TIG 200 A 15.4 V AC & DC 80V

100% Duty Cycle AC/DC Stick 175 A 27.0 V Normal O.C.V.AC/DC TIG 150 A 14.8 V 72 V (AC) 59 V (DC)

A-2INSTALLATION

SQUARE WAVE TIG 275

A-2

TECHNICAL SPECIFICATIONS - Square Wave TIG 275 (K1618-1)

For AC/DC Stick, DC TIG and Balanced AC TIGWelding at 275A 40% Duty Cycle

w/o Optional K1620-1 Power Factor CapacitorsBased on the 1996 U.S. National Electrical Code

For Unbalanced AC TIG Welding above 180A,255A 40% Duty Cycle, Maximum Penetrationw/o Optional K1620-1 Power Factor Capacitors

Based on the 1996 U.S. National Electrical Code

INPUT - SINGLE PHASE ONLY

RECOMMENDED INPUT WIRE AND FUSE SIZES

Input

Voltage /

phase/

Frequency

220/1/50/60

380/1/50/60

415/1/50/60

Input

Amperes

106

60

55

Type 75°C

Copper Ground

Wire in

Conduit AWG

(IEC) Sizes

6 (13.3 mm2)

8 (8.4 mm2)

8 (8.4 mm2)

Fuse

(Super Lag)

or Breaker

Size(1)

125

70

70

Type 75°C

Copper Wire in

Conduit AWG

(IEC) Sizes


4 (21.2 mm2)

8 (8.4 mm2)

8 (8.4 mm2)

Type 75°C

Copper Ground

Wire in

Conduit AWG

(IEC) Sizes

6 (13.3 mm2)

8 (8.4 mm2)

8 (8.4 mm2)

Type 75°C

Copper Wire in

Conduit AWG

(IEC) Sizes


3 (25.0 mm2)

6 (13.3 mm2)

6 (13.3 mm2)

Input

Amperes

139

79

72

Height Width Depth WeightPower 24.06 in. 19.15 in. 28.00 in. Approx. 340 lbs.Source 611 mm 486 mm 711 mm 154 kg.

Lift Hook add 3.57” (91 mm)

Power Source 33.40 in. 27.65 in. 40.65 in. Approx. 385 lbs.on 848 mm 702 mm 1033 mm 175 kg.

Undercarriage

PHYSICAL DIMENSIONS

Fuse

(Super Lag)

or Breaker

Size(1)

175

90

90

(1) Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of cur-rent increases.

CodeNumber

10524

Input Current at Input Current at Input Current at Idle Current Idle Power40% Duty Cycle 60% Duty Cycle 100% Duty Cycle

DC STICK, DC STICK, DC STICK,DC TIG, UNBALANCED AC TIG DC TIG, UNBALANCED AC TIG DC TIG, UNBALANCED AC TIGBALANCED AC TIG BALANCED AC TIG BALANCED AC TIG

99/57/52 139/79/72 83/45/421 12/64/59 63/36/33 86/49/45 8/6/5 900 WMax.

StandardVoltage

220/380/415/1/50/60

RATED OUTPUT & ADDITIONAL OUTPUT CAPACITYDuty Cycle Amps Volts at Rated Amperes Current Range Auxiliary Power

40% Duty Cycle AC/DC Stick 275 A 31.0 V 5-315 Amps 220 Volts AC, 2 AmpsNEMA Class II (40) AC/DC TIG 255 A 20.2 V Schuko Receptacle

and 2 Amp Circuit Breaker60% Duty Cycle AC/DC Stick 225 A 29.0 V MAX O.C.V.

AC/DC TIG 200 A 18.0 V AC & DC 80V

100% Duty Cycle AC/DC Stick 175 A 27.0 V Normal O.C.V.AC/DC TIG 150 A 16.0 V 72 V (AC) 59 V (DC)

A-3INSTALLATION

SQUARE WAVE TIG 275

A-3

ELECTRIC SHOCK can kill.•Only qualified personnel should perform this installation.

•Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

• Do not touch electrically hot parts.• Always connect the Square Wave TIG 275 grounding screw

(located on the right rear corner of the base) to a good electricalearth ground.

• Always connect the Square Wave TIG 275 to a power supplygrounded per the National Electrical Code and any local codes.

WARNING

Read entire installation section before startinginstallation.

Safety Precautions

SELECT SUITABLE LOCATION

Place the welder where clean cooling air can freely cir-culate in through the rear louvers and out through theside louvers. Dirt, dust or any foreign material that canbe drawn into the welder should be kept at a minimum.Failure to observe these precautions can result inexcessive operating temperatures and nuisance trips.

STACKING

Square Wave TIG 275’s cannot be stacked.

LIFTING AND MOVING

The Square Wave TIG 275 should be lifted with a hoist.(It weighs approximately 330 lbs./150 kg.) An optionalundercarriage is available to easily move the unit. Referto the Accessories section of this manual. The SquareWave TIG 275 is designed to be used with a K932-1Undercarriage. Complete installation instructions areincluded with the K932-1 Undercarriage. When theundercarriage is properly installed, the Square WaveTIG 275 lift bale is nonfunctional. Do not attempt to liftthe power source with the undercarriage attached.The undercarriage is designed for hand moving only;mechanized towing can lead to personal injury and/ordamage to the Square Wave TIG 275.

TILTING

Each machine must be placed on a secure, levelsurface, either directly or on a recommendedundercarriage. The machine may topple over if thisprocedure is not followed.

ENVIRONMENTAL RATING

The Square Wave TIG 275 power source carries anIP21 environmental rating. It may be used in normalindustrial and commercial environments. It is rated foruse in damp, dirty rain-sheltered environments.

MACHINE GROUNDING AND HIGH FRE-QUENCY INTERFERENCE PROTECTION

The frame of the welder must be grounded. A groundscrew marked with the symbol is located at the right rearcorner of the base for this purpose. See your local and nation-al electrical codes for proper grounding methods.

The spark gap oscillator in the high frequency generator, beingsimilar to a radio transmitter, can be blamed for many radio, TVand electronic equipment interference problems. These prob-lems may be the result of radiated interference. Proper ground-ing methods can reduce or eliminate radiated interference.

The Square Wave TIG 275 has been field tested under rec-ommended installation conditions and has been found to com-ply with F.C.C.allowable radiation limits. A certificate (S14929)is being sent with each welder for customer convenience. If hedesires or is required to obtain certification of compliance withF.C.C.RF Energy Radiation Limits, this certificate can be used.It is the customer's responsibility to obtain this certification. Thiswelder has also been found to comply with NEMA standardsfor high frequency stabilized power sources.

Radiated interference can develop in the following fourways:

1. Direct interference radiated from the welder.

2. Direct interference radiated from the welding leads.

3. Direct interference radiated from feedback into the power lines.

4. Interference from re-radiation of “pickup” by ungrounded metallic objects.

Keeping these contributing factors in mind, installingequipment per the following instructions should mini-mize problems.

1. Keep the welder power supply lines as short as pos-sible and enclose as much of them as possible inrigid metallic conduit or equivalent shielding for adistance of 50 feet (15.2m). There should be goodelectrical contact between this conduit and thewelder case ground. Both ends of the conduitshould be connected to a driven ground and theentire length should be continuous.

A-4INSTALLATION

SQUARE WAVE TIG 275

A-4

2. Keep the work and electrode leads as short as pos-sible and as close together as possible. Lengthsshould not exceed 25 ft (7.6m). Tape the leadstogether when practical.

3. Be sure the torch and work cable rubber coveringsare free of cuts and cracks that allow high frequen-cy leakage. Cables with high natural rubber content,such as Lincoln Stable-Arc® better resist high fre-quency leakage than neoprene and other syntheticrubber insulated cables.

4. Keep the torch in good repair and all connectionstight to reduce high frequency leakage.

5. The work piece must be connected to an earthground close to the work clamp, using one of the fol-lowing methods:

a) A metal underground water pipe in direct contactwith the earth for ten feet or more.

b) A 3/4” (19mm) galvanized pipe or a 5/8” (16mm)solid galvanized iron, steel or copper rod drivenat least eight feet into the ground.

The ground should be securely made and the ground-ing cable should be as short as possible using cable ofthe same size as the work cable, or larger. Groundingto the building frame electrical conduit or a long pipesystem can result in re-radiation, effectively makingthese members radiating antennas. (This is not recom-mended).

6. Keep all access panels and covers securely inplace.

7. All electrical conductors within 50 ft (15.2m) of thewelder should be enclosed in grounded rigid metal-lic conduit or equivalent shielding. Flexible helically-wrapped metallic conduit is generally not suitable.

8. When the welder is enclosed in a metal building, themetal building should be connected to several goodearth driven electrical grounds (as in 5 (b) above)around the periphery of the building.

Failure to observe these recommended installationprocedures can cause radio or TV and electronicequipment interference problems and result in unsatis-factory welding performance resulting from lost highfrequency power.

1On European, 50/60 Hz. models, entry is through a 1.75 inch (46mm) diam-eter hole. A reducing washer and plastic strain relief good for 18.0 to 25.4 mm(.709 to 1.00 inch) cords is provided. For larger input conductors a customersupplied plastic strain relief should be used.

SUPPLY CONNECTIONS

Be sure the voltage, phase, and frequency of the inputpower is as specified on the rating plate, located on therear of the machine.

See Figure A.1 for the location of the rating plate, theentry hole, and the reconnect panel.

FIGURE A.1

1. Input Entry 4. 220V Receptacle & Breaker2. Rating Plate (50/60 HZ. Machines Only.)3. 115V Receptacle & Breaker 5. Gas Input Fitting

(60 HZ. Machines only)

Remove the right case side to reveal the reconnectpanel. Welder supply line entry provision is in the caserear panel. Entry is through a 1.4 inch (36 mm) diam-eter hole in the case back.1

All connections should be made in accordance with alllocal codes and national electrical codes. Installationby a qualified electrician is recommended.

1. Connect the terminal marked (at the base of thewelder below the reconnect panel) to an earth ground.

2. Connect the input leads to terminals marked L1 (U)and L2 (V) on the reconnect panel. Use a single phaseline or one phase of a two or three phase line.

1

2

5

3 4

A-5INSTALLATION

SQUARE WAVE TIG 275

A-5

Fuse the input circuit with the recommended super lagfuses or delay type1 circuit breakers. Choose an inputand grounding wire size according to local or nationalcodes or refer to the Technical Specifications page atthe beginning of this section. Using fuses or circuitbreakers smaller than recommended may result in"nuisance" tripping from welder inrush currents even ifnot welding at high currents.

Unbalanced AC TIG welding draws higher input cur-rents than those for Stick, DC TIG, or Balanced AC TIGwelding. The welder is designed for these higher inputcurrents. However, where unbalanced AC TIG weldingabove 180 amps is planned, the higher input currentsrequire larger input wire sizes and fuses per theTechnical Specifications page at the beginning ofthis section.

INPUT RECONNECT PROCEDURE

On multiple input voltage welders, be sure the recon-nect panel is connected per the following instructionsfor the voltage being supplied to the welder.

FAILURE TO FOLLOW THESE INSTRUCTIONSCAN CAUSE IMMEDIATE FAILURE OF COMPO-NENTS WITHIN THE WELDER.------------------------------------------------------------------------Welders are shipped connected for the highest inputvoltage as listed on the rating plate.To change this con-nection, refer to the following instructions:

1. Remove the right case side to reveal the reconnectpanel.

2. Reconnect the lead marked A to the terminal studcorresponding to the input voltage used. Refer tothe figure representing the model being reconnect-ed:

Figure A.2 208/230/460/1/60 Domestic ModelFigure A.3 460/575/1/60 Domestic/Canadian ModelFigure A.4 220/380/415/1/50/60 European Model

(Con’t)

460V

3 (MID)

4 (HIGH)

230V

power at the disconnect switch or fuse box before making any connections. Use input and grounding lead sizes as specified in the operating manual. Failure to followinstructions below can cause immediate failure of components within the welder.

Powered by high voltage which can kill. Turn off all input

5.

208V

2.

L1 (U)

4.

3.

2 (LOW)

1. Connect the input power leads to the input terminals, L1 (U) and L2 (V), at the rightbelow. Connect the input power leads with the hardware provided. Completelytighten all fasteners.

Connect a grounding lead to the ground stud located on the machine base nearthe input terminals.

Welders are shipped connected for the highest rated single phase input voltagewith the lead marked "A" connected to the stud marked "4 (HIGH)".

For middle range input, reconnect the lead marked "A" to the stud marked "3 (MID)".

For low range input, reconnect the lead marked "A" to the stud marked "2 (LOW)".

SINGLE PHASE INPUT POWER SUPPLY CONNECTION INSTRUCTIONS:

SINGLEPHASEINPUT

L2 (V)

POWER FACTOR CAPACITORSLEADS FOR OPTIONAL

208/230/460 DOMESTIC MODEL

WARNING:

Figure A.2Reconnect Panel Instructions for 208/230/460 Domestic Model

1 Also called "inverse time" or "thermal/magnetic" circuit breakers; circuitbreakers which have a delay in tripping action that decreases as the magni-tude of the current increases.

CAUTION

A-6INSTALLATION

SQUARE WAVE 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 rightbelow. Connect the input power leads with the hardware provided. Completelytighten all fasteners.





power at the disconnect switch or fuse box before making any connections. Use input and grounding lead sizes as specified in the operating manual. Failure to followinstructions below can cause immediate failure of components within the welder.

SINGLE PHASE INPUT POWER SUPPLY CONNECTION INSTRUCTIONS:

2.

3 (MID)

2 (LOW)

L2 (V)

L1 (U)

5.

4.

3.

LEADS FOR OPTIONALPOWER FACTOR CAPACITORS

4 (HIGH)

INPUTPHASESINGLE

1.

460/575 CANADIAN MODEL

Figure A.3Reconnect Panel Instructions for 460/575 Canadian Model

415V

380V

220V

1. Connect the input power leads to the input terminals, L1 (U) and L2 (V), at the rightbelow. Connect the input power leads with the hardware provided. Completelytighten all fasteners.





Powered by high voltage which can kill. Turn off all inputpower at the disconnect switch or fuse box before making any connections. Use input and grounding lead sizes as specified in the operating manual. Failure to followinstructions below can cause immediate failure of components within the welder.

WARNING:SINGLE PHASE INPUT POWER SUPPLY CONNECTION INSTRUCTIONS:

5.

4.

3.

2.

LEADS FOR OPTIONAL

L2 (V)

L1 (U)2 (LOW)

3 (MID)

4 (HIGH)

SINGLEPHASEINPUT

POWER FACTOR CAPACITORS

220/380/415 EUROPEAN MODEL

Figure A.4Reconnect Panel Instructions for 220/380/415 European Model

A-7INSTALLATION

SQUARE WAVE TIG 275

A-7

Designations on the reconnect panel LOW, MID, andHIGH correspond to the nameplated input voltages ofa triple voltage welder. Dual voltage welders use onlyLOW and HIGH.

EXAMPLE: On a 208/230/460 volt welder, LOW is208V, MID is 230V, and HIGH is 460V.

3. Make sure all connections are tight. Replace thecase side and all screws.

OUTPUT CONNECTIONS

To avoid being startled by a high frequency shock,keep the TIG torch and cables in good condition.------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Turn the power switch of the powersource “OFF” before installing adapterson cable or when connecting or discon-necting adapter plugs to power source.

----------------------------------------------------------------------------See Figure B.1 for the location of the work and elec-trode terminals, the gas and optional water solenoids,and the Remote Receptacle.The Square Wave TIG275 is equipped with Twist-Mate connectors for theelectrode and work connection.

WORK CABLE CONNECTION

The Twist-Mate connection allows fast and reliablework cable attachment to the work terminal of theSquare Wave TIG 275 welding power supply.

Assemble the work cable by attaching the correctTwist-Mate adapter and work clamp to an adequately-sized welding cable. The Twist-Mate cable plug includ-ed with the machine is designed to accept a weldingcable size of of #2 to #1. See Table A.1 and A.2 for rec-ommended sizes and corresponding hardware.

Assemble the correct Twist-Mate-adapter plug to thework cable as follows:

1. Skin the cable jacket to 1.00 in (25.4 mm) for a #2thru 2/0 (35 thru 70 mm2) cable. Skin the cablejacket to 1.50 in (38.1 mm) for a 2/0 thru 3/0 (70 thru95 mm2) cable.

2. If necessary, trim the cable end of the rubber bootto match the diameter of the cable.

3. Slide the rubber boot onto the skinned cable end.Use soap for lubricant if required.

4. Slide the copper tube into the brass plug. Insertskinned cable into the copper tube.

5. Tighten set screw(s) to collapse copper tube.Screw(s) must apply firm pressure against weldingcable.

6. Slide the rubber boot over the brass plug. The rub-ber boot must be positioned to completely cover allelectrical surfaces after the plug is locked into thereceptacle. For more details see S18737PRINT orinstructions included with the adapter kit.

WARNING

TABLE A.1Cable Sizes for Combined Lengths of Copper

Electrode and Work Cable

Machine SizeLengths up to

100 ft 100 to 200 ft 200 to 250 ft

275 Amp40% Duty Cycle #1 (42.4mm2) 1/0 (53.5mm2) 2/0 (67.4mm2)

TABLE A.2Recommended Work and Stick Electrode

Components

Twist MateCable Plug

for WorkLead

(#2 to #1)


for WorkLead

(1/0 to 2/0)


for WorkLead

(2/0 to 3/0)

WorkClamp

ElectrodeHolder

K852-50 K852-70 K852-95 K910-1 K909-4

SEE

WELDING CABLE

TRIMABOVE

BOOT

COPPER TUBE

SET SCREW

(70-95 SIZE MAYHAVE 2 SET

BRASS PLUG

SCREWS)

A-8INSTALLATION

SQUARE WAVE TIG 275

A-8

TIG TORCH CONNECTION

The Twist-Mate connection allows fast and reliable TIGtorch attachment to the electrode terminal of theSquare Wave TIG 275 welding power supply. Twist-Mate TIG adapters are made of brass, combining highelectrical conductivity with mechanical strength. Theyare available in several sizes and styles to accommo-date a wide selection of gas and water-cooled TIGtorches.

• Air-Cooled TIG Torch connections refer to TWIST-MATE ADAPTER for LA-9 and LA-17 TIG TORCHSection.

• Water-Cooled TIG Torch connections refer to TWIST-MATE ADAPTER for LW-18 and LW-20 TIG TORCHSection.

Any torch having hoses and cables equipped withCompressed Gas Association (CGA) style fittings canbe connected to an appropriate Twist-Mate adapter(see ACCESSORIES section). The power source mustbe switched off while making any of these connections.

Do not operate a water-cooled torch without an ade-quate coolant supply. Set-ups using recirculatedcoolant require that the cooler be switched on and run-ning. If the water solenoid valve option is used with acooler, the coolant does not flow until the solenoid isactuated.

For set-ups using water as a single-pass throughcoolant, install a strainer into the system upstream ofthe Square Wave TIG 275 to reduce the concentrationof particles that could contaminate the system.Otherwise, flow passages could become obstructed orclogged, causing torch overheating or failure. Theoptional water solenoid valve may also malfunction.

When the water solenoid valve option is installed intothe Square Wave TIG 275, connect the coolant supplyline from either cooler outlet or single-pass supply tothe “Water Inlet” fitting located on the machine’s casefront. Connect the TIG torch’s smaller water fitting tothe “Water Out” fitting also located on the case front. Anon-metallic coolant line is required between the elec-trode connection and the drain or cooler inlet. Thisreduces the possibility of an electrical hazard.

TIG welding torches are available with 12.5 and 25 foot(3.8 and 7.6 m, respectively) long cables. Use theshorter length whenever possible to reduce radio inter-ference problems.

The high-pressure cylinder of inert shielding gas mustbe equipped with a flow regulator that limits the gaspressure to 150 psi maximum at the machine’s gasinlet. This brass inlet fitting is located on the rear panelof the Square Wave TIG 275. Install a hose betweenthe gas flow meter and the inlet fitting.

For other conditions, consult the manufacturer’sinstructions for the water cooler or TIG torch beingused.

CYLINDER could explode if damaged.

•Keep cylinder upright and chainedto a support.

•Keep cylinder away from areas where it could bedamaged.

•Never allow the torch to touch the cylinder.

•Keep cylinder away from live electrical circuits.

•Maximum inlet pressure 150 psi.___________________________________________

WARNING

A-9INSTALLATION

SQUARE WAVE TIG 275

A-9

TWIST-MATE ADAPTER FOR LA-9and LA-17 TIG TORCH

The Twist-Mate connection allows fast and reliable TIGtorch connections to the electrode terminal of theSquare Wave TIG 275. The Twist-Mate adapter, strainrelief boot and retaining compound needed to connectan LA-9 or LA-17 torch (or any equivalent air-cooledTIG torch with a right-hand male 3/8-24 fitting) areincluded with the Square Wave TIG 275.

Assemble the the LA-9 or LA-17 TIG torch to the Twist-Mate adapter as follows:

1. Slide the strain relief boot over the TIG torch’spower cable with gas fitting.

2. Apply a small amount of retaining compound to thefitting threads as shown. Thread the fitting to theTIG adapter and tighten to ensure a sealed gasconnection and a good electrical connection. (35-45in-lbs)

3. Hold the TIG adapter, with cable installed, firmly inplace by securing it into the Twist- Mate receptacleon the power source or into a padded vise. Alignthe hex in the boot with the hex on the adapter.Firmly push the boot onto the adapter, rocking theboot to assist installation. Use soap for lubricant ifrequired.

4. Examine the strain relief boot and TIG adapter forcorrect assembly. The boot should nest into theTwist-Mate receptacle on the power source. Allelectrical surfaces should be completely coveredwhen in the Twist-Mate receptacle on the powersource. For more details see M19115PRINT includ-ed with the machine.

TWIST-MATE ADAPTER FOR LW-18and LW-20 TIG TORCH

The Twist-Mate connection allows fast and reliable TIGtorch connections to the electrode terminal of theSquare Wave TIG 275. The Twist-Mate adapter andstrain relief boot needed to connect an LW-18 or LW-20torch (or any equivalent water-cooled TIG torch withthe fittings shown in the diagrams under step 2 and 3.)are included with the Square Wave TIG 275.

Assemble the the LW-18 or LW-20 TIG torch to theTwist-Mate adapter as follows:

1. Slide the strain relief boot over the TIG torch’spower/water cable (large fitting) and gas hose(small fitting without notches on hex). Also slide awater hose into the strain relief boot as shown.

2. Thread the power/water cable (large fitting) from thetorch to the large port on the TIG adapter and tigtento ensure a water tight connection. Next, thread thegas hose (small fitting without notches on hex) tothe port marked “G” on the TIG adapter and tightento ensure a sealed gas connection. Next, thread thewater hose to cooler (or to water drain) to the portmarked “W” on the TIG adapter.

3. Check all connections made in step 2 for gas andwater leaks before proceding.

TIG ADAPTER

TIG TORCH POWER CABLE WITH GAS FITINGRETAINING COMPOUND

STRAIN RELIEF BOOT

STRAIN RELIEF BOOTTIG ADAPTER

WATER HOSE

GAS HOSE FROM TORCH

POWER/WATER CABLE FROM TORCH

G

W

PORT (RH 5/8-18)

PORT (LH 5/8-18)

GAS CONNECTION

CONNECTIONPOWER/WATER

PORT (LH 7/8-14)

WATER CONNECTION

COMPLETED ASSEMBLY

W

G

"IN"

OR

COOLANT

OPTIONAL

WATER HOSE

"OUT"COOLANT

FLO

W

WATER SOLENOID KIT

WA

TER

(RH 5/8-18 MALE FITTING)

WATER HOSE FROM TORCH

GAS HOSE FROM TORCH

(SEPARATELY PROVIDED)

(SEPARATELY PROVIDED)

HOSE COUPLER

COOLANT

LW-18 OR LW-20

TIG TORCH(SEPARATELY PROVIDED)

(LH 5/8-18 MALE FITTING)

"OUT""IN"COOLANT

MAGNUM

CONNECTION DIAGRAM

POWER/WATER CABLE FROM TORCH(LH 7/8-14 MALE FITTING)

WATER HOSE(SEPARATELY PROVIDED)

WATER COOLER

A-10INSTALLATION

SQUARE WAVE TIG 275

A-10

4. Hold the TIG adapter, with cables and hosesinstalled, firmly in place by securing it into the Twist-Mate receptacle on the power source or into apadded vise. Apply a thin film of lubricant to theboot’s lead in chamfer area. Also apply lubricant tothe lead in chamfer and 2" diameter on the TIGadapter. Next align the strain relief boot keys withthe TIG adapter slots. Now firmly push the bootonto the adapter, rocking the boot to assist installa-tion.

5. Examine the strain relief boot and TIG adapter forcorrect assembly. The boot should nest into theTwist-Mate receptacle on the power source. Theboot face will be 1/8 inch away from the machinefront. All electrical surfaces should be completelycovered when in the Twist-Mate receptacle on thepower source. For more details see M19116PRINTincluded with the machine.

STICK ELECTRODE CABLE CONNECTION

The Twist-Mate connection allows fast and reliablestick electrode attachment to the electrode terminal ofthe Square Wave TIG 275 welding power supply.

Assemble the stick electrode cable by attaching thecorrect Twist-Mate adapter and electrode holder to anadequately-sized welding cable. The Twist-Mate cableplug is NOT provided with the machine for the stickelectrode connection. See Table A.1 and A.2 for rec-ommended sizes and corresponding hardware.

Assemble the correct Twist-Mate adapter plug to thestick electrode cable as detailed in “Work CableConnection”.

DO NOT CONNECT A TIG TORCH AND STICKELECTRODE CABLE AT THE SAME TIME. THEYWILL BOTH BE ELECTRICALLY HOT WHENEVERTHE OUTPUT CONTACTOR IS ENERGIZED.------------------------------------------------------------------------

INSTALLATION OF FIELD INSTALLEDOPTIONS

Installation instructions are included with the followingaccessories:

K559-2 Magnum Cooler Mounting Bracket

K932-1 Undercarriage When the undercarriage isproperly installed, the Square Wave TIG 275 lift bale isnonfunctional. Do not attempt to lift the power sourcewith the undercarriage attached. The undercarriage isdesigned for hand moving only; mechanized towingcan lead to personal injury and/or damage to theSquare Wave TIG 275.

K1619-1 TIG Pulser Kit

K1620-1 Power Factor Capacitor Kit

K1621-1 Water Solenoid Kit

K1622-1 Twist Mate Adapter Kit for LA9 & LA17Torches (Included with Machine)

K1622-2 Twist Mate Adapter Kit for LW18 & LW20Torches (Included with Machine)

K1622-3 Twist Mate Adapter Kit for LA26 Torch

K852-50 Twist Mate Cable Plug for #2 to #1 Work Lead(Included with Machine)

K852-70 Twist Mate Cable Plug for 1/0 to 2/0 WorkLead

K852-95 Twist Mate Cable Plug for 2/0 to 3/0 WorkLead

Installation of the K963-1 or K963-2 Hand Amptrol, theK814 Arc Start Switch and the K870 Foot Amptrol areas follows:

Connect the 6-pin MS-type (Amphenol) connector tothe Remote Receptacle (See Figure 3). Secure withthe threaded collar.

COMPLETED ASSEMBLY

WARNING

B-1OPERATIONB-1

SQUARE WAVE TIG 275

ELECTRIC SHOCKcan kill.

• Do not touch electrically live parts orelectrode with skin or wet clothing.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

• Read and follow “Electric Shock Warnings”in the Safety section if welding must be per-formed under electrically hazardous condi-tions such as welding in wet areas or on orin the workpiece.

FUMES AND GASEScan be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust toremove fumes from breathingzone.

WELDING SPARKScan cause fire orexplosion

• Keep flammable material away.

• Do not weld on containers thathave held combustibles.

ARC RAYScan burn.

• Wear eye, ear and bodyprotection.

SAFETY PRECAUTIONS

Read and understand this entire section before operat-ing the machine.

Observe additional Safety Guidelines detailed inthe beginning of this manual.

WARNING

B-2OPERATIONB-2

SQUARE WAVE TIG 275

2

A

GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL

&

&

POWER SWITCHSYMBOL MEANING

ON

OUTPUT CONTROLSYMBOL MEANING

CURRENT CONTROL(OUTPUT)

OFF

INPUT POWER

OVERTEMPERATURE

AC WAVE BALANCE CONTROLSYMBOL MEANING

AC WAVE BALANCE

CLEAN (INCREASINGPOSITIVE POLARITY)

PENETRATE (INCREASINGNEGATIVE POLARITY)

MODE SWITCHSYMBOL MEANING

TIG 2-STEP

TIG 4-STEP

STICK

POLARITY SWITCHSYMBOL MEANING

DC- POLARITY

DC+ POLARITY

AC POLARITY

POST FLOW CONTROL AND DOWN SLOPE TIME CONTROL

SYMBOL MEANING

POST FLOW TIME

DOWN SLOPE TIME

&

&

B-3OPERATIONB-3

SQUARE WAVE TIG 275

GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL

OPTIONAL WATER SOLENOID CONNECTIONSSYMBOL MEANING

WATER (COOLANT)INPUT

OUTPUT CONNECTIONSSYMBOL MEANING

WORKCONNECTION

ELECTRODECONNECTION

WATER (COOLANT)OUTPUT

ADDITIONAL SYMBOLSSYMBOL MEANING

REMOTE CONTROL

DO NOT SWITCHWHILE WELDING

WARNING

PROTECTIVEGROUND

TIG (GTAW)

SINGLE PHASE

SINGLE PHASETRANSFORMER

AC & DC RECTIFIERPOWER SOURCE

B-4OPERATIONB-4

GENERAL DESCRIPTION

The Square Wave TIG 275 is a constant current, singlerange square wave AC/DC TIG (GTAW) arc weldingpower source with built-in high frequency stabilization.It also has stick (SMAW) capability. A TIG Pulser Kit,Power Factor Capacitor Kit, and a Water Solenoid Kitare available as field installed options.

The Square Wave TIG 275 includes advanced featuressuch as Presettable Digital Meters, Auto Balance™, 2-Step/4-Step operation, adjustable Down slope Timecontrol and Fan as Needed. It also features Twist Mateconnections for the electrode and work leads. In addi-tion, fixed preflow and variable post flow timers areincluded to control the shielding gas, as well as thewater flow when using the optional water solenoid.

RECOMMENDED PROCESSES ANDEQUIPMENT

The Square Wave TIG 275 is recommended for the TIG(GTAW) and stick (SMAW) welding processes within itsoutput capacity of 5 to 315 amps, on both AC and DCpolarity. It is compatible with all Magnum TIG acces-sories, as well as many industry standard items, suchas TIG torches, hoses, and water coolers.

DESIGN FEATURES AND ADVANTAGES

• Meets NEMA CLASS II (40) and IP21 environmentalcertification. CSA NRTL/C certified (Domestic andCanadian Models Only).

• Meets IEC-974-1 and IP21 environmental certifica-tion. CE certified (European Model Only).

• Built in Digital Ammeter and Voltmeter for preciseprocess control. When not welding, the digital amme-ter displays the peak current set with the output con-trol knob. This allows the user to easily preset thepeak current within the full output range of themachine. This includes a persistence feature whichcaptures and continues to display the peak weldingcurrent and it’s corresponding voltage for five sec-onds after the weld is completed.

• AC Wave Balance control knob provides flexibility tothe customer. Set it to the Auto Balance position andthe circuitry automatically provides the properamount of cleaning and penetration for normal ACTIG welding. For special applications simply dial inthe amount of cleaning and penetration needed.

• Fan As Needed (FAN) circuit turns ‘ON’ the fan onlywhen cooling is needed. FAN minimizes the amount

of dust, dirt, and other foreign material drawn into themachine. A build up of these materials can causeexcessive operating temperatures and nuisance shutdowns.

• 2-STEP/4-STEP TIG/STICK mode control switch. 4-STEP mode requires the use of an optional Arc StartSwitch. This welding mode reduces fatigue by elimi-nating the need to manually control the weld currentduring the weld.

• Down Slope Time control is active in 4-STEP TIGmode. It controls the amount of time (approximately1 to 10 seconds) it takes the weld current to rampdown from the Preset level to 25% ±10% of that level.

• Post Flow Time control is active in the 2 and 4-STEPTIG modes. It controls the amount of time (approxi-mately 5 to 50 seconds) the shielding gas flows afterthe weld is completed.

• Robotic Interface connection on the PC board can beconnected to the machines Remote Receptacle forautomated welding procedures. This interface allowsremote control of the trigger and output current of themachine as well as providing a signal when the weldis established. (For details contact the Lincoln Automation Center)

• Built in High Frequency Generator automatically per-forms in the correct mode. If the machine is in STICKmode, the HF stays ‘OFF’. IF the machine is in DCTIG mode, the HF comes ‘ON’ and stays on until thearc is established. IF the machine is in AC TIG mode,the HF comes ‘ON’ and stays on continuously to sta-bilize the arc.

• Automatic Local/Remote current selection. Themachine automatically senses if an Amptrol, Arc StartSwitch or TIG Pulser is plugged in and transfers cur-rent control from local to remote.

• Built in preflow time of 0.5 seconds. Preflow time iseliminated if welding restarts during the perviousweld’s post flow. This avoids unnecessary delayswhen making repeated welds.

• Simple dial and switch design provides the customerwith flexible control of the welding process withoutunnecessary complication. Controls which are notneeded in the weld mode selected are automaticallylocked out.

• Twist Mate connectors are provided for the electrodeand work connections. This style connector makesthe gas and current connections for the TIG torch atthe same time. (Adapter plugs are provided)

SQUARE WAVE TIG 275

B-5OPERATIONB-5

• DC+/AC/DC- Polarity Switch allows the welder tochange polarity without reconnecting leads.

• Provides excellent arc starting and stability through-out the machines wide current range (5 to 315 Amps)to handle the vast majority of TIG welding applica-tions.

• Simple output current dial allows the user to presetthe peak current within the full output range of themachine.

• Highly resistant to AC arc rectification.

• Thermostatically protected to prevent equipmentdamage.

• No tungsten spitting within current range of electrode.

• Designed to make maintenance and servicing easy.

• 115 Volt Receptacle with 10 Amp Circuit Breaker.Domestic and Canadian Models Only.

• 220 Volt European (Schuko) type Receptacle with 2Amp Circuit Breaker. European Model Only.

• Low Voltage Trigger Circuit (18 VAC) for maximumoperator safety.

• Remote Receptacle for Amptrol or Arc Start Switchconnection.

• Gas Valve Inlet fitting conforms to Compressed GasAssociation (CGA) standards.

LIMITATIONS

The Square Wave TIG 275 is not recommended for ACTIG welding when high concentrations of helium gasare used for shielding. This causes starting and arcrectification problems. Also the Square Wave 275 isnot recommended for arc gouging due to it's limitedoutput capacity. The Square Wave TIG 275 is also notrecommended for pipe thawing.

DUTY CYCLE AND TIME PERIOD

The duty cycle is based upon a 10 minute time period;i.e., for 40% duty cycle, it is 4 minutes welding and 6minutes idling. If the duty cycle(s) are significantlyexceeded, the thermostatic protection will shut off theoutput until the machine cools to a normal operatingtemperature. (Refer to Technical Specificationspage)

SQUARE WAVE TIG 275

B-6OPERATIONB-6

1. Current Control - This knob is used to setthe welding current from 5 to 315 amps. Read thecomplete Operating Instructions section for moreinformation on Local and Remote setting of current.

2. AC Wave Balance Control - This knob isactive in the AC TIG mode only. It is used to set theamount of cleaning and/or penetration producedduring an AC TIG weld. Auto Balance™ automati-cally sets the AC Wave balance according to thewelding current. If manual adjustment is desired,the balance can be adjusted from +0 (maximumcleaning) to +10 (maximum penetration).

Read the Advanced Features section for a com-plete explanation of the AC Wave Balance.

3. Post Flow Time Control - This knob is activein the TIG mode only. It adjusts the post flow timefrom 5 to 50 seconds for shielding gas. It alsoadjusts cooling water flow when the optionalK1621-1 Water Solenoid Kit is used.

4. Down Slope Time Control - This knob isactive in 4-Step TIG mode only. It adjusts the time(from 0.5 to 10 seconds) the welding output takes toramp down from the preset level to 25% ±10% ofthat level.

5. Mode Switch - A three position toggle switch usedto select the welding mode. Refer to the WELDINGOPERATION section for more information on howthe machine functions in each of the followingmodes:

Stick: This mode is used for the stick electrode(SMAW) welding process. In this position the onlyactive control is the output current control. The outputterminals are continuously energized.

2-Step TIG: This mode is used for the TIG (GTAW)welding process. An Arc Start switch must be used toweld. The Down Slope Time has no effect in this mode.

4-Step TIG: This mode is used for the TIG (GTAW)welding process. An Arc Start switch must be used toweld. All controls are active in this mode.

SQUARE WAVE TIG 275

CONTROLS AND SETTINGSAll operator controls and adjustments are located on the case front of the Square Wave TIG 275. Refer to FigureB.1 and corresponding explanations following.

FIGURE B.1 - CONTROL PANEL

10

65 7 8 6 9

11

12

13

14

15

1

2

3

4

1. Output Control Knob2. AC Wave Balance Knob3. Post Flow Knob4. Down Slope Time Knob5. Mode Switch6. Trimmer Potentiometer7. Digital Ammeter8. Digital Voltmeter9. Thermal Protection Light10. Power Switch11. Polarity Switch12. Electrode Connection (Twist-Mate Connector)13. Work Connection (Twist-Mate Connector)14. Remote Control Amphenol15. Water Solenoid (Optional)

A

2

B-7OPERATIONB-7

6. Trimmer Potentiometers - Allows the meters tobe calibrated in the field.

7. Digital Ammeter - The ammeter displays actualwelding current during a weld cycle and displaysthe peak current for approximately 5 seconds afterwelding is complete. Otherwise the machine’s setcurrent is displayed. Read the complete OperatingInstructions section for more information on theAmmeter.

8. Digital Voltmeter - This meter displays weldingvoltage, as measured on the output studs of theSquare Wave TIG 275. After welding is complete,the meter displays the welding voltage correspond-ing to the peak welding current and displays thisvalue for approximately 5 seconds

9. Thermal Protection Light - A yellow light whichonly lights when an over temperature situationoccurs. See the Maintenance Section for moreinformation on thermostatic protection.

10. Power Switch - Turns power “ON” or

“OFF” to the welder. When switched “ON” thedigital meters will illuminate, indicating that thepower is on.

11. Polarity Switch - Selects DC+, + AC

or DC- - welding polarity without reconnectingleads. DO NOT SWITCH WHILE WELDING.

12. Twist Mate Electrode and

13. Work Connections - Easy to connect elec-trode and work connections. This style ElectrodeConnection makes the gas and current connec-tions for the TIG torch at the same time. (Adapterplugs are provided with the machine.)

14. Remote Receptacle - For Amptrol, Arc StartSwitch or Robotic Interface connection.

15. Optional Water Solenoid Connections -

Easy to install this optional feature which allowsfor water flow control for water cooled torches.

WELDING OPERATION

TIG WELDING

Familiarize yourself with the Controls and SettingsSection before attempting operation of the SquareWave TIG 275.

TIG WELDING GUIDELINES

TIG welding can be done in either the TIG 2-Step

or the TIG 4-Step Weld Mode. TIG 2-Step is typ-ically used with Hand or Foot Amptrols, with RemoteCurrent control. TIG 4-Step typically uses an Arc Startswitch and Local Current Control, because it providesa very brief current upslope, and a .5 to 10 secondadjustable current downslope. TIG 4-Step also func-tions like a trigger interlock, making it unnecessary tohold down the Arc Start switch during a weld. If remotecurrent control is desired in this mode, a device whichprovides separate arc start and current control must beused. Read the TIG Welding Sequence of Operationsections for more details on 2-Step and 4-Step opera-tion.

Recommended tungsten electrode sizes, stickouts,currents, cup or nozzle sizes are shown in Table B.1.SINCE WELDING APPLICATIONS CAN VARY, THISCHART IS INTENDED AS A GUIDE ONLY.

SQUARE WAVE TIG 275

B-8OPERATIONB-8

SQUARE WAVE TIG 275

(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium orpure helium shielding gasses.

(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):Pure . . . . . . . . . . . . . . . EWP1% Thoriated . . . . . . . . EWTh-12% Thoriated . . . . . . . . EWTh-2Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for2% Thoriated Tungsten in AC and DC applications.

(3) DCEP is not commonly used in these sizes.

(4) TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:#4 = 1/4 in. (6 mm)#5 = 5/16 in. (8 mm)#6 = 3/8 in. (10 mm)#7 = 7/16 in. (11 mm)#8 = 1/2 in. (12.5 mm)

#10 = 5/8 in. (16 mm)(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles,

which are less prone to breakage, but cannot withstand high temperatures and high duty cycles.

TABLE B.1 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES (2)

.010 (.25)0.020 (.50)0.040 (1.0)

1/16 (1.6)

3/32 (2.4)1/8 (3.2)

5/32 (4.0)3/16 (4.8)1/4 (6.4)

2-155-2015-80

70-150

150-250250-400

400-500500-750

750-1000

(3)

(3)

(3)

10-20

15-3025-40

40-5555-80

80-125

2-155-15

10-60

50-100

100-160150-210

200-275250-350325-450

2-155-20

15-80

70-150

140-235225-325

300-400400-500500-630

2-1510-2020-30

30-80

60-130100-180

100-240190-300250-400

---5-2020-60

60-120

100-180160-250

200-320290-390340-525

3-8 (2-4)5-10 (3-5)5-10 (3-5)

5-10 (3-5)

13-17 (6-8)15-23 (7-11)

21-25 (10-12)23-27 (11-13)28-32 (13-15)

3-8 (2-4)5-10 (3-5)5-10 (3-5)

9-13 (4-6)

11-15 (5-7)11-15 (5-7)

13-17 (6-8)18-22 (8-10)23-27(11-13)

#4, #5, #6

#5, #6

#6, #7, #8

#8, #10

1%, 2%ThoriatedTungsten


PureTungsten


ZirconiatedPure

Tungsten


Zirconiated AluminumStainless

Steel

TungstenElectrodeDiameterin. (mm)

TIG TorchNozzle

Size (4), (5)

DCEN ( - ) DCEP ( + ) Unbalanced Wave Balanced Wave

AC Approximate ArgonGas Flow RateC.F.H. (1/min.)

TIG WELDING SEQUENCE OF OPERATION

WELDING IN TIG MODE (2-STEP)

In 2-STEP mode an Arc Start switch or Amptrol mustbe used. The switch or Amptrol is pressed to start theweld. (Step 1) Output continues until the switch orAmptrol is released. (Step 2)

1. Connect the Twist Mate plug to the receptacle locat-ed on the front of the machine.The connection locksinto place with a quarter turn making both the powerand gas connections. See the TIG TORCH CON-NECTION section to install the Twist Mate plug onyour torch.

2. Connect an Arc Start Switch or an Amptrol to theRemote Amphenol.

3. Turn the welder, gas supply and water supply (ifequipped), on. The digital ammeter/voltmeter dis-plays will illuminate when the power is on. NOTE:Cooling fan may not be “ON” when not welding.(See MAINTENANCE Section)

4. Set the MODE switch to “2-STEP TIG”.

5. Set the peak current displayed on the digital amme-ter with the output control knob.

6. Select AC or DC- electrode polarity. See Table B.2.

7. If welding with AC polarity, set the AC WaveBalance Knob to Auto Balance™. This gives theoptimum ratio between cleaning and penetration,automatically adjusted for the output current. Ifmanual adjustment of the AC Wave Balance isdesired, adjust the wave balance to the desired set-tings. See the Advanced Features section for moreinformation on setting and using the AC WaveBalance.

TABLE B.2RECOMMENDED POLARITY

SETTINGS FOR TIG WELDING

Type of WeldingElectrodePolarity

Stainless Steel

Aluminum & Magnesium

Other Metals

DC-

AC

DC-

PRESS(STEP #1)

PREFLOW(0.5 sec FIXED)

OPTIONALTIG PULSER

RELEASE(STEP #2)

PRESET CURRENT

POSTFLOW(0.5 to 10 sec. ADJUSTABLE

B-9OPERATIONB-9

8. Set the Post Flow Time with the post flow knob.Post flow control knob adjusts the time that theshielding gas flows (and cooling water flow, if theoptional water solenoid is used) after the weldcycle. Use short post flow times with low currentsand small tungstens, use long post flow times athigh output currents with large tungstens.

9. With the torch held safely away from everything,press the Arc Start Switch or Amptrol and set thegas flow meter. Release the switch or Amptrol. Thewelder is now ready for welding.

10. Position the tungsten electrode at the start of theweld at a 65˚ to 75˚ angle with the horizontal sothat the electrode is approximately 1/8" (4 mm)above the work piece. Press the Arc Start Switch.This opens the gas (and optional water solenoid)valves to automatically purge air from the hoseand torch. After a 0.5 second preflow time, thehigh frequency becomes available to strike the arc.

11. Hold the Arc Start Switch or Amptrol down until anarc is established. If using an Amptrol, read theSection on Hand and Foot Amptrol Operation.Release the Arc Start Switch or Amptrol to stopthe arc and start the Post Flow timer. After thePost Flow time has expired, the gas and (optionalwater solenoid) valves will close. To make anoth-er weld, repeat steps 10 and 11.

WELDING IN TIG MODE (4-STEP)

In 4-STEP mode an Arc Start switch must be used.The switch is pressed and then released to start theweld cycle. Pressing and releasing the switch a sec-ond time ends the weld cycle. This eliminates the needto continuously hold down the switch during the weld.The process works as follows:

(STEP #1) First Press: Initiates a 0.5 second preflowof shielding gas then starts the weld at a current equalto 5 Amps or 25% +/- 10 % of preset current (whichev-er is greater).

(STEP #2) First Release: The output current ramps upto the preset level in 0.5 seconds.

(STEP #3) Second Press: The output current rampsdown to 5 Amps or 25% +/- 10 % of the preset current(whichever is greater). The time it takes to ramp downcan be adjusted from approximately 0.5 to 10 secondswith the Down Slope Time control knob.

(STEP #4) Second Release: Output is turned off stop-ping the weld and starting the 5 to 50 seconds postflow set with the Post Flow control knob.

1. Connect the Twist Mate plug to the receptacle locat-ed on the front of the machine. The connectionlocks into place with a quarter turn making both thepower and gas connections. See the TIG TORCHCONNECTION section to install the Twist Mate plugon your torch.

2. Connect an Arc Start Switch to the RemoteAmphenol.

3. Turn the welder, gas supply and water supply (if soequipped), on. The digital ammeter/voltmeter dis-play will illuminate when the power is on. NOTE:Cooling fan may not be “ON” when not welding.(See MAINTENANCE section)

4. Set the MODE switch to “4-STEP TIG”.

5. Set the peak current displayed on the digital amme-ter with the output control knob.

6. Select AC or DC- electrode polarity. See Table B.2.

7. If welding with AC polarity, set the AC WaveBalance Knob to Auto Balance™. This gives theoptimum ratio between cleaning and penetration,automatically adjusted for the output current. Ifmanual adjustment of the AC Wave Balance isdesired, adjust the wave balance to the desired set-tings. See the Advanced Features section for moreinformation on setting and using the AC WaveBalance.

8. Set the Post Flow time with the Post Flow knob.Post Flow time provides shielding gas flow (andcooling water, if used) after the weld. Use shortPost Flow times with low currents and small tung-stens and long Post flow times at high output cur-rents and large tungstens.

9. Set the Downslope Time with the Downslope TimeKnob. This will adjust the time of the crater fill peri-od.

SQUARE WAVE TIG 275

PRESS #1(STEP #1)

PREFLOW(0.5 sec. FIXED)

OPTIONALTIG PULSER

DOWNSLOPE(0.5 to 10 sec. ADJUSTABLE

STARTCURRENT

RELEASE #1(STEP #2)

PRESS #2(STEP #3)

PRESET CURRENT

RELEASE #2(STEP #4)

CRATER CURRENT

POSTFLOW(5 to 50 sec. ADJUSTABLE)

B-10OPERATIONB-10

10. With the torch held safely away from everything,press the Arc Start Switch and set the gas flowmeter. Release the switch. The welder is now readyfor welding.

11. Position the tungsten electrode at the start of theweld at a 65˚ to 75˚ angle with the horizontal so thatthe electrode is approximately 1/8" (4 mm) above thework piece. Press the Arc Start Switch. This opensthe gas and water valves to automatically purge airfrom the hose and torch. After a 0.5 second preflowtime, the high frequency becomes available to strikethe arc.

12. Hold the Arc Start Switch down until an arc is estab-lished. The arc will start at a low current value that isequal to 25% +/- 10 % of the preset current estab-lished in Step 5 or 5 Amps, whichever is greater.

13. Release the Arc Start Switch and the current willramp up to the preset maximum current in 0.5 sec-onds and remain there indefinitely.

14. Press the Arc Start Switch a second time to initiatethe Down Slope time. The current will ramp down toa crater fill level of 25% +/- 10 % of the preset currentor 5 Amps whichever is greater within the time setwith the Down Slope knob in Step 9.

15. Release the Arc Start Switch to stop the arc and startthe Post Flow timer. After the post flow time hasexpired, the gas and optional water valves will close.The make another weld, repeat steps 11 through 15.

HAND AND FOOT AMPTROL OPERATION

Both the Hand and Foot Amptrol work in a similar man-ner. They are meant to be used for remote current con-trol. The TIG 2-Step mode must be selected whenusing an Amptrol for remote current control.

For simplicity, the following explanation will refer only to"Amptrols", meaning both Foot and Hand models. Theterm "minimum" refers to a Foot pedal in the "up" posi-tion, as it would be with no foot pressure, or a HandAmptrol in the relaxed position, with no thumb pres-sure. "Maximum" refers to a fully depressed FootAmptrol, or a fully extended Hand Amptrol.

The Amptrol is capable of controlling the output currentfrom 5 amps to the preset current on the output controlknob. For example, if the preset is at 200 amps, theAmptrol, when depressed just past its minimum posi-tion, will cause the Square Wave TIG 275 to weld at 5amps. At the Amptrol's maximum position, the outputwill be near 200 amps.

It is important to note that, for many applications, thetungsten will not start an arc at only 5 amps. (Refer to

the TIG Welding Guidelines for recommended tungstencurrents.) To start an arc reliably, it is important todepress the Amptrol far enough so that the machineoutput current is near the tungsten operating range. Inthe example above, a 3/32" tungsten may be used onDC- to weld near 200 amps. To start the weld, theoperator may have to depress the Amptrol approxi-mately 1/4 of the way down, or to nearly 50 amps, inorder to start the arc. Merely depressing the Amptrol toits 5 amp minimum position will not start the arc.

ADVANCED TIG WELDING FEATURES

AC WAVE BALANCE AND AUTO BALANCE™

The AC Wave Balance feature is unique to the SquareWave TIG 275. It is active only in AC TIG mode. It con-trols the amount of positive and negative current in theAC output.

The Square Wave TIG 275 allows the operator to selectAuto Balance™. This selection provides automaticadjustment of the AC Wave Balance; it is suitable formost welding conditions. Auto Balance™ gives theideal amount of cleaning and penetration, based on thewelding current output.

Manual adjustment of the AC Wave Balance is alsopossible. Manual Balance settings vary from 0 (maxi-mum cleaning) to 10 (maximum penetration). A settingof 3 yields a balanced output (equal amounts of clean-ing and penetration). Use the following as a guidewhen setting the Balance manually:

BALANCED (3): The amounts of positive and nega-tive are the same.

CLEANING (0 to 2): Provides more positive currentthan negative current. Since the positive cur-rent produces the "cleaning" or oxide removalon aluminum, this setting is used for welding onheavily oxidized aluminum.

PENETRATION (4 to 10): Provides more negative cur-rent than positive. The arc plasma will be moreconcentrated and more easily directed towhere the heat is needed. Higher penetrationsettings allow a given size of tungsten to carrymore current.

CAUTION: Use only the amount of cleaning requiredbecause the greater amount of positive current willheat the tungsten more and possibly cause it to melt or"spit". Also, the arc is usually more flared and less sta-ble with more cleaning current.In general, use just enough "cleaning" to removeoxides and to give good wetting of the puddle.

SQUARE WAVE TIG 275

B-11OPERATIONB-11

STICK WELDING

1. Turn the welder “ON”.The digital ammeter/voltmeterwill illuminate when the power is on.

2. Set the Mode Switch to “STICK”. Set the output cur-rent displayed on the digital ammeter with theOutput Control Knob. No other functions or adjust-ments operate in the Stick Mode.

3. Select the desired DC+/AC/DC- electrode polarity.

4. Clamp the electrode in the electrode holder, startthe weld by lightly touching the electrode to thework. Stop the weld by pulling the electrode awayfrom the work piece.

AUXILIARY POWER

60 HERTZ DOMESTIC MACHINES

The Square Wave TIG 275 machines rated for 60 Hzoperation provides 10 amps of 115 volt AC power at astandard NEMA 5-15R receptacle, located on thelower case back of the machine. This circuit is protect-ed from shorts and overloading by a 10 amp circuitbreaker, located next to the receptacle. The auxiliarycircuit is intended for running water coolers and smallpower tools, whose current draw is within the 10 amprating. Note that some types of equipment, especiallypumps and large motors, have starting currents whichare significantly higher than their running current.These higher starting currents may cause the circuitbreaker to open. If this situation occurs, the usershould refrain from using the Square Wave TIG 275auxiliary for that equipment.

50/60 HERTZ EUROPEAN MACHINES

The Square Wave TIG 275 machines rated for 50/60Hzoperation provides 2 amps of 220 volt AC power at acontinental European (Schuko) type receptacle, locat-ed on the lower case back of the machine. This circuitis protected from shorts and overloading by a 2 ampcircuit breaker, located above the receptacle. The aux-iliary circuit is intended for running water coolerswhose current draw is within the 2 amp rating of thereceptacle. Note that some types of equipment, espe-cially pumps and motors, have starting currents whichare significantly higher than their running currents.These higher starting currents may cause the circuitbreaker to open. If this situation occurs, the usershould refrain from using the Square Wave TIG 275auxiliary for that equipment.

SQUARE WAVE TIG 275

C-1ACCESSORIESC-1

ACCESSORIES INCLUDED WITHMACHINE

K852-50 - Twist Mate Cable Plug for #2 to #1 WorkLead.

K1622-1 - Twist Mate Adapter Kit for LA9 and LA17Torches.

K1622-2 - Twist Mate Adapter Kit for LW18 and LW20Torches.

OPTIONAL ACCESSORIES

K963-1, -2 - Hand Amptrol

K870 - Foot Amptrol

K814 - Arc Start Switch

K559-2 - Magnum® Cooler Mounting Bracket

K932-1 - Undercarriage When the undercarriage isproperly installed, the Square Wave TIG 275 lift bale isnonfunctional. Do not attempt to lift the power sourcewith the undercarriage attached. The undercarriage isdesigned for hand moving only; mechanized towingcan lead to personal injury and/or damage to theSquare Wave TIG 275.

K1619-1 - TIG Pulser Kit

K1620-1 - Power Factor Capacitor Kit

K1621-1 - Water Solenoid Kit

K1622-3 - Twist Mate Adapter Kit for LA26 Torch

K852-70 - Twist Mate Cable Plug for 1/0 to 2/0 WorkLead

K852-95 - Twist Mate Cable Plug for 2/0 to 3/0 WorkLead

SQUARE WAVE TIG 275

D-1MAINTENANCED-1

SQUARE WAVE TIG 275

ELECTRIC SHOCK can kill.

• Only qualified personnel shouldperform this maintenance.

• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on thisequipment.

• Do not touch electrically hot parts.

To avoid receiving a high frequency shock, keep theTIG torch and cables in good condition.

Very little routine maintenance is necessary to keepyour Square Wave TIG 275 running in top condition.No specific schedule can be set for performing the fol-lowing items; factors such as hours of usage andmachine environment should be considered whenestablishing a maintenance schedule.

1. Periodically blow out dust and dirt which may accu-mulate within the welder using an air stream.

2. Inspect welder output and control cables for fraying,cuts, and bare spots.

3. Inspect the spark gap at regular intervals to main-tain the recommended spacing. See the ServiceProcedures Section for complete information onspark gap settings.

4. The fan motor has sealed ball bearings whichrequire no maintenance.

SAFETY PRECAUTIONS

ROUTINE AND PERIODIC MAINTENANCE

WARNING

WARNING

OVERLOAD PROTECTION

THERMOSTATIC PROTECTION

This welder has thermostatic protection from excessiveduty cycles, overloads, loss of cooling, and high ambi-ent temperatures. When the welder is subjected to anoverload or loss of cooling, a thermostat will open. Thiscondition will be indicated by the illumination of the yel-low Thermostatic Protection Light on the case front(see Figure 3). The fan will continue to run to cool thepower source. No welding is possible until the machineis allowed to cool and the Thermostatic ProtectionLight goes out.

FAN AS NEEDED (F.A.N.)

The Square Wave TIG 275 has the F.A.N. circuit fea-ture, which means the cooling fan will operate onlywhile welding; then for about 6 minutes after weldinghas stopped. The cooling fan will operate continuous-ly if the yellow Thermostatic Protection Light in “ON”.(See Design Features and Advantages Section)

SERVICE PROCEDURES

Use extreme caution when working with the secondarycircuit of the high frequency transformer. Turn the inputpower off using the disconnect switch or fuse boxbefore working inside the machine. This is particularlyimportant when working on the secondary circuit of thehigh voltage transformer (T3) because the output volt-age is dangerously high.

DO NOT APPLY POWER TO THE SQUARE WAVETIG 275 WITH THE SIDES AND ROOF REMOVED.The case front and case back assemblies tend to leanin towards the center assembly; there is a danger of ashort circuit when this occurs. If you must troubleshootthe machine with power applied, do so with the roof inplace, and check for shorts before applying power.------------------------------------------------------------------------

Operation of the Square Wave TIG 275 should be trou-ble-free for the life of the machine. Should a malfunc-tion occur, however, the following procedures will beuseful to trained service personnel with experience inrepairing arc welding equipment.

WARNING

D-2MAINTENANCED-2

COMPONENT LOCATION AND ACCESS

Control PC Board:

Remove the left case side. Use a 3/8" Nut Driver orother suitable tool.

Note: The Case side can be removed while roof is inplace, as long as the three screws which secure theroof to the case side are removed. The PC Board ismounted on left divider assembly and can be removedwith a phillips head screwdriver.

Display PC Board, Arc Starter/Bypass PCBoard:

Remove the roof and both case sides. Use a 3/8" NutDriver or other suitable tool. These PC Boards arelocated on the inside case front of the machine.

Spark Gap Assembly, High VoltageTransformer:

Remove the right case side. Use a 3/8" Nut Driver orother suitable tool. The high voltage transformer ismounted to the base. The spark gap assembly is locat-ed on the inside case front.

Main Rectifier:

Remove the roof and both case sides. Next, removethe case back assembly. Use a 3/8" Nut Driver or othersuitable tool. The main rectifier is mounted to the maintransformer, in front of the cooling fan.

SPARK GAP ADJUSTMENT

The spark gap is set at the factory to a gap of 0.015inches (0.4 mm). This setting is adequate for mostapplications. Where less high frequency is desired, thesetting can be reduced to 0.008 inches (0.2 mm).

To adjust the spark, first be sure that the input power tothe machine is ‘OFF’ AT THE DISCONNECT SWITCHOR FUSE BOX. The high voltages developed in thehigh frequency circuit can be lethal. Next, remove theright case side. Use a 3/8" Nut Driver or other suitabletool. Disconnect the two push on wires to the sparkgap blocks and pull back the dust shield. Check thespark gap spacing with a feeler gauge. If adjustment isrequired, pull off one of the two leads going to the alu-minum spark gap blocks. Adjust the gap by looseningthe Allen head screw, reset the gap and tightening thescrew in the new position. Replace the dust shield andthe two leads removed earlier. Reinstall the case side.

SQUARE WAVE TIG 275

.015 Spark Gap

RIGHT SIDE VIEW OF MACHINE

FIGURE D.1 SPARK GAP

E-1TROUBLESHOOTINGE-1

SQUARE WAVE TIG 275

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions. Simply follow the three-stepprocedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM(SYMPTOMS)”. This column describes pos-sible symptoms that the machine may exhib-it. Find the listing that best describes thesymptom that the machine is exhibiting.Symptoms are grouped into the followingcategories: output problems, function prob-lems, TIG mode problems, TIG welding prob-lems and Stick welding Problems.

Step 2. PERFORM EXTERNAL TESTS.The second column labeled “POSSIBLEAREAS OF MISADJUSTMENT(S)” lists theobvious external possibilities that may con-tribute to the machine symptom. Performthese tests/checks in the order listed. Ingeneral, these tests can be conducted with-out removing the case wrap-around cover.

Step 3. RECOMMENDED COURSE OFACTION

If you have exhausted all of the items in step2. Contact your Local Lincoln AuthorizedField Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianand machine operator and will invalidate your factory warranty. For your safety and to avoidElectrical Shock, please observe all safety notes and precautions detailed throughout this manual.__________________________________________________________________________

WARNING

DO NOT use a volt-ohm meter to measure output voltages in TIG mode. The HighFrequency Arc Starter voltage can damage the meter.

CAUTION


SQUARE WAVE TIG 275

Observe all Safety Guidelines detailed throughout this manual


CAUTION

GENERAL MACHINE TROUBLE

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENTS(S)

RECOMMENDEDCOURSE OF ACTION

Machine will not turn on.

No machine output.

Control panel display does not func-tion, but the output is normal.

The Voltmeter always reads "000",but the output is normal.

1. Input supply not "hot". Check input sup-ply line voltage and fuses.

2. Input power switch (S1) faulty. Checkand replace.

1. Make sure the input Power Switch (S1) isin the “ON” position.

2. A protective thermostat may be open.An open thermostat disables machineoutput. Allow machine to cool and ther-mostat will close. The yellow thermallight (TL1) should be lit in this condition.

3. If the machine is not “hot” (i.e. you havenot been welding) and the thermostatlight is lit, the thermostat wiring or a ther-mostat may be faulty. Check for continu-ity between leads 313 and 314 at P3 onthe Control PC Board. If not present,test each wire and thermostat individual-ly.

4. The Control PC Board may be faulty.See PC Board TroubleshootingProcedures

5. Main Transformer (T1) may be faulty.

1. Check for loose connections at theControl PC Board (P4) or at the DisplayBoard (P20 & P21)..

2. The Display PC Board may be faulty.See PC Board TroubleshootingProcedures.

3. The Control PC Board may be faulty.See PC Board TroubleshootingProcedures.

1. Check leads 252 and 253 and their con-nections to the Polarity Switch (S2) andto the Control PC Board connection (J6).


Contact your Local Lincoln AuthorizedField Service Facility for technicaltroubleshooting assistance.


SQUARE WAVE TIG 275



CAUTION


PROBLEMS(SYMPTOMS)



The Ammeter displays “000", but themachine has output with no control.

One of the meters is blank.

Accessories plugged into the 115volt receptacle do not work.(220 volt receptacle on Europeanmodel only)

Machine regularly overheats; ther-mostat (s) open.

1. The shunt lead connections may beopen. Check the red lead (222) andwhite lead (221) twisted pair all the wayfrom the shunt back to the Control PCboard connector (J2).

2. The Control PC Board may be faulty.See PC Board TroubleshootingProcedures.

1. Check for loose connections at ControlPC Board (P4) and at the Display PCBoard (20 & 21)The Display.


1. Is accessory defective? Plug it into aknown "hot" receptacle to see if it works.

2. Circuit Breaker CB may be open. Beforeresetting the circuit breaker, find out whyit opened. See the Auxiliary Power sec-tion for more information.

1. Check for proper voltage at fan.If proper voltage is present, but fan is notrotating or is rotating slowly, replace fanmotor.If proper voltage is not present, but fan isnot rotating or is rotating slowly, the out-put fan circuit on the control PC Boardmay be faulty.

2. Dirt and dust have clogged the coolingchannels inside the machine. Blow outthe machine with clean, dry compressedair.

3. Are the duty cycles being exceeded?Read the Instruction Manual thoroughlyfor duty cycle information.

4. Is there adequate clearance around theside and back of the machine, especiallynear the intake and exhaust louvers? Donot block the flow of cooling air duringoperation.



SQUARE WAVE TIG 275



CAUTION


PROBLEMS(SYMPTOMS)



The machine makes a very loudbuzzing noise in DC stick, or in DCTIG when the Arc Start Switch orAmptrol is pressed.

The machine has output and themeters are “ON” but there is no highfrequency present and the gas sole-noid does not function.

High frequency is present, but badstarting at low currents.(Approximately 15 Amps and below)

Stick electrode "Blasts Off" whentouched to the work piece.

Cannot adjust AC Wave Balance.

Variable or sluggish welding arc.

1. Diode D1 may be shorted. Checkand replace.

2. One of the main SCR’s may beshorted. Check and replace.

1. Check and replace 5 Amp Fuse(F1) located below the Control PCBoard on the right. (Fuse is pre-sent on European models only)

1. Check and replace 5 Amp Fuse(F2) located below the Control PCBoard on the left. (Fuse is presenton European models only)

1. Weld current is set too high forelectrode size. Reduce the presetcurrent.

2. One of the main SCR’s may beshorted.

3. The Control PC Board may befaulty. See PC BoardTroubleshooting Procedures.

1. AC Wave Balance Function is onlyoperational in the AC TIG mode.


1. Poor work or electrode connec-tion.

2. Welding leads too small. Uselarger work and electrode leads

3. Welding current set too low.



APR96

STICK WELDING TROUBLE


SQUARE WAVE TIG 275



CAUTION

TIG WELDING TROUBLE

PROBLEMS(SYMPTOMS)



Machine does not respond (no gasflow, no high frequency, no open cir-cuit voltage) when Arc Start Switchor Amptrol is pressed. Thermal lightis not lit.

No gas or water flow (with optionalwater solenoid) when Arc StartSwitch or Amptrol is pressed in theTIG Weld Mode.

No High Frequency.

1. Defective Arc Start Switch orAmptrol. Check for continuitybetween pins D and E on cableconnector when Arc Start Switchor Amptrol is pressed.


1. Gas supply is empty or not turnedon.

2. Pinched, disconnected, or leakinggas or water hose.

3. Gas and/or water lines or sole-noids are blocked with dirt. Cleanout and use filters to prevent reoc-currence.

4. Defective gas and/or water sole-noid. Check and replace.


1. Spark gap is too large. Reset gapper Periodic Maintenance Sectioninstructions.

2. Check gas solenoid operation. If itis not working, check 115V circuitfrom Main Transformer (T1).Check Fuse (F1) on Europeanmodels only.

3. Defective high voltage transformer(T2). Check and replace.

4. One or more of the followingcomponents may be open: R5 orC6. Check and replace.




SQUARE WAVE TIG 275



CAUTION

TIG WELDING TROUBLE

PROBLEMS(SYMPTOMS)



Weak High Frequency.

Output quits momentarily; gas flowand high frequency are also inter-rupted.

1. Spark gap is too close. Resetgap per Periodic MaintenanceSection instructions.

2. Work and electrode cables inpoor condition, allowing high fre-quency to "leak" to ground. Usegood quality cables, preferablythose with a high natural rubbercontent, and as short as possi-ble.

3. No shielding gas. Adjust gasflow for a flow of 10 to 30 CFH(4.7 to 14.1 1/min) for most appli-cations. (High frequency will notjump from the tungsten to workwithout shielding gas).

1. May be caused by high frequen-cy interference. Is the machinegrounded properly, according tothe installation instructions? Arethere other machines in the areawhich may be strong sources ofhigh frequency? Make sure thatthey are also properly installedand grounded.

2. Some internal ground connec-tions may have become loose.Check that the screws whichmount the Control PC Board andthe Bypass Stabilizer PC Boardare tight. Also, all case partsshould be in place, and the casescrews should be tight.



SQUARE WAVE TIG 275


CAUTION

PC BOARD TROUBLESHOOTINGPROCEDURE

Before replacing a PC Board which is suspected of beingdefective, visually inspect the PC Board in question for anyelectrical or mechanical damage to any of the components orconductors on the board, partially insulated molex pins orconnectors.

a. If there is no visible damage to the PC Board, install a newone and see if this remedies the problem. If the problemis remedied, reinstall the old PC Board to see if the prob-lem still exists. If the problem no longer exists with old PCBoard:

1. Check the PC Board harness connector pins forcorrosion, contamination or looseness.

2. Check leads in the plug harness for loose orintermittent connections.

b. If PC Board has visible electrical damage, before possiblysubjecting the new PC Board to the same cause of failure,check for possible shorts, opens or grounds caused by:

1. Frayed or pinched lead insulation.

2. Poor lead termination, such as a poor contact ora short to adjacent connection or surface.

3. Shorted or open control cable leads, or otherexternal leads.

4. Foreign matter or interference behind the PCBoards.

c. If PC Board has visible mechanical damage, inspect forcause, then remedy before installing a replacement PCBoard.

If there is damage to the PC Board or if replacing PCBoard corrects problem, return it to the local LincolnElectric Field Service Shop.

INPUT - BYPASS PC BOARD (EUROPEANMODELS ONLY)

This board is mounted to the case front and connectsto the input power at the line switch. It passes excesshigh frequency to ground, protecting the machine andpower line. For proper operation it must be securelygrounded, by means of its ground and mountingscrews to the case front. The quick connect terminalsfrom the line switch must be fully seated. Failures ofthis board should be very rare.

BYPASS / STABILIZER PC BOARD

The board is mounted between the output terminals. Itpasses excess high frequency to ground before it canreach the inside of the machine. For proper operation,it must be securely grounded, by means of its groundand mounting screws, to the case front. Failures of thisboard should be very rare.

DISPLAY PC BOARD

The board is mounted directly to the front panel. TheControl P.C. Board supplies power and metering infor-mation to the board.

CONTROL PC BOARD

This board, located on the left divider assembly, is theheart of the machine. All welding output is controlledby this board. The Display board receives its informa-tion from the Control board as well. Very little externaldiagnostic work can be performed on this board. If onecontrol or function of the machine does not appear tobe working, it is best to trace out the wiring associatedwith that function all the way back to the Control boardwith an ohmmeter. If all checks out there, verify thatthe following voltages are present at the output of theauxiliary leads at the main transformer, T1.

CONTROL PC BOARDAUXILIARY LEAD VOLTAGES

Main Transformer (T1) Plug P8 ApproximateAuxiliary Lead Number Locations Voltage

209 to 210 1 to 9 18 VAC201 to 204 4 to 6 18 VAC

231 to 232A 2 to 12 115 VAC211A to 212 13 to 14 23 VAC

Often, replacement with a known good board is thebest service method. Remove the board that is sus-pected to be defective. Carefully look over the board,checking for burnt traces or components. If none arefound, install the known good board. If the trouble goesaway, reinstall the suspected bad board to confirm thatthe board was indeed at fault. If the problem is nowgone with the original board installed, the problem isprobably with one of the leads or connectors going tothe board.

Consult the Lincoln Service Department if further trou-bleshooting assistance is required.

F-1WIRING DIAGRAMF-1

SQUARE WAVE TIG 275

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SQUARE WAVE TIG 275

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SQUARE WAVE TIG 275

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F-4F-4

Now Available...12th EditionThe Procedure Handbook of Arc Welding

With over 500,000 copies of previous editions publishedsince 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry.

This printing will go fast so don’t delay. Place your order now using the coupon below.

The hardbound book contains over 750 pages of welding infor-mation, techniques and procedures. Much of this material has never been included in any other book.

A must for all welders, supervisors, engineers anddesigners. Many welding instructors will want to use the book asa reference for all students by taking advantage of the low quan-tity discount prices which include shipping by4th class parcel post.

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How To Read Shop Drawings

The book contains the latest information and applicationdata on the American Welding Society Standard WeldingSymbols. Detailed discussion tells how engineers and drafts-men use the “short-cut” language of symbols to pass onassembly and welding information to shop personnel.

Practical exercises and examples develop the reader’s abilityto visualize mechanically drawn objects as they will appear intheir assembled form.

187 pages with more than 100 illustrations. Size 8-1/2” x 11”Durable, cloth-covered board binding.


New Lessons in Arc WeldingLessons, simply written, cover manipulatory techniques;

machine and electrode characteristics; related subjects, suchas distortion; and supplemental information on arc weldingapplications, speeds and costs. Practice materials, exercises,questions and answers are suggested for each lesson.

528 pages, well illustrated, 6” x 9” size, bound in simulated,gold embossed leather.


Need Welding Training?The Lincoln Electric Company operates the oldest and

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For details write: Lincoln Welding School22801 St. Clair Ave.Cleveland, Ohio 44117-1199.

and ask for bulletin ED-80 or call 216-383-2259 and ask for theWelding School Registrar.

Lincoln Welding SchoolBASIC COURSE $700.00

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Lincoln Welding School Titles: Price Code Quantity Cost(ED-80) New Lessons in Arc Welding $5.00 L

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WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TOBE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

square wave tig 275

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