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Lincoln Electric Precision TIG 275, Service Manual

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Lincoln Electric Precision TIG 275 Service Manual Download Page 39

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E-1

E-1

PRECISION TIG 275

Theory of Operation

..............................................................................................................

Section E

General Description ....................................................................................................................E-2
Input Power Circuit......................................................................................................................E-2
Output Rectification, Control Board and Feedback ....................................................................E-3
High Voltage/High Frequency Circuit..........................................................................................E-4
DC Welding Output .....................................................................................................................E-5
AC Welding Output .....................................................................................................................E-6
SCR Operation............................................................................................................................E-7
Protective Circuits .......................................................................................................................E-8

Fan As Needed (F.A.N.)........................................................................................................E-8
Thermal Protection ...............................................................................................................E-8
Overload Protection..............................................................................................................E-8

TABLE OF CONTENTS

-THEORY OF OPERATION SECTION-

POWER

SWITCH

RE

CO

NN

EC

T

   

 P

AN

EL

OPTIONAL POWER

        FACTOR

POLARITY

  SWITCH 

BYPASS            BOARD

WORK

FRONT

ELECTRODE

REAR

ELECTRODE

78

 V

AC

X1

X2

AC

AC

DC

DC

SHUNT

CH

O

KE

HIGH FREQUENCY

  TRANSFORMER

  HIGH VOLTAGE

  TRANSFORMER

THERMOSTAT

115 VAC

115 VAC

11

5 V

AC

FAN

GA

TE

 LE

AD

S

FE

ED

BA

CK

   

GAS

SOLENOID

11

5 V

AC

11

5 V

AC

LED's

THERMOSTAT

20 VAC

20 VAC

CONTROL BOARD

  

BACKGROUND

    CIRCUIT 

   FROM 

CONTROL

  BOARD

63

.5 

VA

C

CORRECTION

CAPACITORS

REAR GANG

   SCR

BRIDGE

ADVANCED CONTROL

PANEL RECEPTACLE

 MINIMUM

 OUTPUT

CONTROL

 MAXIMUM

  OUTPUT

 CONTROL

PROTECTION

    BOARD

   REMOTE

RECEPTACLE

METER

 STICK

   TIG

SWITCH

  BALANCE

  CONTROL

  POST

  FLOW

   LOCAL/REMOTE

        SWITCH

FIGURE E.1 – PRECISION TIG 275 BLOCK LOGIC DIAGRAM

Summary of Contents for Precision TIG 275

Page 1: ...TY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 10806 10807 10893 11158 11159 Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products Copyright Lincoln Globa...

Page 2: ... 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 purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy ...

Page 3: ...eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor ex...

Page 4: ...e welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to...

Page 5: ...ravaillant à proximité au soudage à lʼaide dʼécrans appropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écr...

Page 6: ...enance Section D Theory of Operation Section E Troubleshooting and Repair Section F How to Use Troubleshooting Guide F 2 Safety Precautions F 3 Troubleshooting Guide F 4 Test Procedures F 19 Oscilloscope Waveforms F 39 Replacement Procedures F 45 Retest After Repair F 61 Electrical Diagrams Section G Parts Manual P404 P558 Series RETURN TO MAIN INDEX ...

Page 7: ...onal Output Capacity A 3 Wire and Fuse Sizes A 3 Physical Dimensions A 3 Temperature Ranges A 3 Safety Precautions A 4 Stacking A 4 Lifting and Moving A 4 Tilting A 4 High Frequency Interference Protection A 4 Input Electrical Connections A 5 Ground Connection A 5 Output Cables Connections Limitations A 6 TIG Torch Connection A 7 Auxiliary Power Connections A 8 Remote Control A 8 Robotic Interface...

Page 8: ...lance 70 Penetration AC TIG Idle Amps Idle Power 40 AC DC Stick Balance TIG Unbalance 70 Penetration AC TIG 60 AC DC Stick Balance TIG Unbalance 70 Penetration AC TIG 100 AC DC Stick Balance TIG Unbalance 70 Penetration AC TIG Idle Amps Idle Power RATED INPUT SINGLE PHASE ONLY K Number K1825 1 K1826 1 K2619 1 K1826 2 K2619 2 K1827 1 RATED OUTPUT NEMA EW1 Class ll 40 K1825 1 K1826 1 2 K2619 1 2 Dut...

Page 9: ...Duty Cycle with out Standard Power Factor Correction Capacitors Based on the 1999 U S National Electrical Code For Unbalanced AC TIG Welding Above 275 Amps 255A 40 Duty Cycle Auto Balance Penetration with out Standard Power Factor Correction Capacitors Based on the 1999 U S National Electrical Code RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage phase Frequency 208 1 60 230 1 60 460 1 60 575 1...

Page 10: ...on TIG 275 power sources carry an IP21S Environmental rating They are rated for use in damp dirty rain sheltered environments HIGH FREQUENCY INTERFERENCE PROTECTION The frame of the welder must be grounded A ground screw marked with the symbol is located on the input connection panel Figure A 1 for this purpose See your local and national electrical codes for proper grounding methods The spark gap...

Page 11: ... around the periphery of the building are rec ommended Failure to observe these recommended installation procedures can cause radio or TV interference prob lems and result in unsatisfactory welding performance resulting from lost high frequency power INPUT and GROUNDING CONNECTIONS ELECTRIC SHOCK can kill Turn the input power OFF at the disconnect switch or fuse box before working on this equip me...

Page 12: ...ELDING 1 Connect the terminal marked below the recon nect 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 phase line or one phase of a two or three phase line 3 On multiple input voltage welders be sure the reconnect panel is connected for the voltage being supplied to the welder Failure to follow these instructions can cause...

Page 13: ... containers Contact your supplier for specifics CYLINDER could explode if damaged Keep cylinder upright and chained to a support Keep cylinder away from areas where it could be damaged Never allow the torch to touch the cylinder Keep cylinder away from live electrical cir cuits Maximum inlet pressure 150 psi The Precision TIG machines do not have Hi Freq available at the Stick electrode stud there...

Page 14: ...t break er cools the button can be reset by pressing it back in Note When the breaker trips not only will the auxil iary and cooler power be interrupted but so will the power to the shielding gas solenoid and machine cooling fan The Precision TIG Export models also provide a grounded 220 VAC Euro type Schuko receptacle and a 5 amp circuit breaker located on the upper case back on the reconnect sid...

Page 15: ...ther the MAXIMUM OUTPUT nor the MINIMUM OUTPUT panel controls limit the inter face control setting over the rated output range of the machine The diagram in Figure A 4 below shows the remote receptacle plug connections and signals for robotic interface Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master ...

Page 16: ...10 NOTES PRECISION TIG 275 A 10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 17: ... B Safety Precautions B 2 Product Description B 2 Recommended Process and Equipment B 3 Controls and Settings B 4 Welding Operation B 5 B 8 Internal Set Up Controls B 9 2 Step Trigger Modes B 10 4 Step Trigger Modes B 11 TIG Weld Cycle Chart B 12 Set Up for TIG Amptrol Welding B 13 Making a TIG Weld with an Amptrol B 14 Recommended Electrode Amperage Ranges B 14 ...

Page 18: ... Water Solenoid are available as field installed optional kits Also a new Undercarriage with double gas bottle rack is available for field installation as well as a new Under Cooler Cart which is also included in an avail able efficiently integrated entire TIG Welding Package with convenient built in storage provisions for welding equipment and components The Precision TIG 275 includes advanced fe...

Page 19: ...series cannot be used for torch connection PRECISION TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RECOMMENDED EQUIPMENT INTERFACE FOR CODES ABOVE 11000 TIG water cooled TIG air cooled Machine PT275 Welding Package K2618 1 PT275 K2619 1 2 Input Cable Clamp User prov...

Page 20: ...n the Polarity Switch is set to AC the TIG mode provides continuous high frequency to stabi lize the arc for AC TIG welding Hi Freq turns on after preflow time with the arc start switch closure and turns off when the arc goes out after the arc start switch opens Arc voltage and current are sensed to determine if the arc is established or out PRECISION TIG 275 CONTROLS AND SETTINGS The Front Contro...

Page 21: ...put can be set with the remote Amptrol The new MicroStartTM Technology minimum current circuit provides for low end welding down to 2 amps previously unobtainable on an SCR platform TIG machine 7 MINIMUM OUTPUT CONTROL AND DISPLAY SWITCH A smaller knob is used to preset the minimum cur rent level only for TIG mode Pressing the Display momentary switch toggle left to Minimum Set posi tion displays ...

Page 22: ... 0 1 2 3 4 5 6 7 8 9 Selection 5 0 1 2 3 4 5 Description HS TIG Hot Start of output setting 0 Only setting for SS0 above 10 20 30 40 50 60 70 80 90 UP Upslope Time None Only setting for SS1 SS2 above 0 5 sec 1 0 sec 1 5 sec 2 0 sec 2 5 sec TIG Mode Menu with Advanced Control Panel installed Default Factory Setting Indicated by blinking decimal point Default Factory Setting Indicated by blinking de...

Page 23: ...ptacle is provided for the connection of an Amptrol or other remote control See Figure B 2 When the Current Control Switch See Item 5 is in the REMOTE position the Amptrol or other remote 10K pot connected to the Remote receptacle con trols the TIG or Stick mode output within the range preset by the Maximum and Minimum Output con trols See Item 6 7 and 8 for meter display When the Current Control ...

Page 24: ...s when the output current drops below this level SPOT ON position provides the peak current level set by the Maximum Output Control for a time deter mined by the SPOT TIME control A red panel light is ON to indicate SPOT mode 14 PULSE FREQUENCY CONTROL This knob is used to set the Pulse Frequency over the peak pulse range of about 0 1 pps to 20 pps One pulse cycle time 1 pps 10 to 05 sec range 15 ...

Page 25: ... and Low 12 factory set levels are selectable which are good for most stick welding applications ON Higher for a crisper arc often desired for 6010 type electrodes OFF Lower Arc Force as shipped for a softer arc with 7018 or general type electrodes Switch 6 7 Not functional on codes above 11000 See item 7a for adjustment of Hot Start and Arc Force Switch 8 NOT CURRENTLY FUNCTIONAL TIG WELDING FEAT...

Page 26: ...h Button Output Current Gas Pre Flow Post Flow Normal Sequence Torch Button Output Current Gas Pre Flow Post Flow START CRATER CURRENT UP SLOPE DOWN SLOPE With DIP Switch 2 OFF With DIP Switch 2 ON As Shipped Actuate the trigger a second time during down slope to immediately end down slope Hold the trigger to maintain crater current Torch Button Output Current Gas Pre Flow Post Flow Actuate the tr...

Page 27: ...he normal down slope period Actuate the trigger again during down slope to immediately end down slope and stop Or actuate and hold the trigger during down slope to immediately end down slope and maintain crater current Hold the trigger for more than 1 second to activate the restart function When the trigger is released up slope will occur Hold the first trigger pull to maintain the starting curren...

Page 28: ...en 4 STEP Trigger Re closed or 2 STEP Trigger Opened 4 STEP Trigger Re opened after Downslope Time DOWNSLOPE Adjust 0 10 sec w Advan Panel Fixed 0 sec w o POSTFLOW Adjust 2 60 sec or x2 CRATER FILL LEVEL Advanced Panel Select Mach Min or MIN Setting as w o Panel With PULSE ON No Pulsing During Upslope Time or When Downslope Drops Below Background Setting ON TIME Adjustable 5 95 PULSE FREQ Adjustab...

Page 29: ...ut Press Display switch and Set to desired min Amptrol Start Crater output level Postflow Set as low as required Higher for larger tungsten and current Maximum Output Set to desired max Amptrol output level A Ad dv va an nc ce ed d P Pa an ne el l Controls SETUP GUIDELINES FOR TIG WELDING WITH AN AMPTROL Both the Hand and Foot Amptrols work in a similar manner They are meant to be used for remote ...

Page 30: ...ngsten in AC and DC applications Balanced Wave Unbalanced Wave requires derating of the electrode MAKING A TIG WELD WITH AN AMPTROL 1 Install welding equipment per Section A 5 2 Setup controls per Section B 9 3 Turn on the shielding gas supply and torch coolant input supply if used Note The Precision TIG Under Cooler or Water Solenoid connected to the Cooler receptacle runs with the Fan As Needed ...

Page 31: ... TABLE OF CONTENTS ACCESSORIES Accessories Section C Optional Equipment for Codes Below 11000 C 2 Optional Equipment for Codes Above 11000 C 3 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 32: ...with 5 front casters 10 rear wheels and a handle K1830 1 Water Solenoid Kit Provides for stopping flow of external water supply Connects to coolant inlet and cooler receptacle of Precision TIG Cannot be used with a water cooler K870 Foot Amptrol Single pedal foot activation of arc start switch and output control with 25ʼ plug cable K870 1 Start Pedal Foot Amptrol Independent start pedal on control...

Page 33: ...s a cooler in a drawer with hoses and a lockable storage drawer on a dual bottle undercar riage see below K1869 1 Undercarriage Includes a dual bottle rack with chain and an under carriage with 5 front casters 10 rear wheels and a handle K1830 1 Water Solenoid Kit Provides for stopping flow of external water supply Connects to coolant inlet and cooler receptacle of Precision TIG Cannot be used wit...

Page 34: ... 4 NOTES PRECISION TIG 275 C 4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 35: ...Return to Master TOC TABLE OF CONTENTS MAINTENANCE Maintenance Section D Safety Precautions D 2 Routine and Periodic Maintenance D 2 Overload Protection D 2 Fan As Needed F A N D 2 Service Procedures D 3 Component Location and Access D 3 Spark Gap Adjustment D 3 Major Component Location D 4 ...

Page 36: ...ght is lit see Thermostatic Protection THERMOSTATIC PROTECTION This welder has thermostatic protection from excessive duty cycles overloads loss of cooling and excessive ambient temperatures When the welder is subjected to an overload or inadequate cooling the primary coil thermostat and or secondary coil thermostat will open This condition will be indicated by the illumination of the yellow Therm...

Page 37: ... less high frequen cy is desired the setting can be reduced to 0 008 inch es 0 2 mm Use extreme caution when working with the high frequency circuit The high voltages developed can be lethal Turn the input power off using the dis connect switch or fuse box before working inside the machine This is particularly important when working on the secondary circuit of the high volt age transformer T3 beca...

Page 38: ...3 Case Back Assembly 4 Center Assembly 5 Case Cover Assembly RE MO RE MO TE TE LO CA L LO CA L MA XIM UM MA XIM UM DISP LA DISP LA Y Y MI NIMU M MI NIMU M MO DE MO DE A AC B C BA LA NC E AL AN CE PO ST FL O PO ST FL OW W DC ON OF F PO WER AC DC PRECISION TIGTM 375 TH E LIN CO LN EL EC TR IC CO MP AN Y CL EV EL AN D OH IO US A DO NO T SW ITC H WH ILE WE LD ING SQ UA RE WAV E PO WER SO UR CE featuri...

Page 39: ...ION SECTION POWER SWITCH RECONNECT PANEL OPTIONAL POWER FACTOR POLARITY SWITCH BYPASS BOARD WORK FRONT ELECTRODE REAR ELECTRODE 78 VAC X1 X2 AC AC DC DC SHUNT CHOKE HIGH FREQUENCY TRANSFORMER HIGH VOLTAGE TRANSFORMER THERMOSTAT 115 VAC 115 VAC 115 VAC FAN GATE LEADS FEEDBACK GAS SOLENOID 115 VAC 115 VAC LED s THERMOSTAT 20 VAC 20 VAC CONTROL BOARD BACKGROUND CIRCUIT FROM CONTROL BOARD 63 5 VAC COR...

Page 40: ...ut power is connected to the PRECISION TIG 275 through the power switch to the reconnect panel located in the rear of the machine The machine can be configured for any one of three input voltages 208 VAC 230 VAC or 460 VAC by con necting the jumper strap to the appropriate terminal on the reconnect panel When the input power switch is turned on the input voltage is applied directly to the primary ...

Page 41: ...ut SCR bridge The control board regulates the firing of the output SCRs which control the output of the machine See SCR Operation The control board also monitors the thermostats and controls the gas solenoid the thermal light the high voltage transformer and the cooling fan The optional advanced control panel also plugs into and interfaces with the control board THEORY OF OPERATION FIGURE E 3 OUTP...

Page 42: ...BOARD REMOTE RECEPTACLE METER STICK TIG SWITCH BALANCE CONTROL POST FLOW LOCAL REMOTE SWITCH HIGH VOLTAGE HIGH FREQUENCY CIRCUIT The control board passes the 115 VAC voltage to the primary of the high voltage transformer The secondary of the high voltage transformer is coupled to a spark gap generator and also to the primary winding of the high frequency transformer The secondary of the high frequ...

Page 43: ...ence When the machine is in the DC mode the background cir cuitry provides an added boost of voltage to the output terminals This circuitry is controlled by the control board THEORY OF OPERATION FIGURE E 5 DC WELDING OUTPUT POWER SWITCH RECONNECT PANEL OPTIONAL POWER FACTOR POLARITY SWITCH BYPASS BOARD WORK FRONT ELECTRODE REAR ELECTRODE 78 VAC X1 X2 AC AC DC DC SHUNT CHOKE HIGH FREQUENCY TRANSFOR...

Page 44: ...F OPERATION FIGURE E 7 AC WELDING OUTPUT POWER SWITCH RECONNECT PANEL OPTIONAL POWER FACTOR POLARITY SWITCH BYPASS BOARD WORK FRONT ELECTRODE REAR ELECTRODE 78 VAC X1 X2 AC AC DC DC SHUNT CHOKE HIGH FREQUENCY TRANSFORMER HIGH VOLTAGE TRANSFORMER THERMOSTAT 115 VAC 115 VAC 115 VAC FAN GATE LEADS FEEDBACK GAS SOLENOID 115 VAC 115 VAC LED s THERMOSTAT 20 VAC 20 VAC CONTROL BOARD BACKGROUND CIRCUIT FR...

Page 45: ... cycle time in the ON state and the remainder of the time in the OFF state The amount of time spent in the ON state is con trolled by the gate An SCR is fired by a short burst of current into the gate This gate pulse must be more positive than the cath ode voltage Since there is a standard PN junction between gate and cathode the voltage between these terminals must be slightly greater than 0 6V O...

Page 46: ...ate cooling the primary coil thermostat and or secondary coil thermostat will open This condition will be indicated by the illumination of the yellow Thermal Shutdown light on the front panel The fan will continue to run to cool the power source Postflow occurs when Tig welding is shut down but no welding is possible until the machine is allowed to cool and the yellow Thermal Shutdown light goes o...

Page 47: ...olenoid Test F 31 Static SCR Test F 33 Active SCR Test F 35 Typical Output Voltage Waveform DC Tig Mode F 39 Typical Output Voltage Waveform AC Tig Mode F 40 Typical AC Voltage Waveform 50 AMPS AC Tig Mode F 41 Typical AC Voltage Waveform 2 AMPS AC Tig Mode F 42 Typical Output Voltage Waveform 200 AMPS DC Tig Mode F 43 Replacement Procedures High Voltage Transformer Removal Replacement F 45 Contro...

Page 48: ...NDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the ...

Page 49: ...rd canʼt be installed immediately put it back in the static shielding bag If the PC Board uses protective shorting jumpers donʼt remove them until installation is complete If you return a PC Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symp t...

Page 50: ...115 VAC at the receptacle 1 Check the input voltage The input voltage must match the rat ing plate and the voltage con nection Refer to Reconnect Procedure in the Installation section of this manual 2 Make sure that the input power switch is in the ON position 3 Check for blown or missing fuses in the input lines 4 Check circuit breaker CB1 Reset if necessary 1 Check the input power switch reconne...

Page 51: ... BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced Process panel or harness is defective 1 Make sure the polarity switch is in the proper position and func tioning correctly 2 One of the thermostats may be tripped Allow the machine to cool The thermal light will be on 3 Make sure the welding cables torch...

Page 52: ...y Check or replace See the Wiring Diagram 2 Check for loose or faulty wires on the thermostats and associat ed circuitry See the Wiring Diagram 3 The fan motor may be faulty or mechanically obstructed The fan should run when welding or when a thermostat is open 4 The control board may be faulty The machine does not respond no gas flow no high frequency and no open circuit voltage when the arc star...

Page 53: ... of the heavy current carrying leads 3 Perform the SCR Bridge Test 4 Perform the T1 Transformer Test 5 Check the output current con trols for proper operation Normal resistance is 10 000 ohms See the Wiring Diagram 6 The control board may be faulty F 7 F 7 PRECISION TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master...

Page 54: ...ve 1 Perform the SCR Bridge Test 2 Perform the T1 Transformer Test 3 Check the output current con trols for proper operation Normal resistance is 10 000 ohms See the Wiring Diagram 4 Check leads 221 and 222 between the output shunt and the control board See the Wiring Diagram 5 The control board may be faulty Accessories plugged into the volt receptacle do not work 1 Make sure the accessory plug a...

Page 55: ...ncoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS The machine makes a very loud buzzing noise in DC Stick or in DC TIG modes There is no current draw from the machineʼs output ter minals The machine is not exter nally loaded 1 Inspect the...

Page 56: ...n that they are grounded prop erly 2 Make sure the Amptrol is operat ing properly 3 Check to make sure that the input voltage is correct for the machine Refer to Reconnect Procedure in the Installation section of this manual 1 Check for loose or faulty con nections on the leads between the remote receptacle the pro tection board and plug J22 on the protection board See the Wiring Diagram 2 Check p...

Page 57: ... functions normally the Advanced Process panel or harness is defective 1 If the machine is in a dirty envi ronment with conductive contam inants check and clean the spark gap with a low pressure air stream per the maintenance instructions 2 Check the spark gap operations and setting Normal is 0 015 Refer to the Maintenance Section of this manual 3 Check circuit breaker CB1 Reset if necessary 4 Che...

Page 58: ... ing the high frequency to leak to ground Use good quality cables preferably those with a high natural rubber content and as short as possible 3 If helium shielding gas is being used reduce the percentage of helium 4 Make sure the tungsten elec trode is the correct size for the process 1 The high voltage transformer T2 may be faulty 2 Capacitor C6 may be faulty 3 The high frequency transformer T3 ...

Page 59: ... or replace 2 The current control may be set too low 3 The tungsten electrode may be contaminated Replace or sharpen 4 The electrode may be too large for the process 5 If a helium blend is being used as a shielding gas reduce the percentage of helium 6 Check the welding cables for loose or faulty connections 1 Check spark gap adjustment See the Maintenance Section 2 This may be a welding proce dur...

Page 60: ...connector J 3 If the machine functions normally the Advanced Process panel or harness is defective 1 Welding current may be too high for the electrode size Reduce current control setting or use a larger diameter electrode 1 Perform the SCR Bridge Test 2 The control board may be faulty Variable or sluggish welding arc when welding in the Stick mode 1 Check the work and electrode cables for loose or...

Page 61: ...trical troubleshooting assistance before you proceed Call 1 888 935 3877 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The meter does not display V volt or minimum current NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advance...

Page 62: ...ocess panel or harness is defective 1 The AC wave balance control is operational only in the TIG mode 1 Check the AC balance control R2 and associated leads for loose or faulty connections See the Wiring Diagram 2 The control board may be faulty Gas pre flow and post flow time is too long 1 If an advanced control board is installed check dip switch set ting on the board See Installation Manual 1 C...

Page 63: ... or minimum current NOTE BEFORE REPLACING A CONTROL BOARD If an Advanced Control Panel is installed remove it and replace the Jumper in connector J 3 If the machine functions normally the Advanced Process panel or harness is defective 1 Toggle the display switch It may be dirty 1 Check the leads between the display switch and the control board See the Wiring Diagram 2 The display switch may be fau...

Page 64: ...18 NOTES F 18 PRECISION TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 65: ...ecautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help aid the technician in meter circuits calibration MATERIALS NEEDED Voltmeter Ohmmeter 3 ...

Page 66: ... follows 1 Set the TIG mode and without closing the arc start switch preset the panel maximum output control so the panel digital meter reads 200 amps 2 Using a DC avg digital test voltmeter with at least 0 5 accuracy at 1 000v measure the DC voltage between pin 2 lead 303 and pin 1 lead 306 at the right side meter plug nearest the trim mer 3 This voltage should match the 200A panel meter reading ...

Page 67: ...chine will shut down to protect internal holding resistor from over heating METER CALIBRATION ADJUSTMENTS continued X X X X X X X X X X X X X X XXX XXX X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X DZ16 C47 R274 D58 R93 D21 X11 D65 C106 C35 Q17 D80 Q23 Q14 C31 R96 C128 C152 R318 R333 C76 R331 DZ22 D67 C155 R134 X10 R205 C34 C19 C45 C59 C87 ...

Page 68: ...22 F 22 PRECISION TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES ...

Page 69: ...nd will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935...

Page 70: ...rom the Spark Gap Assembly See Figure F 2 5 Insulate the leads from each other and from the case 6 When voltage testing and scope measure ments are complete reconnect the three leads to the Spark Gap Assembly 7 Reassemble the right side case cover FIGURE F 2 SPARK GAP ASSEMBLY RE MO RE MO TE TE LO CA L LO CA L MA XIM UM MA XIM UM DIS PL A DIS PL AY Y MIN IMU M MIN IMU M MO DE MO DE A AC B C BA LA ...

Page 71: ...cian or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before ...

Page 72: ...o step 6 See Wiring Diagram 6 Unplug P22 from protection board Measure resistance at P22 See Tables 7 If readings below are OK protection board is bad 8 If readings below are wrong remote amptrol or remote receptacle is bad FIGURE F 3 Plug J5 viewed from pin end 1 5 6 7 8 4 3 2 Jumper Table F 1 Table F 2 RESISTANCE BETWEEN Pins 5 7 Open when trigger open short when trigger closed Increasing from 0...

Page 73: ...arranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure ...

Page 74: ...rect transformer secondary voltages per Table F 3 5 Carefully check for 63 5 VAC at leads 267 to lead 268 Lead 268 is located at the background rectifi er Note Lead 267 is located at resistor R8 See Wiring Diagram 6 Carefully check for 115 VAC at leads 231 to 232 Note Lead 231 is located at the 115 VAC recepta cle on the back of the machine Lead 232 is located at the 15 amp circuit breaker CB1 7 I...

Page 75: ...204 X1 TO X2 PRIMARY WINDINGS H1 TO H2 H1 TO H3 H1 TO H4 SECONDARY VOLTAGES 20 VAC 18VAC 78 VAC PRIMARY VOLTAGES 208 VAC 230 VAC 460 VAC NOTE If the input voltages vary the secondary voltages will vary accordingly Based on 208 230 460 models For other voltage models refer to appropriate Wiring Diagram Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to...

Page 76: ...Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F 30 NOTES F 30 ...

Page 77: ...l invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 ...

Page 78: ...trigger and check for approximately 115 VAC at the solenoid leads 231A and 235 If the correct voltage is present the solenoid should activate and gas should flow 8 If voltage is present at leads 231A and 235 and the solenoid does not activate the solenoid may be defective The solenoid can be further checked by removing leads 231A and 235 from the solenoid and applying the external isolated 115 VAC...

Page 79: ... not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The SCR test is a quick check to determine if an SCR is shorted or leaky See machine waveform section for normal and abnormal SCR waveforms MATERIALS NEEDED 3 8 Nut Driver A...

Page 80: ...om anode to cathode of SCR1 Reverse the meter leads and check from cathode to anode of SCR1 See Figure F 5 If a low resistance is indicated in either direc tion SCR1 is faulty Replace the SCR Bridge Assembly See SCR Bridge Assembly Removal and Replacement 4 Repeat Step 3 testing SCR2 SCR3 and SCR4 5 To further check the SCRʼs functions use an SCR tester and proceed to the Active SCR Test NOTE Also...

Page 81: ...r any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The Active SCR test will determine if the device is able to be gated ON and conduct cur rent from anode to cathode MATERIALS NEEDED 3 8 Nut Driver TIG 275...

Page 82: ...RECI SION TIG 275 machine 2 Locate and remove plug J4 from the control board See Figure F 7 3 Perform the following test for all four SCRs See Figure F 8 4 Construct the circuit outline in Figure F 8 One 6V lantern battery can be used Resistor values are 10 The voltmeter scale should be approximately 0 5 or 0 10 volts 5 Battery Test Check the battery by shorting leads A and C and then close switch...

Page 83: ...der test 6 volt lantern battery SW1 Figure F 8 Active SCR Test Set Up R1 4 ohms 10 watts R2 3 ohms 10 watts Resistor values are 10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 84: ...wo seconds and release The voltmeter should read 3 to 6 volts before and after switch SW 2 is released If the voltmeter does not read or reads only while SW 2 is depressed the SCR or battery is defective Repeat Battery Test Procedure described in Step 5 9 Open switch SW 1 disconnect the gate lead G and reverse the A and C leads on the SCR Close switch SW 1 The voltmeter should read zero If the vol...

Page 85: ...t Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure This is the typical AC output voltage waveform generated from a properly operating machine Note that each ver tical division represents 20 volts and that each horizontal division represents 5 milliseconds in time NOTE Scope probes connected at machine output terminals probe to electro...

Page 86: ...erly operating machine Note that each ver tical division represents 20 volts and that each horizontal division represents 5 milliseconds in time The machine was loaded with a resistance grid bank NOTE Scope probes connected at machine output terminals probe to electrode probe to work Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal SCOPE SETTINGS AC BALANCE CONTROL IN AUTO ...

Page 87: ...est equipment Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure This is the typical DC output voltage waveform generated from a properly operating machine Note that each ver tical division represents 20 volts and that each horizontal division represents 5 milliseconds in time NOTE Scope probes connected at machine output terminals prob...

Page 88: ...om a properly operating machine Note that each ver tical division represents 20 volts and that each horizontal division represents 5 milliseconds in time NOTE Scope probes connected at machine output terminals probe to electrode probe to work Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal SCOPE SETTINGS AC BALANCE CONTROL IN AUTO OUTPUT CONTROL AT MINIMUM Return to Sectio...

Page 89: ...sion represents 20 volts and that each horizontal division represents 5 milliseconds in time NOTE Scope probes connected at machine output terminals probe to electrode probe to work NOTE AC balance control set at Balanced position TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED TO 200 AMPS DC TIG MODE HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and waveform checks with...

Page 90: ...44 F 44 PRECISION TIG 275 NOTES Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 91: ...ian or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before y...

Page 92: ...Figure F 10 10 Remove the high voltage transformer REPLACEMENT PROCEDURE 1 Replace the high voltage transformer 2 Secure the new transformer using the four phillips head mounting screws Refer to Figure F10 for insulator location 3 Replace the 3 8 screw securing the spark gap assembly box 4 Reconnect leads S and F 5 Reconnect high voltage transformer lead to the capacitor 6 Reconnect leads 231D and...

Page 93: ...E MO RE MO TE TE LO CA L LO CA L MA XIMU M MA XIMU M DISP LA DISP LA Y Y MI NIMU M MI NIMU M MO DE MO DE A AC B C BA LA NC E AL AN CE PO ST FL O PO ST FL OW W DC ON OF F PO WER AC DC PRECISION TIGTM 375 TH E LIN CO LN EL EC TR IC CO MP AN Y CL EV EL AN D OH IO US A DO NO T SW ITC H WH ILE WE LD ING SQ UA RE WAV E PO WER SO UR CE featuring MICRO START TM TE CH NO LO GY WAR NING LINCOLN ELECTRIC SPA...

Page 94: ...48 NOTES F 48 PRECISION TIG 275 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 95: ... the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assista...

Page 96: ...ount the new control board in its proper position using the eight phillips head mount ing screws 3 Replace any necessary cable ties 4 Reconnect plugs previously removed from the control board 5 Secure the control box assembly using the two 3 8 mounting screws previously removed RE MO RE MO TE TE LO CA L LO CA L MA XIM UM MA XIM UM DIS PL A DIS PL AY Y MI NIM UM MI NIM UM MO DE MO DE A AC B C BA LA...

Page 97: ...TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued J12 J11 J10 J9 J8 J6 J5 J4 Figure F 13 Control Board Plug Locations ...

Page 98: ...52 F 52 PRECISION TIG 275 NOTES Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 99: ...achine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proce...

Page 100: ...m the output bridge See Figure F 14 10 Using a 3 8 nut driver remove the four SCR bridge mounting bolts Note insulator washer placement upon removal REPLACEMENT PROCEDURE 1 Replace the SCR bridge 2 Replace the four SCR bridge mounting bolts previously removed Note Be sure to replace insulating wash ers in their proper positions 3 Reconnect lead 218 and Pos lead previ ously removed 4 Replace the sh...

Page 101: ...rn to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING REPAIR SCR BRIDGE REMOVAL AND REPLACEMENT continued Negative LIFT BAIL STABILIZER 217 B G4 G3 G2 G1 Pos X1 Shunt 220A Bridge Mounting Bolts 216 218 Figure F 14 SCR BRIDGE CONNECTIONS ...

Page 102: ...r paper towel 4 Inspect the mounting surfaces of each new diode Remove all burrs and wipe clean Do not use steel wool or any abrasive cleanser on the diode mounting surface 5 Apply a thin 0 0003 to 0 0007 uniform layer of E1868 Dow Corning 340 heat sink compound to the heat sink mounting surface a Do not apply compound to diode stud or mounting threads b The diode threads must be clean and free of...

Page 103: ...hine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed...

Page 104: ... removed nameplate 10 The polarity switch is ready for removal REPLACEMENT PROCEDURE 1 Replace the polarity switch 2 Secure the polarity switch in its original posi tion with the 7 16 mounting nuts 3 Firmly press the lower nameplate back into its original position on the case front 4 Press the polarity switch handle back onto its shaft 5 Secure polarity switch handle with the phillips head screw p...

Page 105: ...your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION T...

Page 106: ...he SCR mounting surface using a putty knife or similar tool DO NOT SCRATCH THE SCR MOUNTING SURFACE 6 Polish each heat sinkʼs mounting surface using NO 000 fine steal wool Wipe surface clean with a lint free cloth or paper towel 7 Inspect the mounting surfaces of each new SCR a Remove all burrs and wipe clean Do not use steel wool or any abrasive cleanser on the SCR mounting sur faces 8 Apply a th...

Page 107: ...achine must be retested INPUT IDLE AMPS Input Volts Hertz 208 60 230 60 460 60 575 60 Maximum Idle Amps without PFC 6 5 3 2 Maximum Idle Amps without PFC 36 32 16 13 OPEN CIRCUIT VOLTAGES MAXIMUM AC OPEN CIRCUIT VOLTAGE MAXIMUM DC OPEN CIRCUIT VOLTAGE 75 VAC 68 VDC MAXIMUM ACCEPTABLE OUTPUT VOLTAGE AT MINIMUM OUTPUT SETTINGS DC TIG Mode 2 Amps 20 Volts MAXIMUM ACCEPTABLE OUTPUT VOLTAGE AT MAXIMUM ...

Page 108: ...62 NOTES PRECISION TIG 275 F 62 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 109: ...age 2 G 14 Control P C Board Schematic Codes above 11000 G4762 Page 3 G 15 Control P C Board Schematic Codes above 11000 G4762 Page 4 G 16 Control P C Board Schematic Codes above 11000 G4762 Page 5 G 17 Control P C Board Assembly Codes above 11000 G4763 1 G 18 Protection P C Board Schematic M16115 G 19 Protection P C Board Assembly M16062 1 G 20 ByPass Stabilizer P C Board Schematic S22530 1 Code ...

Page 110: ...NNECT PANEL H4 H2 H1 H3 250 S1 POWER SWITCH H1 C5 C4 CAPACITORS OPTIONAL POWER FACTOR C2 A GROUND HIGH MID LOW COM 251 2 1 3 4 5 6 8 9 10 7 2 1 3 4 5 6 8 9 10 7 J2 J3 2 1 3 4 5 6 8 9 10 7 OR N C 230 VOLT CONNECTION CONNECT STRAP TO MID H3 208 VOLT CONNECTION CONNECT STRAP TO LOW H2 407 L1 U L2 V FRONT ELECTRODE REAR ELECTRODE WORK TRANSFORMER PRIMARY THERMOSTAT TRANSFORMER SECONDARY THERMOSTAT PUL...

Page 111: ...C1 RECONNECT PANEL H4 H2 H1 250 S1 POWER SWITCH H1 C5 C4 CAPACITORS OPTIONAL POWER FACTOR C2 A GROUND HIGH MID LOW COM 251 2 1 3 4 5 6 8 9 10 7 2 1 3 4 5 6 8 9 10 7 J2 J3 2 1 3 4 5 6 8 9 10 7 OR N C 460 VOLT CONNECTION CONNECT STRAP TO LOW H2 407 L1 U L2 V FRONT ELECTRODE REAR ELECTRODE WORK TRANSFORMER PRIMARY THERMOSTAT TRANSFORMER SECONDARY THERMOSTAT PULSE 2 STEP 401 404 ON OFF 411 401A 4 STEP...

Page 112: ...P POSITION N F PLUGS INTO LOWER SWITCHED RECEPTACLE PRECISION TIG 275 WIRING DIAGRAM L9 L10 L7 L6 L5 L12 L4 L13 L11 J3 N D N C C1 RECONNECT PANEL H4 H2 H1 H3 S1 POWER SWITCH H1 CAPACITORS OPTIONAL POWER FACTOR C2 GROUND HIGH MID LOW COM 251 2 1 3 4 5 6 8 9 10 7 2 1 3 4 5 6 8 9 10 7 J2 J3 2 1 3 4 5 6 8 9 10 7 OR N C 380 400 VOLT CONNECTION CONNECT STRAP TO MID H3 220 230 VOLT CONNECTION CONNECT STR...

Page 113: ... ADVANCED CONTROL PANEL OPTIONAL PANNEAU DE COMMANDE AVANCÉ OPTION PANEL DE CONTROL AVANZADO OPCIONAL BACKGROUND ARRIÈRE PLAN FONDO PRISE À DISTANCE RECEPTÁCULO REMOTO PROTECTION PCB CI PROTECTION PCB DE PROTECCIÓN TIG OPTION PCB CI OPTION TIG PCB DE OPCIÓN TIG CONTROL PC BOARD CI DE COMMANDE TABLEAU DE TARJETA ELECTRONICA DE CONTROL VENTILATEUR VENTILADOR ÉCLATEUR ABERTURA DE CHISPA ARC STARTER A...

Page 114: ...D A E C F G H S2 S2A CLOSED FERMÉ CERRADO OPEN OUVERT ABIERTO CLOSED FERMÉ CERRADO VENTILATEUR VENTILADOR TARJETA ELECTRONICA DE DERIVACIÓN ESTABILIZADOR ARC STARTER AS BLY ENSEMBLE DÉMARREUR D ARC ENSAMBLE DE ARRANCADOR DE ARCO REAR ELECTRODE ÉLECTRODE ARRIÈRE ELECTRODO POSTERIOR FRONT ELECTRODE ÉLECTRODE AVANT ELECTRODO FRONTAL WORK PIÈCE TRABAJO VIEW OF CONNECTOR ON PC BOARD ELECTRICAL SYMBOLS ...

Page 115: ...ECTIFIER X14 231B 231E 236 TOROID TOROID HI FREQ 115VAC GAS 115VAC FAN 115VAC 235 260 265 266 252 253 MICRO SWITCH ON POLARITY SWITCH VOLT FEEDBACK ELECTRODE VOLT FEEDBACK WORK 265 266 252 253 MICRO SWITCH ON POLARITY SWITCH TOROID 6J11 12J11 1J11 9J11 POWER SWITCH MICRO SWITCH 215 212 212 215 PRECISION TIG 375 ONLY PRECISION TIG 375 ONLY PRECISION TIG 275 ONLY 262 263 214 213 TSTAT TSTAT COOLER 1...

Page 116: ... BALANCE REMOTE RED GREEN GREEN GAS GREEN THERMAL YELLOW B W B W B W B W 331 332 333 B W 334 335 331 331 332 332 333 333 334 334 335 335 B W B W B W B W B W 6J10 1J10 7J10 2J10 8J10 3J10 9J10 4J10 10J10 5J10 TOROID LED LIGHTS R9 CW CW R10 FREQUENCY ON TIME CW R12 DOWN SLOPE 401C 401D 402 403 405 406 407 CW R11 BACK GROUND B W PULSE OFF TRIGGER 4 STEP 2 STEP 401B 404 401A 411 401 408 409 410 FREQ 0...

Page 117: ...908 PAGE 1 G 9 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 118: ...908 PAGE 2 G 10 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 119: ...908 PAGE 3 G 11 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 120: ...0 183 CAPACITOR ALEL 120MF 50V 20 C49 C60 2 S16668 7 CAPACITOR CEMO 820pF 50V 5 C53 1 S13490 92 CAPACITOR ALEL 3300 50V 30 10 C81 C82 C98 C99 C117 C131 C133 C135 C136 C137 C140 C160 C161 C162 C163 15 T11577 58K CAPACITOR CD 0047 3000V 20 C84 1 S13490 40 CAPACITOR TAEL 2 7 50V 10 C93 C108 2 S16668 1 CAPACITOR CEMO 22pF 100V 5 C95 C96 C97 3 T11577 46K CAPACITOR CD 05 600V 80 20 C102 C138 2 S16668 9 ...

Page 121: ...762 PAGE 1 G 13 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 122: ...762 PAGE 2 G 14 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 123: ...762 PAGE 3 G 15 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 124: ...762 PAGE 4 G 16 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 125: ...762 PAGE 5 G 17 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 126: ...16668 6 CA PACITOR CEM O 4700pF 50V 10 C10 C24 C58 3 S16668 3 CA PACITOR CEM O 100pF 100V 5 C14 C15 C141 3 S13490 181 CA PACITOR ALEL 22 63V 20 C18 C19 C37 C38 C62 C72 C73 C74 C75 C79 C80 C88 C91 C104 C107 C112 C128 C134 C142 C144 C145 C146 C147 C150 C151 C152 C153 C154 C156 C159 C170 31 S16668 5 CA PACITOR CEM O 022 50V 20 C22 C51 2 T11577 54 CA PACITOR CD 750PF 1000V 10 C23 C52 2 S13490 183 CA P...

Page 127: ...D MAY CHANGE J23 2 MFD CAPACITORS RESISTORS Ohms UNLESS OTHERWISE SPECIFIED 1A 400V ELECTRICAL SYMBOLS PER E1537 DIODES UNLESS OTHERWISE SPECIFIED GENERAL INFORMATION 1 4W 022 50V LABELS UNLESS OTHERWISE SPECIFIED _ _ _ LAST NO USED D R C J23 5 J23 3 39mH L4 39mH L1 J22 5 J22 4 J22 1 J22 2 J22 6 3000V 0047 C5 3000V 0047 C1 3000V 0047 C2 3000V 0047 C6 J22 3 39mH L2 J23 8 3000V 0047 C3 39mH L6 39mH ...

Page 128: ...nd may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTRICAL DIAGRAMS G 20 PRECISION TIG 275 PC BOARD ASSEMBLY PROTECTION M16062 1 IDENTIFICATION 0047 3000 V 39 mH HEADER HEADER P C BD BLANK T11577 58 T12218 9F S18248 6 S18248 8 L8081 B PART NO REQ D 6 6 1 1 1 C1 C2 C3 C4 C5 C6 1 L1 L2 L3 L4 L5 L6 J22 J23 1 9 28 2001M CAPA...

Page 129: ...TED 1 4W OF A COMPLETE ELECTRICAL SYMBOLS PER E1537 EARTH GROUND CONNECTION Graphic Graphic FRAME CONNECTION ARC STABILIZER CAPACITOR RESISTOR N A SHOW THE EXACT COMPONENTS COMMON CONNECTION AND SCREW TO STEEL STANDOFF ON MACHINE MFD 022 50V CAPACITORS UNLESS OTHERWISE SPECIFIED SINCE COMPONENTS OR CIRCUITRY ON RESISTORS Ohms POWER SUPPLY SOURCE POINT VOLTAGE NET 1A 400V CONTROLS HAVING A COMMON C...

Page 130: ...he quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTRICAL DIAGRAMS G 22 PRECISION TIG 275 PC BOARD ASSEMBLY BYPASS STABILIZER L10121 1 CODE 10806 10807 IDENTIFICATION IDENTIFICATION PART NO PART NO REQ D REQ D ITEM ITEM BYPASS STABILIZER L10121 1 XXX XXXXXXXXXXX XXXXXXXXXXX XXX XXXXXXXXXXX XXX ...

Page 131: ...TION OWNED BY THE LINCOLN ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF UNLESS OTHERWISE SPECIFIED THE LINCOLN ELECTRIC CO CIRCUIT BOARD S WITH PUBLISHED STANDARDS WITHOUT AFFECTING THE INTERCHANGEABILITY SHOW THE EXACT COMPONENTS EQUIP NOTES MFD 022 50V 24206 CAPACITORS BOARD SINCE COMPONENTS OR CIRCUITRY ON ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOL...

Page 132: ...ay result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTRICAL DIAGRAMS G 24 PRECISION TIG 275 PC BOARD ASSEMBLY BYPASS AND CE L10882 1 CODE 10893 3 20 98 10882 1 L IDENTIFICATION PART NO REQ D ITEM BYPASS L10882 1 B Y P A S S L 1 0 8 8 2 1 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x...

Page 133: ...G4039 PAGE 1 G 25 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 134: ...G4039 PAGE 2 G 26 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 135: ...FR DZ1 1 S 25046 1SM T ZENE R DIODE SM D 0 5W 5 1V 5 SOD123 DZ2 DZ3 2 S 25046 4SM T ZENE R DIODE SM D 0 5W 12V 5 S OD 123 N D J1 1 S 24020 12 CONNE CTOR M OLE X M INI PCB 12 PIN TIN N D J2 J3 2 S 21135 10 CONNE CTOR M OLE X M INI BLIND F 10 P IN LED1 LED2 2 S 25080 2SM T LED S M D GRE EN CLEA R S1206 Q1 Q5 2 S 25051 4SM T TRANSISTOR S M D NM F SOT 23 0 115A 60V 7002LT1 SS Q2 Q3 Q4 Q6 Q7 5 S 25050 ...

Page 136: ...G4760 PAGE 1 G 28 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 137: ...G4760 PAGE 2 G 29 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 138: ...G4760 PAGE 3 G 30 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 139: ...IC 2700pF 50V 5 X7R S 0805 C9 C27 C28 C46 4 S25020 27S M T CA PACITOR SM D CER 0 1M F 50V 20 80 Z5U S0805 C11 1 S25020 9SM T CA PACITOR SM D CERAM IC 47pF 50V 5 COG S 0805 C35 C36 C37 C48 4 S25020 24S M T CA PACITOR SM D CERAM IC 1 0M F 25V 10 X7R S1206 C60 1 S25020 14S M T CA PACITOR SM D CERAM IC 330pF 100V 5 COG S0805 D1 1 S25040 2SM T DIODE SM D 1A 400V DO 214BA AC D2 D3 D4 D5 D6 D7 D8 7 S2504...

Page 140: ...tion below ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ _________...

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