RETURN TO MAIN MENU IM703-A PRECISION TIG 375 For use with machines having Code Numbers: November, 2004 10809; 10810; 10894 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS For Gasoline Engines: The engine exhaust from For Diesel Engines: Diesel engine exhaust and this product contains chemicals known to the some of its constituents are known to the State State of California to cause cancer, birth defects, of California to cause cancer, birth defects, and or other reproductive harm. other reproductive harm. ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 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 bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 3.b.
iii iii SAFETY WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the 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.
iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi vi TABLE OF CONTENTS Page. Installation ..........................................................................................................Section A Technical Specifications ........................................................................................A-1,A-2 Safety Precautions.. ............................................................................................................................................... .A-3 Select Suitable Location ..................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS-PRECISION TIG 375 (K1903-1 Domestic Package*-60Hz) (K1833-1 Domestic,K1833-2 Canadian-60Hz) (K1834-1 Export-50/60Hz) RATED INPUT - SINGLE PHASE ONLY K Number K1833-1 K1903-1 R NRTL/C K1833-2 R NRTL/C K1834-1 N80 IEC 60974-1 Duty Cycle-Applications 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 Am
A-2 A-2 INSTALLATION RATED OUTPUT - IEC 60974-1 (K1834-1) Duty Cycle-Applications 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 Volts at Rated Amperes Amps 35.0 24.0 375 350 34.0 23.0 350 325 32.0 21.
A-3 INSTALLATION A-3 SAFETY PRECAUTIONS ENVIRONMENTAL RATING Read entire installation section before starting installation. Precision TIG 375 power sources carry an IP21S Environmental rating. They are rated for use in damp, dirty rain-sheltered environments. WARNING MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation.
A-4 A-4 INSTALLATION 3. Be sure the torch and work cable rubber coverings are free of cuts and cracks that allow high frequency leakage. Cables with high natural rubber content, such as Lincoln Stable-Arc® better resist high frequency leakage than neoprene and other synthetic rubber insulated cables. INPUT and GROUNDING CONNECTIONS WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. 4.
A-5 A-5 INSTALLATION Welders are shipped connected for the highest input voltage as listed on the rating plate. To change this connection, designations on the reconnect panel LOW, MID, and HIGH correspond to the name plated input voltages of a triple voltage welder. Dual voltage welders use only LOW and HIGH. Recommended Cable Sizes for Combined Lengths of Copper Work and Electrode Cables using 75o C Wire: EXAMPLE: On a 208/230/460 volt welder, LOW is 208V, MID is 230V, and HIGH is 460V.
A-6 A-6 INSTALLATION FIGURE A.
A-7 A-7 INSTALLATION FIGURE A.
A-8 A-8 INSTALLATION ROBOTIC INTERFACE CONNECTION Robotic interface can be made at the Remote Receptacle (See Operation Section B-2). The machine is shipped with the remote receptacle circuit internally connected to receptacle J5 of the Control board for standard Amptrol operation. In order to enable the remote receptacle for robotic interface its connection plug must be moved from J5 to J5A on the Control board. (Refer to the machine Wiring Diagram.
OPERATION B-1 B-1 SAFETY PRECAUTIONS PRODUCT DESCRIPTION Read and understand this entire section before operating the machine. The Precision TIG 375 is part of a new family of industrial arc welding power sources providing constant current, single range square wave AC/DC TIG (GTAW) with new patented (pending) Micro-StartTM Technology, Presettable Min. and Max. Output controls, and built-in high frequency stabilization for continuous AC TIG and DC TIG starting.
B-2 OPERATION RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Precision TIG 375 is recommended for the TIG (GTAW) and Stick (SMAW) welding processes within its output capacity range of 2 amps DC, or 5 amps AC, to 420 amps AC/DC. It is compatible with most Magnum TIG accessories (refer Equipment Limitations), as well as many industry standard items, such as TIG torches, hoses, and water coolers.
B-3 B-3 OPERATION CONTROLS AND SETTINGS The Front Control Panel contains the knobs and switches necessary for adjusting the operation of the Precision TIG 375, with function indicator lights and an electronic display for volts and amps. The components are described below: FIGURE B.1 - CONTROL PANEL 1. POWER SWITCH 2. POLARITY SWITCH 3. MODE SWITCH 4. AC BALANCE CONTROL 5. LOCAL/REMOTE CURRENT CONTROL SWITCH 6. MAXIMUM OUTPUT CONTROL 7. MINIMUM OUTPUT CONTROL AND DISPLAY SWITCH 8.
B-4 OPERATION • When the Polarity Switch is set to DC (- or +), the TIG mode provides high frequency only for starting. Hi-Freq. turns on after pre-flow time with the arc start switch closure, and turns off when the arc is established* • Also functions for DC+ polarity to permit "balling" of tungsten for AC TIG welding. 4. AC BALANCE CONTROL – The potentiometer control permits AC wave balance adjustment from Max. Penetration (~85% negative wave) with the control at Max. full CW position, to Max.
B-5 B-5 OPERATION 8. DIGITAL METER AND DISPLAY SWITCH– A 3digit LED meter is used to monitor the preset and actual welding procedure based on the Display (momentary) switch position: • Before welding with Display switch in center (normal) position, the digital meter displays the preset welding amps set by Maximum Output control knob (See Item 6). If in Stick mode using REMOTE (See Item 5.), the digital meter displays the preset welding amps set by the Remote control.
B-6 OPERATION • In 4-Step position allows welding without continuously holding the start switch trigger. The arc start switch functions in the following manner: 1. Closing switch starts preflow, then arc starts at Minimum (Start) setting level (See Item 7). If the trigger is maintained closed after preflow time the output remains at the Start level until it is released. 2. Opening switch initiates fixed (0.5 sec.) ramp time from Start setting level to Weld setting. 3.
B-7 OPERATION INTERNAL SET UP CONTROLS Precision TIG 375 Advanced Panel has the following additional control features which are set up using the DIP Switch (S1) provided on the internal panel of this option.
B-8 OPERATION FIGURE B.
B-9 OPERATION FIGURE B.
B-10 B-10 OPERATION TIG WELD CYCLE CHART 2 or 4-STEP Trigger Closed 4-STEP Trigger ST 1 Open SEE ITEM 12 SEE ITEM 12 With PULSE ON No Pulsing During Upslope Time or When Downslope Drops Below Background Setting MAXIMUM OUTPUT SETTING Adjustable 2-Max.A 4-STEP Trigger Re-closed or 2-STEP Trigger Opened 4-STEP Trigger Re-opened after Downslope Time SEE ITEM 12 SEE ITEM 12 CRATER-FILL LEVEL Advanced Panel Select: SEE ITEM 6 Amptrol or Remote (PEAK) Range Mach. Min. or MIN.
B-11 B-11 OPERATION The new foot pedal provides such independent action distinction of precisely where the arc start switch actuates without over-riding minimum control pedal position, and precisely where the control pedal has been returned to minimum position without inadvertently deactuating the arc start switch. The result is repeatable consistency in TIG weld starting and crater-fill for manual process control.
B-12 B-12 OPERATION Close the arc start switch. This opens the gas valve to automatically purge air from the hose and torch, then shields the arc strike area. After the 0.5 second preflow time, the high frequency becomes available to strike the arc. When the arc strikes the torch coolant (if used) starts to flow. Also, if welding DC- TIG, the high frequency shuts off just after the arc strikes. MAKING A TIG WELD WITH AN AMPTROL 1. Install welding equipment per Section A-5. 2.
C-1 ACCESSORIES OPTIONAL EQUIPMENT FACTORY INSTALLED OPTIONS The basic Precision TIG 375 machine is factory equipped with: • K1829-1 Precision TIG Advanced Control Panel. Provides 2/4-step trigger with adjustable Pulser controls and Down slope timer for TIG welding. Also includes adjustable Hot Start and Arc Force internal panel controls for stick welding and other user selectable features. • Power Factor correction capacitor. • A 3/8" Adapter (S20403-4) for air cooled torch connection.
D-1 MAINTENANCE SAFETY PRECAUTIONS D-1 OVERLOAD PROTECTION FAN-AS-NEEDED (F.A.N.) WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. WARNING To avoid receiving a high frequency shock, keep the TIG torch and cables in good condition.
D-2 D-2 MAINTENANCE FIGURE C.1 SPARK GAP SERVICE PROCEDURES Operation of the Precision TIG should be trouble-free for the life of the machine. Should a malfunction occur, however, the following procedures will be useful to trained service personnel with experience in repairing arc welding equipment: .
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 technician and 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Thermal light comes on 1. Thermal shut down. Dirt and dust may have clogged the cooling channels inside machine; air intake and exhaust louvers may be blocked.; welding application may exceed recommended duty cycle. Wait until machine cool down and thermal light goes out.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS RECOMMENDED COURSE OF ACTION METER PROBLEMS Meter does not light up 1. Bad meter or its connection 2. Bad connection at P8 of Control PC board 3. Faulty Control PC board Meter does not display V (Volt) or Min A (Minimum current) 1.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS RECOMMENDED COURSE OF ACTION HI-FREQ PROBLEMS No hi-freq 1. Circuit breaker CB1 open 2. Bad connection at P12 of Control PC board 3. Spark gaps shorted 4. Faulty Control PC board Hi-freq intensity too weak 1. Dirty spark gap or improper gap setting 2. Faulty Arc Starter assembly Hi-freq on continuously in DC Tig Hi-freq shuts off after starting in AC Tig 1.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS RECOMMENDED COURSE OF ACTION PRESET & OUTPUT CONTROL PROBLEMS Meter does not display preset 1. Faulty potentiometer R1 or its connection 2. Bad connection at P9 of Control PC board 3. Faulty Advanced Control PC board ( if present ) or its connection to the main Control PC board 4.
E-6 E-6 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS RECOMMENDED COURSE OF ACTION STICK WELDING PROBLEMS Stick electrode "blast off" when arc is struck 1. Current may be set too high for electrode size Stick electrode "sticks" in the weld puddle 2.
E-7 E-7 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS RECOMMENDED COURSE OF ACTION TIG PROBLEMS Arc "pulsates" in AC polarity, DC 1.Micro switch S2A on polarity switch polarity is o.k. does not open in AC polarity Black area along weld bead 1. Oily or organic contamination from work piece 2. Tungsten electrode may be contaminated 3. Leaks in gas line, torch, or connections Output quits momentarily; gas flow 1.
TIG MODE (STICK) 316C + R R9 FREQ B 2-STEP TRIGGER 4-STEP W - R4 A B C D E F 401C B DISPLAY W R10 ON TIME REMOTE RECEPTACLE A B C D E F OFF PULSE ON W L8 - G + (PULSE ON) A B C D E F 4 1 2 3 6 5 R12 R11 BACKGROUND Y W DOWN SLOPE B - + G B W B + G - (THERMAL) (P. FLOW) (REMOTE) B R3 R1 313A POST FLOW N.C.
TIG MODE (STICK) 316C + R R9 FREQ B 2-STEP TRIGGER 4-STEP W - R4 A B C D E F 401C B DISPLAY W R10 ON TIME REMOTE RECEPTACLE A B C D E F OFF PULSE ON W L8 - G + (PULSE ON) A B C D E F 4 1 2 3 6 5 R12 R11 BACKGROUND Y W DOWN SLOPE B - + G B W B + G - (THERMAL) (P. FLOW) (REMOTE) B R3 R1 313A POST FLOW N.C.
TIG MODE (STICK) 316C R9 FREQ B + R 319 2-STEP TRIGGER 4-STEP R2 W - R4 A B C D E F 401C B W R10 ON TIME REMOTE RECEPTACLE A B C D E F OFF PULSE ON W L8 - G + (PULSE ON) A B C D E F 4 1 2 3 6 5 R12 R11 BACKGROUND Y W DOWN SLOPE B - + G B W B + G - (THERMAL) (P. FLOW) (REMOTE) B R3 R1 313A POST FLOW N.C.
PRECISION TIG 375 27.97 27.16 49.67 43.20 18.67 5.86 3.47 K1903-1 DOMESTIC PACKAGE 45.31 40.96 6.84 13.
PRECISION TIG 375 .75 .30 11.00 22.00 20.50 ** ** LOCATION OF (4) O.284 BASE MOUNTING HOLES. 3.44 TORCH HOLSTER 2.11 TORCH BOX 31.00 3.47 1.00 .28 12.77 K1833-1 DOMESTIC, K1833-2 CANADA AND K1834-1 EXPORT 26.00 24.00 ** L11660 XB-UF 2.
NOTES PRECISION TIG 375
WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO l Do not touch electrically live parts or electrode with skin or wet clothing. l Insulate yourself from work and ground. l Keep flammable materials away. l Wear eye, ear and body protection. l No toque las partes o los electrodos bajo carga con la piel o ropa mojada. l Aislese del trabajo y de la tierra. l Mantenga el material combustible fuera del área de trabajo.
Keep your head out of fumes. Use ventilation or exhaust to remove fumes from breathing zone. l Los humos fuera de la zona de respiración. l Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. l Desconectar el cable de alimentación de poder de la máquina antes de iniciar cualquier servicio. l No operar con panel abierto o guardas quitadas. Spanish Gardez la tête à l’écart des fumées. Utilisez un ventilateur ou un aspirateur pour ôter les fumées des zones de travail.
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