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IM898
PRECISION TIG 375 |
March, 2008 |
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For use with machines having Code Numbers: 11161, 11162 |
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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. And, most importantly, think before you act and be careful.
Precision TIG 375 Welding
Package shown with optional
Advanced Control Panel
IP21S
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
•World's Leader in Welding and Cutting Products •
•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
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SAFETY
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WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
For Diesel Engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
For Gasoline Engines: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
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 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 of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes
outdoors.
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1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
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1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
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1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.
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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may 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, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure them 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 and work 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 as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ʻ95
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SAFETY |
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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 bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the 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 semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should 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 and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin 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 expose themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES can be dangerous.
5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5.b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturerʼs instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employerʼs safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
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SAFETY
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WELDING and CUTTING
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. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to physical damage.
•A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
Jan, 07
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SAFETY |
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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 LʼArc
1.Protegez-vous contre la secousse électrique:
a.Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b.Faire trés attention de bien sʼisoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c.Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le refroidir.
e.Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f.Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode sʼapplicuent aussi au pistolet de soudage.
2.Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de nʼimporte quelle partie du corps.
3.Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a.Utiliser un bon masque avec un verre filtrant approprié ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.
b.Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de lʻarc.
c.Protéger lʼautre personnel travaillant 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, pantalons sans revers, et chaussures montantes.
5.Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier.
6.Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles.
7.Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8.Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils se rompent.
9.Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10.Ne pas souder en présence de vapeurs de chlore provenant dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11.Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1.Relier à la terre le chassis du poste conformement au code de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2.Autant que possible, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.
3.Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4.Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ʻ93
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Thank You
v 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!
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
-Register your machine with Lincoln Electric either via fax or over the Internet.
•For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
•For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy 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:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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TABLE OF CONTENTS |
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Page. |
Installation .......................................................................................................... |
Section A |
Technical Specifications ........................................................................................ |
A-1,A-2 |
Safety Precautions.. ............................................................................................................................................... |
.A-3 |
Select Suitable Location........................................................................................ |
A-3 |
Grinding ................................................................................................................. |
A-3 |
Stacking................................................................................................................. |
A-3 |
Undercarriage Lifting and Moving ......................................................................... |
A-3 |
Tilting ..................................................................................................................... |
A-3 |
Environmental Rating ............................................................................................ |
A-3 |
Machine Grounding and High Frequency Interference Protection ....................... |
A-3, A-4 |
Input and Grounding Connections.............................................................................. |
A-4 |
Output Cable, Connections and Limitations ................................................................ |
A-5 |
Work Cable Connection .................................................................................. |
A-5 |
Stick Electrode Cable Connection .................................................................. |
A-5 |
TIG Torch Connection ..................................................................................... |
A-6 |
Auxiliary Power Connections .......................................................................... |
A-7 |
Remote Control (If Used)................................................................................ |
A-7 |
Robotic Interface Connection .................................................................. |
A-7, A-8 |
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OPERATION.......................................................................................................................................................... |
Section B-1 |
Safety Precautions....................................................................................................... |
B-1 |
Product Description...................................................................................................... |
B-1 |
Pipe Thawing......................................................................................................... |
B-1 |
Duty Cycle: ............................................................................................................ |
B-1 |
Recommended Processes and Equipment........................................................... |
B-2 |
Controls and Settings ............................................................................. |
B-3 Thru B-6 |
Internal Set Up Controls........................................................................................ |
B-7 |
Stick Welding Features.......................................................................................... |
B-7 |
TIG Welding Features ........................................................................................... |
B-7 |
2 Step Trigger Modes...................................................................................... |
B-8 |
4 Step Trigger Modes .................................................................................... |
B-9 |
TIG Welding Cycle Chart .................................................................................... |
B-10 |
Setup Guidelines for TIG Welding with an Amptrol..................................... |
B-10, B11 |
Making a TIG Weld with an Amptrol.................................................................... |
B-12 |
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Accessories ............................................................................................................................................... |
.......Section C |
Optional Equipment ..................................................................................................... |
C-1 |
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Maintenance...................................................................................................................................................... |
Section D |
Safety Precautions....................................................................................................... |
D-1 |
Routine and Periodic Maintenance.............................................................................. |
D-1 |
Overload Protection ..................................................................................................... |
D-1 |
Service Procedures, Component Access,Spark Gap Adjustment ............................... |
D-2 |
Under-Cooler Service .................................................................................................. |
D-2 |
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Troubleshooting............................................................................................................................................. |
Section E |
Safety Precautions....................................................................................................... |
E-1 |
How To Use TroubleShooting Guide............................................................................ |
E-1 |
Troubleshooting ................................................................................................. |
E-2 to E-7 |
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Diagrams.............................................................................................................................................................. |
Section F |
Wiring Diagrams .............................................................................................................................................. |
F-1, F-2 |
Dimension Prints ............................................................................................................................................. |
F-3, F-4 |
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Parts List |
......................................................................................................................................................................P-558 |
A-1 |
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INSTALLATION |
A-1 |
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TECHNICAL SPECIFICATIONS-PRECISION TIG 375 (K2624-1 Domestic Package*-60Hz) |
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(K2622-1 Domestic,K2622-2 Canadian-60Hz) |
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RATED INPUT - SINGLE PHASE ONLY |
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Duty Cycle-Applications |
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Voltage + 10% |
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Max. Amps With Power Factor Capacitor |
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40% |
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AC/DC Stick / Balance TIG |
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112/102/51 |
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Unbalance (70% Penetration#) AC TIG |
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139/126/63 |
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K2622-1 |
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60% |
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AC/DC Stick / Balance TIG |
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102/92/46 |
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K2624-1 |
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Unbalance (70% Penetration#) AC TIG |
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208/230/460 |
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128/116/58 |
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100% |
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80/72/36 |
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AC/DC Stick / Balance TIG |
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Unbalance (70% Penetration#) AC TIG |
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104/92/47 |
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68/62/31 |
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Idle Amps |
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40% |
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AC/DC Stick / Balance TIG |
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102/51/41 |
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Unbalance (70% Penetration#) AC TIG |
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125/63/50 |
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60% |
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AC/DC Stick / Balance TIG |
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92/46/37 |
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Unbalance (70% Penetration#) AC TIG |
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116/58/46 |
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K2622-2 |
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100% |
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230/460/575 |
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AC/DC Stick / Balance TIG |
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72/36/29 |
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Unbalance (70% Penetration#) AC TIG |
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94/47/38 |
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Idle Amps |
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62/31/25 |
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Rated Power Factor (Stick) |
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.86 min. |
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Idle Power |
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1.0KW |
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RATED OUTPUT - NEMA EW1 Class ll (40)
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Duty Cycle-Applications |
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Volts at Rated Amperes |
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Amps |
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40% |
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AC/DC Stick / Balance TIG |
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35.0 |
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375 |
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Unbalance (70% Penetration#) AC TIG |
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17.2 |
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350 |
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60% |
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AC/DC Stick / Balance TIG |
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34.0 |
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350 |
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Unbalance (70% Penetration#) AC TIG |
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16.9 |
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325 |
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100% |
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AC/DC Stick / Balance TIG |
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32.0 |
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300 |
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Unbalance (70% Penetration#) AC TIG |
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16.3 |
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275 |
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*Shown on Front of this IM manual with Under-Cooler Cart and Advanced Control Panel (Refer to Optional Equipment)
#Exceeds NEMA Unbalanced Load Specification comparable for Auto-Balance.
PRECISION TIG 375
A-2 |
INSTALLATION |
A-2 |
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ADDITIONAL OUTPUT CAPACITY
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Output Current |
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Maximum Open |
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Type of Output |
Range |
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Circuit Voltage |
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2Amps DC |
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(STICK AND TIG) |
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to |
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CC (Constant Current) |
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AC/DC OCV: 80 |
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420Amps AC-DC* |
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AC/DC (GTAW) |
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Stick (SMAW) |
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Auxiliary Power
15Amp Circuit Breaker and NEMA 5-15R Duplex Receptacle for up to:
115VAC 8 Amp Auxiliary Power Receptacle 115VAC 5 Amp weld Switched Cooler Receptacle
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RECOMMENDED INPUT WIRE AND FUSE SIZES |
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For all Stick, DC TIG, and Balanced AC TIG Welding |
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For Unbalanced AC TIG Welding Above 275 Amps: |
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at 375A/40% Duty Cycle with out Standard Power |
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350A/40% Duty Cycle, Auto-Balance Penetration with |
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Factor Correction Capacitors |
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out Standard Power Factor Correction Capacitors |
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Based on the 1999 U.S. National Electrical Code |
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Based on the 1999 U.S. National Electrical Code |
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Input |
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Type 75°C |
Type 75°C |
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Type 75°C |
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Type 75°C |
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Input |
Fuse |
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Ampere |
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Copper Wire in |
Copper |
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Fuse |
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Input |
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Copper Wire in |
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Copper |
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Voltage / |
(Super Lag) |
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Rating |
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Conduit AWG |
Ground Wire in |
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(Super Lag) |
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Ampere |
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Conduit AWG |
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Ground Wire in |
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phase/ |
or Breaker |
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Rating on |
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(IEC) Sizes |
Conduit AWG |
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or Breaker |
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Rating |
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(IEC) Sizes |
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Conduit AWG |
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40°C (104°F) |
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40°C (104°F) |
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Frequency |
Size1 |
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Nameplate |
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Ambient |
(IEC) Sizes |
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Size1 |
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Ambient |
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(IEC) Sizes |
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208/1/60 |
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150 |
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112 |
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3 (26.7 mm2) |
6 (13.3 mm2) |
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200 |
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139 |
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1 (42.4 mm2) |
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6 (13.3 mm2) |
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230/1/60 |
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150 |
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102 |
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3 (26.7 mm2) |
6 (13.3 mm2) |
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175 |
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126 |
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2 (33.6 mm2) |
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6 (13.3 mm2) |
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460/1/60 |
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80 |
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51 |
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6 (13.3mm2) |
8 (8.4 mm2) |
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80 |
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63 |
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6 (13.3 mm2) |
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8 (8.4 mm2) |
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575/1/60 |
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50 |
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41 |
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8 (8.4 mm2) |
10 (5.3mm2) |
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70 |
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50 |
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6 (13.3 mm2) |
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8 (8.4 mm2) |
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220-230/1/50/60 |
150 |
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119 |
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3 (26.7 mm2) |
6 (13.3 mm2) |
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150 |
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118 |
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3 (26.7 mm2) |
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6 (13.3 mm2) |
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380-400/1/50/60 |
110 |
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69 |
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4 (21.2 mm2) |
6 (13.3 mm2) |
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110 |
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68 |
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4 (21.2 mm2) |
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6 (13.3 mm2) |
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415/1/50/60 |
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110 |
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63 |
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4 (21.2 mm2) |
6 (13.3 mm2) |
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110 |
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62 |
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4 (21.2 mm2) |
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6 (13.3 mm2) |
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PHYSICAL DIMENSIONS
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Height |
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Width |
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Depth |
Weight |
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K2622-1, -2 |
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31.0 in. |
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22.0 in. |
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26.0 in. |
507 lbs. |
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787 mm |
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559 mm |
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660 mm |
230 kgs. |
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K2624-1 |
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49.7 in. |
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28.0 in. |
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41.0 in. |
751 lbs. |
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1262 mm |
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711 mm |
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1041 mm |
341 kgs. |
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TEMPERATURE RANGES |
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OPERATING TEMPERATURE RANGE |
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STORAGE TEMPERATURE RANGE |
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-20°C to +40°C (-04° to +104°F) |
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-40°C to +85°C (-40° to +185°F) |
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TRANSFORMER INSULATION CLASS |
180°C (H) |
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1 ALSO CALLED ʻINVERSE TIME" OR "THERMAL/MAGNETIC " CIRCUIT BREAKERS; CIRCUIT BREAKERS WHICH HAVE A DELAY IN TRIPPING ACTION THAT DECREASES AS THE MAGNITUDE OF CURRENT INCREASES.
* 50/60HZ IEC Max. range exceeds 310A.
PRECISION TIG 375
A-3 |
INSTALLATION |
A-3 |
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SAFETY PRECAUTIONS
Read entire installation section before starting installation.
WARNING
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 Precision TIG 375 grounding screw (behind the reconnect panel cover located near the back of the left case side) to a good electrical earth ground.
•Always connect the Precision TIG 375 to a power supply grounded in accordance with the National Electrical Code and all local codes.
SELECT SUITABLE LOCATION
Place the welder where clean cooling air can freely circulate in through the top rear vents and out through the bottom rear vents. Dirt, dust or any foreign material that can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance trips.
GRINDING
Do not direct grinding particles towards the welder. An abundance of conductive material can cause maintenance problems.
STACKING
The Precision TIG 375's cannot be stacked .
UNDERCARRIAGE LIFTING AND MOVING
When the Precision TIG 375 is purchased as a welding package, or used with any of the available Undercarriage optional accessories, proper installation makes the Precision TIG 375 lift bale nonfunctional. Do not attempt to lift the power source with an undercarriage attached. The undercarriage is designed for hand moving only; mechanized movement can lead to personal injury and/or damage to the Precision TIG 375.
TILTING
Each machine must be placed on a secure, level surface, either directly or on a recommended undercarriage. The machine may topple over if this precaution is not followed.
ENVIRONMENTAL RATING
Precision TIG 375 power sources carry an IP21S Environmental rating. They are rated for use in damp, dirty rain-sheltered environments.
MACHINE GROUNDING AND 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 (FigureA.1) for this purpose. See your local and national electrical codes for proper grounding methods.
The spark gap oscillator in the high frequency generator, being similar to a radio transmitter, can be blamed for many radio, TV and electronic equipment interference problems. These problems may be the result of radiated interference. Proper grounding methods can reduce or eliminate radiated interference.
The Precision TIG 375 has been field tested under recommended installation conditions and has been found to comply with F.C.C. allowable radiation limits. This welder has also been found to comply with NEMA standards for high frequency stabilized power sources.
Radiated interference can develop in the following four ways:
•Direct interference radiated from the welder.
•Direct interference radiated from the welding leads.
•Direct interference radiated from feedback into the power lines.
•Interference from re-radiation of "pickup" by ungrounded metallic objects.
Keeping these contributing factors in mind, installing the equipment per the following instructions should minimize problems:
1.Keep the welder power supply lines as short as possible. Input leads within 50 feet (15.2 m) of the welder should be enclosed in rigid metallic conduit or equivalent shielding. There must be good electrical contact between this conduit and the welder. Both ends of the conduit must be connected to a driven ground and the entire length must be continuous.
2.Keep the work and electrode leads as short as possible and as close together as possible. Lengths should not exceed 25 feet (7.6 m). Tape the leads together when practical.
PRECISION TIG 375
A-4 |
INSTALLATION |
A-4 |
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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.
4.Keep the torch in good repair and all connections tight to reduce high frequency leakage.
5.The work terminal must be connected to a ground within ten feet of the welder, using one of the following methods:
•A metal underground water pipe in direct contact with the earth for ten feet or more.
•A 3/4" (19 mm) galvanized pipe or a 5/8" (16 mm) solid galvanized iron, steel or copper rod driven at least eight feet into the ground.
The ground should be securely made and the grounding cable should be as short as possible using cable of the same size as the work cable, or larger. Grounding to the building frame electrical conduit or a long pipe system can result in re-radiation, effectively making these members radiating antennas. (This is not recommended).
6.Keep all access panels and covers securely in place.
7.All electrical conductors within 50 feet (15.2 m) of the welder should be enclosed in grounded rigid metallic conduit or equivalent shielding. Flexible helically-wrapped metallic conduit is generally not suitable.
8.When the welder is enclosed in a metal building, several good earth driven electrical grounds (as in 5 above) around the periphery of the building are recommended.
Failure to observe these recommended installation procedures can cause radio or TV interference problems and result in unsatisfactory welding performance resulting from lost high frequency power.
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.
Be sure the voltage, phase, and frequency of the input power is as specified on the rating plate, located on the rear of the machine.
Remove the reconnect panel cover located near the back of the left case side to reveal the reconnect panel. Welder supply line entry provision is in the case rear panel. Entry is through a 1.75 inch (44 mm) diameter hole in the case back. Appropriate supply line strain relief clamp is provided by installer. (See Figure A.1)
FIGURE A.1
CONNECT INPUT
POWER LEADS
CONNECT INPUT
GROUND LEAD
CONNECT INPUT
VOLTAGE LEVEL
All connections should be made in accordance with all local codes and national electrical codes. Installation by a qualified electrician is recommended.
1.Connect the terminal marked 
(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 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.
CAUTION
Failure to follow these instructions can cause immediate failure of components within the welder.
------------------------------------------------------------------------
PRECISION TIG 375
A-5 |
INSTALLATION |
A-5 |
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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.
EXAMPLE: On a 208/230/460 volt welder, LOW is 208V, MID is 230V, and HIGH is 460V.
Note: Export model has a voltage range for LOW and MID connections: LOW is 220-230V, MID is 380-400V and High is 415V.
Reconnect the jumper strap to the terminal stud corresponding to the input voltage level used. Make sure all connections are tight.
Fuse the input circuit with the recommended super lag fuses or delay type1 circuit breakers. Choose an input and grounding wire size according to local or national codes or use Section A-2. Using fuses or circuit breakers smaller than recommended may result in "nuisance" tripping from welder inrush currents even if not welding at high currents.
Unbalanced AC TIG welding draws higher input currents than those for Stick, DC TIG, or Balanced AC TIG welding. The welder is designed for these higher input currents. However, where unbalanced AC TIG welding above 275 amps is planned, the higher input currents require larger input wire sizes and fuses per Section A- 2.
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
WARNING
•To avoid being startled by a high frequency shock, keep the TIG torch and cables in good condition
•Turn the power switch of the power source OFF before installing adapters on cable or when connecting or disconnecting adapter plugs to power source.
-----------------------------------------------------------------------
Refer to Figure A.2 for the location of the WORK and STICK terminals, as well as the TIG Torch connection panel.
Recommended Cable Sizes for Combined Lengths of Copper Work and Electrode Cables using 75o C Wire:
Machine Rating |
0 to 100 Ft. |
101 to 200 Ft |
201 to 250 Ft |
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375A/40% |
#1 (42.4 mm2) |
1/0 (53.5 mm2) |
2/0 (67.4 mm2) |
WORK CABLE CONNECTION
A 15ʼ (2/0) weld cable with clamp is available (K2150-1), or included with the Precision TIG Welding Package model. Otherwise, it is user provided.
With power source off, connect a separate work cable to the 1/2-13 threaded "WORK" stud of the welder, and secure a tight connection with the flange nut provided. The work cable should be routed through the cable strain relief hole provided in the base directly below the welding output terminal.
Note: If the Precision TIG is equipped with an UnderCooler or Under-Storage unit, the coiled work cable and clamp, or excess work cable length, may be conveniently stored in the drawer while remaining connected.
STICK ELECTRODE CABLE CONNECTION
If manual stick welding is desired, with power source off, connect a stick electrode cable to the 1/2-13 threaded "STICK Electrode" stud of the welder, and secure a tight connection with the flange nut provided. The electrode cable should be routed through the cable strain relief hole provided in the base directly below the welding output terminal.
WARNING
DISCONNECT STICK ELECTRODE WELDING CABLE WHEN TIG WELDING.
EVEN THOUGH HI-FREQ IS NOT APPLIED TO THE PRECISION TIG STICK TERMINAL, IT WILL BE ELECTRICALLY "HOT" TO WORK WHEN TIG WELDING.
------------------------------------------------------------------------
PRECISION TIG 375
A-6 |
INSTALLATION |
A-6 |
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FIGURE A.2 |
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REMOTE |
TIG TORCH |
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CONTROL |
CONNECTION |
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RECEPTACLE |
PANEL |
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STICK |
WORK |
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STICK |
WORK |
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ELECTRODE |
STUD |
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STUD |
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(Shown without hinged stud cover) |
CABLE |
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FIGURE A |
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STRAIN |
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RELIEF HOLES |
TIG TORCH CONNECTION
The Precision TIG torch connection box, located on the right side of the machine, provides all the input and output connections for the installation of both aircooled and water-cooled TIG torches with fittings conforming to Compressed Gas Association (CGA) standards:
Note: The Precision TIG provides an insulated Torch Reel and Holster for handy and safe storage of connected torch when not welding, and excess torch cable length while welding.
WARNING
Combination connectors (Power/Water and Power/Gas) are electrically "hot" while welding in STICK or TIG modes.
If using an Air-Cooled Torch be sure coolant is shut off and/or Cooler is unplugged from the Precision TIG Water Cooler Receptacle on the torch side of the upper case back.
Observe the safety precautions necessary for handling and using compressed gas 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 circuits.
•Maximum inlet pressure 150 psi.
-----------------------------------------------------------------
The Precision TIG machines do not have Hi-Freq. available at the Stick electrode stud, therefore stud connection adapters (such as LECO. S19257-series) cannot be used for torch connection.
Single-piece cable air-cooled torches with a 3/8-24 RH connector fitting (such as the Magnum PTA-9/-17, or LA- 9/-17) require the provided S20403-4 Torch Connector, while those with a 7/8-14 RH connector fitting (such as the Magnum PTA-26, or LA-26) require the available K2166-1 Torch Connector. (See Figure A.3)
Two-piece cable air-cooled torches (such as PTA-, or LAtorches) can be used with the available K2166-2 1/2” Stud Connector with with a 7/8-14 LH male fitting.
Magnum PTW-18/-20 (or LW-) water-cooled Torches require no adapter for Precision TIG connection.
PRECISION TIG 375
A-7 |
INSTALLATION |
A-7 |
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FIGURE A.3
1/2-13 Stud
For Gas Supply hose with 5/8-18RH male (Provided with Weld Package model)
For Coolant Supply Hoses
with 5/8-18LH male
(Provided with Weld
Package model or
Under-Cooler Cart)
AUXILIARY POWER CONNECTIONS
The Precision TIG machines provide a standard NEMA 5-15R duplex receptacle, located on the upper case back on the torch side of the machine:
•The bottom outlet of this duplex receptacle provides switched 115VAC power for the Under-Cooler, or Water Solenoid accessory. This Cooler receptacle turns on when the arc starts and remains on for about 8 minutes after the arc goes out (with the Fan-As- Needed machine cooling fan, see Maintenance Section), so the Coolerʼs fan and water pump will not run continuously in idle, but will run while welding.
•The top outlet of this duplex receptacle provides at least 8 amps at 115VAC, whenever the Precision TIG Power switch is ON. This auxiliary circuit is intended for running 115VAC accessories or small power tools. Note: Some types of equipment, especially pumps and large motors, have starting currents which are significantly higher than their running current. These higher starting currents may cause the circuit breaker to open. (See next paragraph)
•Both the receptacle circuits are protected from shorts and overloads by a 15 amp circuit breaker, located above the receptacle. If the breaker trips, its button pops out exposing a red ring. When the circuit breaker cools, the button can be reset by pressing it back in.
Note: When the breaker trips, not only will the auxiliary 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 220vac Euro type Schuko receptacle and a 5 amp circuit breaker, located on the upper case back on the reconnect side of the machine, intended for use with a 220vac water cooler.
REMOTE CONTROL (If Used)
The Foot Amptrol (included with the Precision TIG Welding Package), or other Remote accessory, is installed by routing the plug of its control cable up through the left cable strain relief hole provided in the base (see Figure A.2), then connecting the 6-pin plug to the mating Remote receptacle behind the stud panel cover. (See Operation Section B-2 for mating plug wiring.)
Note: If the Precision TIG is equipped with an UnderCooler or Under-Storage unit, the Foot Pedal (or other remote control accessory) and coiled control cable, or excess cable length, may be conveniently stored in the drawer while remaining connected.
PRECISION TIG 375
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