Lincoln Electric IM703-A User Manual

PRECISION TIG 375

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IM703-A

November, 2004

For use with machines having Code Numbers:

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.

10809; 10810; 10894

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

Precision TIG 375 Welding Package shown with optional Advanced Control Panel

IP21S

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

SAFETY

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.

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 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.

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 weld-

ing 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.

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.

___________________________________________________

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.

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 ‘95

SAFETY

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.

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

5.c. 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.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

vapors

5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY

iii

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.

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 been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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 manufacturer’s recommendations.

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

Mar ‘95

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. 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 s’isoler 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 l’eau 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 s’applicuent aussi au pistolet de soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie 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 d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres 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 d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de 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 d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc 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.

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 n’importe quelle partie du corps.

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

a. Utiliser un bon masque avec un verre filtrant approprié ainsi

qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, 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 l’on pique le laitier.

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 l’électricité 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, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

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

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank 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. 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

“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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

TABLE OF CONTENTS

Page.

Installation ..........................................................................................................Section A

Technical Specifications ........................................................................................A-1,A-2

Safety Precautions

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 F

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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PERATION.........................................................................................................................................................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

Sick 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

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

........................................................................................................................................................................P404

.. ............................................................................................................................................... .A-3

REQUENCY INTERFERENCE PROTECTION ...................A-3,A-4

.............................................................................................................................................Section E

vivi

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS-

(K1833-1 Domestic,K1833-2 Canadian-60Hz) (K1834-1 Export-50/60Hz)

RATED INPUT - SINGLE PHASE ONLY

Number

K1833-1

K1903-1

NRTL/C

K1833-2

NRTL/C

K1834-1

N80

IEC 60974-1

Duty Cycle-Applications

40%

AC/DC Stick / Balance TIG

Unbalance (70% Penetration

60%

AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIG

100%

AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIG

Idle Amps

40%

AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIG

60%

AC/DC Stick / Balance TIG

Unbalance (70% Penetration

100%

AC/DC Stick / Balance TIG

Unbalance (70% Penetration#) AC TIG

Idle Amps

Rated Power Factor (Stick)

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

Rated Power Factor (Stick)

Idle Power

) AC TIG

PRECISION TIG 375 (K1903-1 Domestic Package*-60Hz)

Voltage + 10%

208/230/460

230/460/575

220-230/

380-400/415

Max. Amps With Power Factor Capacitor

112/102/51 139/126/63

102/92/46

128/116/58

80/72/36

104/92/47

68/62/31

102/51/41 125/63/50

92/46/37

116/58/46

72/36/29 94/47/38 62/31/25

.86 min.

1.0KW

119/69/63 118/68/62

110/64/59

97/56/52

88/51/47 73/42/39

48/28/25 .67 min. .8KW

RATED OUTPUT - NEMA EW1 Class ll (40) K1903-1,K1833-1,K1833-2

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

*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.

) AC TIG

Volts at Rated Amperes

35.0

17.2

34.0

16.9

32.0

16.3

PRECISION TIG 375

Amps

375 350

350 325

300 275

A-2

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

Output Current

Range

Maximum Open

Circuit Voltage

) AC TIG

2Amps DC

420Amps AC-DC

(STICK AND TIG)

AC/DC OCV: 80

RECOMMENDED INPUT WIRE AND FUSE SIZES

For all Stick, DC TIG, and Balanced AC TIG Welding

at 375A/40% Duty Cycle with out Standard Power

Factor Correction Capacitors

Based on the 1999 U.S. National Electrical Code

Input

Voltage /

phase/

Frequency

208/1/60 230/1/60 460/1/60

575/1/60 220-230/1/50/60 380-400/1/50/60

415/1/50/60

(Super Lag)

Fuse

or Breaker

Size

150 150

50 150 110 110

Input

Ampere

Rating

Rating on

Nameplate

112 102

51 41

119

69 63

Copper Wire in

Conduit AWG

40°C (104°F)

3 (26.7 mm2) 3 (26.7 mm2)

3 (26.7 mm2) 4 (21.2 mm2) 4 (21.2 mm2)

INSTALLATION

Volts at Rated Amperes

35.0

24.0

34.0

23.0

32.0

21.0

ADDITIONAL OUTPUT CAPACITY

Type of Output

15Amp Circuit Breaker and NEMA 5-15R Duplex

CC (Constant Current)

AC/DC (GTAW)

Stick (SMAW)

Type 75°C

(IEC) Sizes

Ambient

6 (13.3mm2)

8 (8.4 mm2)

Ground Wire in

Conduit AWG

6 (13.3 mm2) 6 (13.3 mm2)

8 (8.4 mm2)

10 (5.3mm2) 6 (13.3 mm2) 6 (13.3 mm2) 6 (13.3 mm2)

Type 75°C

Copper

(Super Lag)

or Breaker

(IEC) Sizes

115VAC 8 Amp Auxiliary Power Receptacle

115VAC 5 Amp weld Switched Cooler Receptacle

For Unbalanced AC TIG Welding Above 275 Amps:

350A/40% Duty Cycle, Auto-Balance Penetration with

out Standard Power Factor Correction Capacitors

Based on the 1999 U.S. National Electrical Code

Fuse

Size

200 175

70 150 110 110

Amps

Auxiliary Power

K1903-1, K1833-1, K1833-2

Receptacle for up to:

K1834-1

5 Amp Circuit Breaker

and grounded 220VAC

Euro(Schuko) receptacle

Type 75°C

Input

Ampere

Rating

139 126

63 50

118

68 62

Copper Wire in

Conduit AWG

(IEC) Sizes

40°C (104°F)

Ambient

1 (42.4 mm2) 2 (33.6 mm2) 6 (13.3 mm2) 6 (13.3 mm2) 3 (26.7 mm2) 4 (21.2 mm2) 4 (21.2 mm2)

A-2

375 350

350 325

300 275

Type 75°C

Copper

Ground Wire in

Conduit AWG

(IEC) Sizes

6 (13.3 mm2) 6 (13.3 mm2)

8 (8.4 mm2)

8 (8.4 mm2) 6 (13.3 mm2) 6 (13.3 mm2) 6 (13.3 mm2)

PHYSICAL DIMENSIONS

K1833-1, -2

K1834-1

K1903-1

Height Width Depth Weight

31.0 in. 22.0 in. 26.0 in. 507 lbs. 787 mm 559 mm 660 mm 230 kgs.

49.7 in. 28.0 in. 41.0 in. 751 lbs. 1262 mm 711 mm 1041 mm 341 kgs.

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

-20°C to +40°C (-04° to +104°F)

TRANSFORMER INSULATION CLASS 180°C (H)

ALSO CALLED ‘INVERSE TIME" OR "THERMAL/MAGNETIC " CIRCUIT BREAKERS; CIRCUIT BREAKERS WHICH HAVE ADELAYIN TRIPPING ACTION THAT DECREASES AS

THE MAGNITUDE OF CURRENT INCREASES.

STORAGE TEMPERATURE RANGE

-40°C to +85°C (-40° to +185°F)

*50/60HZ IEC Max. range exceeds 310A.

PRECISION TIG 375

A-3

INSTALLATION

A-3

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.

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. Aground 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 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 NEMAstandards for high frequency stabilized power sources.

Radiated interference can develop in the following four ways:

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.

• 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 and completely enclose them in rigid metallic conduit or equivalent shielding for a minimum distance of 50 feet (15.2 m). 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

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.

• A3/4" (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).

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

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.

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.

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PRECISION TIG 375

A-5

INSTALLATION

A-5

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.

Recommended Cable Sizes for Combined Lengths of Copper Work and Electrode Cables using 75

Machine Rating 0 to 100 Ft. 101 to 200 Ft 201 to 250 Ft

375A/40% #1 (42.4 mm2) 1/0 (53.5 mm2) 2/0 (67.4 mm2)

C Wire:

WORK CABLE CONNECTION

A15’ (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.

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-

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.

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.

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PRECISION TIG 375

A-6

STICK

ELECTRODE

STUD

TIG TORCH

CONNECTIO

PANEL

REMOTE

CONTROL

RECEPTACLE

INSTALLATION

FIGURE A.2

STICK

WORK

A-6

WORK

STUD

(Shown without hinged stud cover)

FIGURE A

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.

CABLE

STRAIN

RELI EF HOLES

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.

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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 LA9/-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)

Observe the safety precautions necessary for handling and using compressed gas containers. Contact your supplier for specifics.

PRECISION TIG 375

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.

A-7

1/2-13

Stud

FIGURE A.3

INSTALLATION

A-7

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-AsNeeded machine cooling fan, see Maintenance Section), so the Cooler’s 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 1 15VAC 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)

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.

• 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.

PRECISION TIG 375

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