Im609 SQUARE WAVE TIG 275 B

User Manual: SQUARE WAVE TIG 275 IM609-B

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IM609-B

Square Wave TIG 275
For use with machines having Code Numbers:
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Specifications and availability of optional
features may have changed.

May, 2001

10523,
10524,
10525,
10605,
10738

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.

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

OPERATOR’S MANUAL

• 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

SAFETY

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
For Gasoline Engines: The engine exhaust from
For Diesel Engines: Diesel engine exhaust and
this product contains chemicals known to the
some of its constituents are known to the State
State of California to cause cancer, birth defects,
of California to cause cancer, birth defects, and
or other reproductive harm.
other reproductive harm.
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
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.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________
1.c. Do not add the fuel near an open flame 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.
____________________________________________________
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.
____________________________________________________
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.
___________________________________________________
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.

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.

___________________________________________________
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.5. Do not work next to welding power source.

Mar ‘95

SAFETY
ELECTRIC SHOCK can kill.

ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

3.b. 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.

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

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.

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.

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.

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 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.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.
5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY
WELDING SPARKS can
cause fire or explosion.

6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. 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.

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.
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.

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.

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

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product •••
as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. 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.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase

_____________________________________

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

TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications.................................................................................A-1, A-2
Select Suitable Location ........................................................................................A-3
Stacking .................................................................................................................A-3
Lifting and Moving .................................................................................................A-3
Tilting. ....................................................................................................................A-3
Environmental Rating ...........................................................................................A-3
Machine Grounding and High Frequency Interference Protection ........................A-3
Supply Connections...............................................................................................A-4
Input Reconnect Procedures .................................................................................A-5
Output Connections...............................................................................................A-7
Work Cable Connections.......................................................................................A-7
TIG Torch Connections ..........................................................................................A-8
Twist-Mate Adapter for LA-9 and LA-17 TIG Torch................................................A-9
Twist-Mate Adapter for LW-18 and LW-20 TIG Torch ............................................A-9
Stick Electrode Cable Connection .......................................................................A-10
Installation of Field Installed Options...................................................................A-10
Operation .........................................................................................................Section B
Safety Precautions ...............................................................................................B-1
Graphic Symbol Definitions ...................................................................................B-2
General Description...............................................................................................B-4
Recommended Processes and Equipment ...........................................................B-4
Design Features and Advantages .........................................................................B-4
Limitations..............................................................................................................B-5
Duty Cycle and Time Period..................................................................................B-5
Controls and Settings ............................................................................................B-6
Welding Operation .................................................................................................B-7
Auxiliary Power ....................................................................................................B-10
Accessories .....................................................................................................Section C
Accessories Included with Machine ......................................................................C-1
Optional Accessories.............................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Maintenance .......................................................................D-1
Overload Protection...............................................................................................D-1
Service Procedures ...............................................................................................D-1
Component Location and Access .........................................................................D-2
Spark Gap Adjustment ..........................................................................................D-2
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How To Use Troubleshooting Guide ......................................................................E-1
Troubleshooting Guide...........................................................................................E-2
PC Board Troubleshooting .....................................................................................E-7
Wiring Diagrams & Dimension Print .............................................................Section F
Parts List ......................................................................................................P316 Series
Parts List ......................................................................................................P383 Series

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Square Wave TIG 275 (K1617-1, and -2)
INPUT - SINGLE PHASE ONLY
Input Current at
Input Current at
Input Current at
Idle
Idle Power
40% Duty Cycle
60% Duty Cycle
100% Duty Cycle
Current
Power
DC STICK,
DC STICK,
DC STICK,
DC TIG,
UNBALANCED AC TIG DC TIG,
UNBALANCED AC TIG DC TIG,
UNBALANCED AC TIG
BALANCED AC TIG
BALANCED AC TIG
BALANCED AC TIG

Standard
Voltage

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

95/86/43
43/35
95/86/43

130/120/61
61/49
130/120/61

76/69/34
34/28
76/69/34

106/97/50
50/41
106/97/50

57/52/26
26/21
57/52/26

82/75/38
38/31
82/75/38

5/4/2
2/1.5
5/4/2

900 WMax.
900 WMax.
900 WMax.

Code
Number

10523
10525
10605

RATED OUTPUT & ADDITIONAL OUTPUT CAPACITY
Duty Cycle

Amps

Volts at Rated Amperes

Current Range

Auxiliary Power

40% Duty Cycle
NEMA Class II (40)

AC/DC Stick
AC/DC TIG

275 A
255 A

31.0 V
16.1 V

5-315 Amps

60% Duty Cycle

AC/DC Stick
AC/DC TIG

225 A
200 A

29.0 V
15.4 V

MAX O.C.V.
AC & DC 80V

115 Volts AC, 10 Amps
Grounded NEMA-5-15R
Receptacle and
10 Amp Circuit Breaker

100% Duty Cycle

AC/DC Stick
AC/DC TIG

175 A
150 A

27.0 V
14.8 V

Normal O.C.V.
72 V (AC) 59 V (DC)

RECOMMENDED INPUT WIRE AND FUSE SIZES
For AC/DC Stick, DC TIG and Balanced AC TIG
Welding at 275A 40% Duty Cycle
w/o Optional K1620-1 Power Factor Capacitors
Based on the 1996 U.S. National Electrical Code
Input
Fuse
Input
Voltage / (Super Lag) Amperes
phase/
or Breaker
(1)
Frequency
Size

w/o Optional K1620-1 Power Factor Capacitors

Based on the 1996 U.S. National Electrical Code

Type 75°C
Type 75°C
Copper Wire in Copper Ground
Fuse
Conduit AWG
Wire in
(Super Lag)
(IEC) Sizes
Conduit AWG or Breaker
(1)
(IEC) Sizes
Size
40°C (104°F) Ambient

Input
Amperes

Type 75°C
Type 75°C
Copper Wire in Copper Ground
Conduit AWG
Wire in
(IEC) Sizes
Conduit AWG
(IEC) Sizes
40°C (104°F) Ambient

208/1/60

125

111

4 (21.2 mm2)

6 (13.3 mm2)

150

130

3 (25.0 mm2)

6 (13.3 mm2)

230/1/60

125

100

4 (21.2 mm2)

6 (13.3 mm2)

150

120

3 (25.0 mm2)

6 (13.3 mm2)

460/1/60

8 (8.4 mm2)

10 (5.3 mm2)

8 (8.4 mm2)

10 (5.3 mm2)

8 (8.4 mm2)

10 (5.3 mm2)

575/1/60
(1)

For Unbalanced AC TIG Welding above 180A,
255A 40% Duty Cycle, Maximum Penetration

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

PHYSICAL DIMENSIONS
Power
Source

Height
24.06 in.
611 mm

Width
19.15 in.
486 mm

Depth
28.00 in.
711 mm

Weight
Approx. 330 lbs.
150 kg.

27.65 in.
702 mm

40.65 in.
1033 mm

Approx. 375 lbs.
170 kg.

Lift Hook add 3.57” (91 mm)

Power Source
on
Undercarriage

33.40 in.
848 mm

SQUARE WAVE TIG 275

A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - Square Wave TIG 275 (K1618-1)
INPUT - SINGLE PHASE ONLY
Standard
Voltage
220/380/415/1/50/60

Input Current at
Input Current at
Input Current at
Idle Current Idle Power Code
Number
40% Duty Cycle
60% Duty Cycle
100% Duty Cycle
DC STICK,
DC STICK,
DC STICK,
UNBALANCED AC TIG DC TIG,
UNBALANCED AC TIG DC TIG,
UNBALANCED AC TIG
DC TIG,
BALANCED AC TIG
BALANCED AC TIG
BALANCED AC TIG
10524
99/57/52
139/79/72
83/45/421
12/64/59
63/36/33
86/49/45
8/6/5
900 WMax.

RATED OUTPUT & ADDITIONAL OUTPUT CAPACITY
Duty Cycle

Amps

Volts at Rated Amperes

Current Range

Auxiliary Power

AC/DC Stick
AC/DC TIG

275 A
255 A

31.0 V
20.2 V

5-315 Amps

220 Volts AC, 2 Amps
Schuko Receptacle
and 2 Amp Circuit Breaker

60% Duty Cycle

AC/DC Stick
AC/DC TIG

225 A
200 A

29.0 V
18.0 V

MAX O.C.V.
AC & DC 80V

100% Duty Cycle

AC/DC Stick
AC/DC TIG

175 A
150 A

27.0 V
16.0 V

Normal O.C.V.
72 V (AC) 59 V (DC)

40% Duty Cycle
NEMA Class II (40)

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

Based on the 1996 U.S. National Electrical Code

Type 75°C
Type 75°C
Copper Wire in Copper Ground
Fuse
Conduit AWG
Wire in
(Super Lag)
(IEC) Sizes
Conduit AWG or Breaker
(1)
(IEC) Sizes
Size
40°C (104°F) Ambient

Input
Amperes

Type 75°C
Type 75°C
Copper Wire in Copper Ground
Conduit AWG
Wire in
(IEC) Sizes
Conduit AWG
(IEC) Sizes
40°C (104°F) Ambient

220/1/50/60

125

106

4 (21.2 mm2)

6 (13.3 mm2)

175

139

3 (25.0 mm2)

6 (13.3 mm2)

380/1/50/60

8 (8.4 mm2)

6 (13.3 mm2)

8 (8.4 mm2)

415/1/50/60

8 (8.4 mm2)

6 (13.3 mm2)

8 (8.4 mm2)

(1)

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

PHYSICAL DIMENSIONS
Power
Source

Height
24.06 in.
611 mm

Width
19.15 in.
486 mm

Depth
28.00 in.
711 mm

Weight
Approx. 340 lbs.
154 kg.

27.65 in.
702 mm

40.65 in.
1033 mm

Approx. 385 lbs.
175 kg.

Lift Hook add 3.57” (91 mm)

Power Source
on
Undercarriage

33.40 in.
848 mm

SQUARE WAVE TIG 275

A-3

INSTALLATION

Read entire installation section before starting
installation.

A-3

ENVIRONMENTAL RATING
The Square Wave TIG 275 power source carries an
IP21 environmental rating. It may be used in normal
industrial and commercial environments. It is rated for
use in damp, dirty rain-sheltered environments.

Safety Precautions

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

MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION

• Turn the input power OFF at the
disconnect switch or fuse box
before working on this
equipment.
• Do not touch electrically hot parts.
• Always connect the Square Wave TIG 275 grounding screw
(located on the right rear corner of the base) to a good electrical
earth ground.
• Always connect the Square Wave TIG 275 to a power supply
grounded per the National Electrical Code and any local codes.

SELECT SUITABLE LOCATION
Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the
side louvers. 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.

STACKING
Square Wave TIG 275’s cannot be stacked.

The frame of the welder must be grounded. A ground
screw marked with the symbol
is located at the right rear
corner of the base 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 Square Wave TIG 275 has been field tested under recommended installation conditions and has been found to comply with F.C.C. allowable radiation limits. A certificate (S14929)
is being sent with each welder for customer convenience. If he
desires or is required to obtain certification of compliance with
F.C.C.RF Energy Radiation Limits, this certificate can be used.
It is the customer's responsibility to obtain this certification. This
welder has also been found to comply with NEMA standards
for high frequency stabilized power sources.

LIFTING AND MOVING

Radiated interference can develop in the following four
ways:

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

1. Direct interference radiated from the welder.

TILTING

1. Keep the welder power supply lines as short as possible and enclose as much of them as possible in
rigid metallic conduit or equivalent shielding for a
distance of 50 feet (15.2m). There should be good
electrical contact between this conduit and the
welder case ground. Both ends of the conduit
should be connected to a driven ground and the
entire length should be continuous.

Each machine must be placed on a secure, level
surface, either directly or on a recommended
undercarriage. The machine may topple over if this
procedure is not followed.

2. Direct interference radiated from the welding leads.
3. Direct interference radiated from feedback into the
power lines.
4. Interference from re-radiation of “pickup” by
ungrounded metallic objects.
Keeping these contributing factors in mind, installing
equipment per the following instructions should minimize problems.

SQUARE WAVE TIG 275

A-4

INSTALLATION

2. Keep the work and electrode leads as short as possible and as close together as possible. Lengths
should not exceed 25 ft (7.6m). Tape the leads
together when practical.
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.

SUPPLY CONNECTIONS
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.
See Figure A.1 for the location of the rating plate, the
entry hole, and the reconnect panel.
FIGURE A.1

4. Keep the torch in good repair and all connections
tight to reduce high frequency leakage.
5. The work piece must be connected to an earth
ground close to the work clamp, using one of the following methods:

a) A metal underground water pipe in direct contact
with the earth for ten feet or more.
b) A 3/4” (19mm) galvanized pipe or a 5/8” (16mm)
solid galvanized iron, steel or copper rod 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 ft (15.2m) of the
welder should be enclosed in grounded rigid metallic conduit or equivalent shielding. Flexible helicallywrapped metallic conduit is generally not suitable.
8. When the welder is enclosed in a metal building, the
metal building should be connected to several good
earth driven electrical grounds (as in 5 (b) above)
around the periphery of the building.
Failure to observe these recommended installation
procedures can cause radio or TV and electronic
equipment interference problems and result in unsatisfactory welding performance resulting from lost high
frequency power.

1. Input Entry
2. Rating Plate
3. 115V Receptacle & Breaker
(60 HZ. Machines only)

4. 220V Receptacle & Breaker
(50/60 HZ. Machines Only.)
5. Gas Input Fitting

Remove the right case side to reveal the reconnect
panel. Welder supply line entry provision is in the case
rear panel. Entry is through a 1.4 inch (36 mm) diameter hole in the case back.1
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
(at the base of the
welder 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.

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

SQUARE WAVE TIG 275

A-5

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 refer to the Technical Specifications page at
the beginning of this section. 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 180 amps is planned, the higher input currents
require larger input wire sizes and fuses per the
Technical Specifications page at the beginning of
this section.

INPUT RECONNECT PROCEDURE
On multiple input voltage welders, be sure the reconnect panel is connected per the following instructions
for the voltage being supplied to the welder.
1

A-5

INSTALLATION
CAUTION

FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN CAUSE IMMEDIATE FAILURE OF COMPONENTS WITHIN THE WELDER.
-----------------------------------------------------------------------Welders are shipped connected for the highest input
voltage as listed on the rating plate. To change this connection, refer to the following instructions:
1. Remove the right case side to reveal the reconnect
panel.
2. Reconnect the lead marked A to the terminal stud
corresponding to the input voltage used. Refer to
the figure representing the model being reconnected:
Figure A.2 208/230/460/1/60 Domestic Model
Figure A.3 460/575/1/60 Domestic/Canadian Model
Figure A.4 220/380/415/1/50/60 European Model
(Con’t)

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

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

SINGLE PHASE INPUT POWER SUPPLY CONNECTION INSTRUCTIONS:

WARNING:

power at the disconnect switch or fuse box before making any connections. Use
input and grounding lead sizes as specified in the operating manual. Failure to follow
instructions below can cause immediate failure of components within the welder.
1. Connect the input power leads to the input terminals, L1 (U) and L2 (V), at the right
below. Connect the input power leads with the hardware provided. Completely
tighten all fasteners.
2. Connect a grounding lead to the ground stud located on the machine base near
the input terminals.
3. Welders are shipped connected for the highest rated single phase input voltage
with the lead marked "A" connected to the stud marked "4 (HIGH)".
4. For middle range input, reconnect the lead marked "A" to the stud marked "3 (MID)".
5. For low range input, reconnect the lead marked "A" to the stud marked "2 (LOW)".

4 (HIGH)
460V
23

3 (MID)

2 (LOW)

SINGLE
PHASE
INPUT
L1 (U)

L2 (V)

LEADS FOR OPTIONAL
POWER FACTOR CAPACITORS

208/230/460 DOMESTIC MODEL

SQUARE WAVE TIG 275

A-6

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

SINGLE PHASE INPUT POWER SUPPLY CONNECTION INSTRUCTIONS:

WARNING:

4 (HIGH)
575V

3 (MID)
46

SINGLE
PHASE
INPUT

L1 (U)

2 (LOW)

L2 (V)

LEADS FOR OPTIONAL
POWER FACTOR CAPACITORS

460/575 CANADIAN MODEL

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

SINGLE PHASE INPUT POWER SUPPLY CONNECTION INSTRUCTIONS:

WARNING:

4 (HIGH)
415V

3 (MID)

2 (LOW)

SINGLE
PHASE
INPUT
L1 (U)

L2 (V)

LEADS FOR OPTIONAL
POWER FACTOR CAPACITORS

220/380/415 EUROPEAN MODEL

SQUARE WAVE TIG 275

A-7

INSTALLATION

Designations on the reconnect panel LOW, MID, and
HIGH correspond to the nameplated 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.
3. Make sure all connections are tight. Replace the
case side and all screws.

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

ELECTRIC SHOCK can kill.
• Turn the power switch of the power
source “OFF” before installing adapters
on cable or when connecting or disconnecting adapter plugs to power source.
---------------------------------------------------------------------------See Figure B.1 for the location of the work and electrode terminals, the gas and optional water solenoids,
and the Remote Receptacle.The Square Wave TIG
275 is equipped with Twist-Mate connectors for the
electrode and work connection.

WORK CABLE CONNECTION

TABLE A.2
Recommended Work and Stick Electrode
Components
Twist Mate
Cable Plug
for Work
Lead
(#2 to #1)

Twist Mate
Cable Plug
for Work
Lead
(1/0 to 2/0)

Twist Mate
Cable Plug
for Work
Lead
(2/0 to 3/0)

Work
Clamp

Electrode
Holder

K852-50

K852-70

K852-95

K910-1

K909-4

Assemble the correct Twist-Mate-adapter plug to the
work cable as follows:
1. Skin the cable jacket to 1.00 in (25.4 mm) for a #2
thru 2/0 (35 thru 70 mm2) cable. Skin the cable
jacket to 1.50 in (38.1 mm) for a 2/0 thru 3/0 (70 thru
95 mm2) cable.
2. If necessary, trim the cable end of the rubber boot
to match the diameter of the cable.
3. Slide the rubber boot onto the skinned cable end.
Use soap for lubricant if required.
BOOT
WELDING CABLE

SEE
ABOVE
TRIM

4. Slide the copper tube into the brass plug. Insert
skinned cable into the copper tube.
SET SCREW
(70-95 SIZE MAY

The Twist-Mate connection allows fast and reliable
work cable attachment to the work terminal of the
Square Wave TIG 275 welding power supply.
Assemble the work cable by attaching the correct
Twist-Mate adapter and work clamp to an adequatelysized welding cable. The Twist-Mate cable plug included with the machine is designed to accept a welding
cable size of of #2 to #1. See Table A.1 and A.2 for recommended sizes and corresponding hardware.
TABLE A.1
Cable Sizes for Combined Lengths of Copper
Electrode and Work Cable
Machine Size

Lengths up to
100 ft

100 to 200 ft

200 to 250 ft

275 Amp
40% Duty Cycle

#1 (42.4mm2)

1/0 (53.5mm2)

2/0 (67.4mm2)

HAVE 2 SET
SCREWS)

COPPER TUBE

BRASS PLUG

5. Tighten set screw(s) to collapse copper tube.
Screw(s) must apply firm pressure against welding
cable.
6. Slide the rubber boot over the brass plug. The rubber boot must be positioned to completely cover all
electrical surfaces after the plug is locked into the
receptacle. For more details see S18737PRINT or
instructions included with the adapter kit.

SQUARE WAVE TIG 275

A-8

INSTALLATION

TIG TORCH CONNECTION

WARNING

The Twist-Mate connection allows fast and reliable TIG
torch attachment to the electrode terminal of the
Square Wave TIG 275 welding power supply. TwistMate TIG adapters are made of brass, combining high
electrical conductivity with mechanical strength. They
are available in several sizes and styles to accommodate a wide selection of gas and water-cooled TIG
torches.
• Air-Cooled TIG Torch connections refer to TWISTMATE ADAPTER for LA-9 and LA-17 TIG TORCH
Section.
• Water-Cooled TIG Torch connections refer to TWISTMATE ADAPTER for LW-18 and LW-20 TIG TORCH
Section.
Any torch having hoses and cables equipped with
Compressed Gas Association (CGA) style fittings can
be connected to an appropriate Twist-Mate adapter
(see ACCESSORIES section). The power source must
be switched off while making any of these connections.
Do not operate a water-cooled torch without an adequate coolant supply. Set-ups using recirculated
coolant require that the cooler be switched on and running. If the water solenoid valve option is used with a
cooler, the coolant does not flow until the solenoid is
actuated.

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 high-pressure cylinder of inert shielding gas must
be equipped with a flow regulator that limits the gas
pressure to 150 psi maximum at the machine’s gas
inlet. This brass inlet fitting is located on the rear panel
of the Square Wave TIG 275. Install a hose between
the gas flow meter and the inlet fitting.
For other conditions, consult the manufacturer’s
instructions for the water cooler or TIG torch being
used.

For set-ups using water as a single-pass through
coolant, install a strainer into the system upstream of
the Square Wave TIG 275 to reduce the concentration
of particles that could contaminate the system.
Otherwise, flow passages could become obstructed or
clogged, causing torch overheating or failure. The
optional water solenoid valve may also malfunction.
When the water solenoid valve option is installed into
the Square Wave TIG 275, connect the coolant supply
line from either cooler outlet or single-pass supply to
the “Water Inlet” fitting located on the machine’s case
front. Connect the TIG torch’s smaller water fitting to
the “Water Out” fitting also located on the case front. A
non-metallic coolant line is required between the electrode connection and the drain or cooler inlet. This
reduces the possibility of an electrical hazard.
TIG welding torches are available with 12.5 and 25 foot
(3.8 and 7.6 m, respectively) long cables. Use the
shorter length whenever possible to reduce radio interference problems.

SQUARE WAVE TIG 275

A-9

INSTALLATION

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

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

The Twist-Mate connection allows fast and reliable TIG
torch connections to the electrode terminal of the
Square Wave TIG 275. The Twist-Mate adapter, strain
relief boot and retaining compound needed to connect
an LA-9 or LA-17 torch (or any equivalent air-cooled
TIG torch with a right-hand male 3/8-24 fitting) are
included with the Square Wave TIG 275.

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

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

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

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

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

STRAIN RELIEF BOOT

TIG ADAPTER

STRAIN RELIEF BOOT

TIG ADAPTER

POWER/WATER CABLE FROM TORCH

RETAINING COMPOUND

GAS HOSE FROM TORCH

TIG TORCH POWER CABLE WITH GAS FITING

2. Apply a small amount of retaining compound to the
fitting threads as shown. Thread the fitting to the
TIG adapter and tighten to ensure a sealed gas
connection and a good electrical connection. (35-45
in-lbs)
3. Hold the TIG adapter, with cable installed, firmly in
place by securing it into the Twist- Mate receptacle
on the power source or into a padded vise. Align
the hex in the boot with the hex on the adapter.
Firmly push the boot onto the adapter, rocking the
boot to assist installation. Use soap for lubricant if
required.

WATER HOSE

2. Thread the power/water cable (large fitting) from the
torch to the large port on the TIG adapter and tigten
to ensure a water tight connection. Next, thread the
gas hose (small fitting without notches on hex) to
the port marked “G” on the TIG adapter and tighten
to ensure a sealed gas connection. Next, thread the
water hose to cooler (or to water drain) to the port
marked “W” on the TIG adapter.
POWER/WATER

WATER CONNECTION

CONNECTION

PORT (LH 5/8-18)

PORT (LH 7/8-14)
W

COMPLETED ASSEMBLY
G

GAS CONNECTION
PORT (RH 5/8-18)

3. Check all connections made in step 2 for gas and
water leaks before proceding.
CONNECTION DIAGRAM
MAGNUM
WATER COOLER
COOLANT
"IN"

OPTIONAL

COOLANT
"OUT"

WATER SOLENOID KIT
COOLANT

COOLANT
"OUT"

"IN"

WATER HOSE

WATER HOSE FROM TORCH

(SEPARATELY PROVIDED)
FLOW

WATER

4. Examine the strain relief boot and TIG adapter for
correct assembly. The boot should nest into the
Twist-Mate receptacle on the power source. All
electrical surfaces should be completely covered
when in the Twist-Mate receptacle on the power
source. For more details see M19115PRINT included with the machine.

(LH 5/8-18 MALE FITTING)

(SEPARATELY PROVIDED)
GAS HOSE FROM TORCH
G

WATER HOSE
(SEPARATELY PROVIDED)

SQUARE WAVE TIG 275

LW-18 OR LW-20
TIG TORCH
(SEPARATELY PROVIDED)

HOSE COUPLER

(RH 5/8-18 MALE FITTING)

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

A-10

INSTALLATION

4. Hold the TIG adapter, with cables and hoses
installed, firmly in place by securing it into the TwistMate receptacle on the power source or into a
padded vise. Apply a thin film of lubricant to the
boot’s lead in chamfer area. Also apply lubricant to
the lead in chamfer and 2" diameter on the TIG
adapter. Next align the strain relief boot keys with
the TIG adapter slots. Now firmly push the boot
onto the adapter, rocking the boot to assist installation.
COMPLETED ASSEMBLY

A-10

INSTALLATION OF FIELD INSTALLED
OPTIONS
Installation instructions are included with the following
accessories:
K559-2 Magnum Cooler Mounting Bracket
K932-1 Undercarriage When the undercarriage is
properly installed, the Square Wave TIG 275 lift bale is
nonfunctional. Do not attempt to lift the power source
with the undercarriage attached. The undercarriage is
designed for hand moving only; mechanized towing
can lead to personal injury and/or damage to the
Square Wave TIG 275.
K1619-1 TIG Pulser Kit

5. Examine the strain relief boot and TIG adapter for
correct assembly. The boot should nest into the
Twist-Mate receptacle on the power source. The
boot face will be 1/8 inch away from the machine
front. All electrical surfaces should be completely
covered when in the Twist-Mate receptacle on the
power source. For more details see M19116PRINT
included with the machine.

K1620-1 Power Factor Capacitor Kit
K1621-1 Water Solenoid Kit
K1622-1 Twist Mate Adapter Kit for LA9 & LA17
Torches (Included with Machine)
K1622-2 Twist Mate Adapter Kit for LW18 & LW20
Torches (Included with Machine)

STICK ELECTRODE CABLE CONNECTION
The Twist-Mate connection allows fast and reliable
stick electrode attachment to the electrode terminal of
the Square Wave TIG 275 welding power supply.
Assemble the stick electrode cable by attaching the
correct Twist-Mate adapter and electrode holder to an
adequately-sized welding cable. The Twist-Mate cable
plug is NOT provided with the machine for the stick
electrode connection. See Table A.1 and A.2 for recommended sizes and corresponding hardware.
Assemble the correct Twist-Mate adapter plug to the
stick electrode cable as detailed in “Work Cable
Connection”.

K1622-3 Twist Mate Adapter Kit for LA26 Torch
K852-50 Twist Mate Cable Plug for #2 to #1 Work Lead
(Included with Machine)
K852-70 Twist Mate Cable Plug for 1/0 to 2/0 Work
Lead
K852-95 Twist Mate Cable Plug for 2/0 to 3/0 Work
Lead
Installation of the K963-1 or K963-2 Hand Amptrol, the
K814 Arc Start Switch and the K870 Foot Amptrol are
as follows:
Connect the 6-pin MS-type (Amphenol) connector to
the Remote Receptacle (See Figure 3). Secure with
the threaded collar.

WARNING
DO NOT CONNECT A TIG TORCH AND STICK
ELECTRODE CABLE AT THE SAME TIME. THEY
WILL BOTH BE ELECTRICALLY HOT WHENEVER
THE OUTPUT CONTACTOR IS ENERGIZED.
------------------------------------------------------------------------

SQUARE WAVE TIG 275

B-1

OPERATION
SAFETY PRECAUTIONS
Read and understand this entire section before operating the machine.

WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
• Read and follow “Electric Shock Warnings”
in the Safety section if welding must be performed under electrically hazardous conditions such as welding in wet areas or on or
in the workpiece.

FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.

WELDING SPARKS
can cause fire or
explosion
• Keep flammable material away.
• Do not weld on containers that
have held combustibles.

ARC RAYS
can burn.
• Wear eye, ear and body
protection.
Observe additional Safety Guidelines detailed in
the beginning of this manual.

SQUARE WAVE TIG 275

B-1

B-2

OPERATION
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
MODE SWITCH

POWER SWITCH
SYMBOL

SYMBOL

MEANING

TIG 2-STEP

OFF

TIG 4-STEP

INPUT POWER

STICK

OVER
TEMPERATURE

POST FLOW CONTROL AND
DOWN SLOPE TIME CONTROL
SYMBOL

MEANING

OUTPUT CONTROL
SYMBOL

POST FLOW TIME

MEANING

CURRENT CONTROL
(OUTPUT)

AC WAVE BALANCE CONTROL
SYMBOL

DOWN SLOPE TIME

POLARITY SWITCH

MEANING

SYMBOL

AC WAVE BALANCE

CLEAN (INCREASING
POSITIVE POLARITY)

PENETRATE (INCREASING
NEGATIVE POLARITY)

SQUARE WAVE TIG 275

MEANING

DC- POLARITY

DC+ POLARITY

AC POLARITY

B-3

OPERATION
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

OPTIONAL WATER SOLENOID CONNECTIONS
SYMBOL

ADDITIONAL SYMBOLS
SYMBOL

MEANING

WATER (COOLANT)
INPUT

REMOTE CONTROL

WATER (COOLANT)
OUTPUT

DO NOT SWITCH
WHILE WELDING

WARNING

PROTECTIVE
GROUND

TIG (GTAW)

OUTPUT CONNECTIONS
SYMBOL

MEANING

WORK
CONNECTION

ELECTRODE
CONNECTION

SQUARE WAVE TIG 275

SINGLE PHASE

SINGLE PHASE
TRANSFORMER
AC & DC RECTIFIER
POWER SOURCE

B-4

OPERATION

GENERAL DESCRIPTION
The Square Wave TIG 275 is a constant current, single
range square wave AC/DC TIG (GTAW) arc welding
power source with built-in high frequency stabilization.
It also has stick (SMAW) capability. A TIG Pulser Kit,
Power Factor Capacitor Kit, and a Water Solenoid Kit
are available as field installed options.
The Square Wave TIG 275 includes advanced features
such as Presettable Digital Meters, Auto Balance™, 2Step/4-Step operation, adjustable Down slope Time
control and Fan as Needed. It also features Twist Mate
connections for the electrode and work leads. In addition, fixed preflow and variable post flow timers are
included to control the shielding gas, as well as the
water flow when using the optional water solenoid.

RECOMMENDED PROCESSES AND
EQUIPMENT
The Square Wave TIG 275 is recommended for the TIG
(GTAW) and stick (SMAW) welding processes within its
output capacity of 5 to 315 amps, on both AC and DC
polarity. It is compatible with all Magnum TIG accessories, as well as many industry standard items, such
as TIG torches, hoses, and water coolers.

DESIGN FEATURES AND ADVANTAGES
• Meets NEMA CLASS II (40) and IP21 environmental
certification. CSA NRTL/C certified (Domestic and
Canadian Models Only).
• Meets IEC-974-1 and IP21 environmental certification. CE certified (European Model Only).
• Built in Digital Ammeter and Voltmeter for precise
process control. When not welding, the digital ammeter displays the peak current set with the output control knob. This allows the user to easily preset the
peak current within the full output range of the
machine. This includes a persistence feature which
captures and continues to display the peak welding
current and it’s corresponding voltage for five seconds after the weld is completed.
• AC Wave Balance control knob provides flexibility to
the customer. Set it to the Auto Balance position and
the circuitry automatically provides the proper
amount of cleaning and penetration for normal AC
TIG welding. For special applications simply dial in
the amount of cleaning and penetration needed.
• Fan As Needed (FAN) circuit turns ‘ON’ the fan only
when cooling is needed. FAN minimizes the amount

B-4

of dust, dirt, and other foreign material drawn into the
machine. A build up of these materials can cause
excessive operating temperatures and nuisance shut
downs.
• 2-STEP/4-STEP TIG/STICK mode control switch. 4STEP mode requires the use of an optional Arc Start
Switch. This welding mode reduces fatigue by eliminating the need to manually control the weld current
during the weld.
• Down Slope Time control is active in 4-STEP TIG
mode. It controls the amount of time (approximately
1 to 10 seconds) it takes the weld current to ramp
down from the Preset level to 25% ±10% of that level.
• Post Flow Time control is active in the 2 and 4-STEP
TIG modes. It controls the amount of time (approximately 5 to 50 seconds) the shielding gas flows after
the weld is completed.
• Robotic Interface connection on the PC board can be
connected to the machines Remote Receptacle for
automated welding procedures. This interface allows
remote control of the trigger and output current of the
machine as well as providing a signal when the weld
is established. (For details contact the Lincoln Automation Center)
• Built in High Frequency Generator automatically performs in the correct mode. If the machine is in STICK
mode, the HF stays ‘OFF’. IF the machine is in DC
TIG mode, the HF comes ‘ON’ and stays on until the
arc is established. IF the machine is in AC TIG mode,
the HF comes ‘ON’ and stays on continuously to stabilize the arc.
• Automatic Local/Remote current selection. The
machine automatically senses if an Amptrol, Arc Start
Switch or TIG Pulser is plugged in and transfers current control from local to remote.
• Built in preflow time of 0.5 seconds. Preflow time is
eliminated if welding restarts during the pervious
weld’s post flow. This avoids unnecessary delays
when making repeated welds.
• Simple dial and switch design provides the customer
with flexible control of the welding process without
unnecessary complication. Controls which are not
needed in the weld mode selected are automatically
locked out.
• Twist Mate connectors are provided for the electrode
and work connections. This style connector makes
the gas and current connections for the TIG torch at
the same time. (Adapter plugs are provided)

SQUARE WAVE TIG 275

B-5

OPERATION

• DC+/AC/DC- Polarity Switch allows the welder to
change polarity without reconnecting leads.
• Provides excellent arc starting and stability throughout the machines wide current range (5 to 315 Amps)
to handle the vast majority of TIG welding applications.
• Simple output current dial allows the user to preset
the peak current within the full output range of the
machine.

B-5

LIMITATIONS
The Square Wave TIG 275 is not recommended for AC
TIG welding when high concentrations of helium gas
are used for shielding. This causes starting and arc
rectification problems. Also the Square Wave 275 is
not recommended for arc gouging due to it's limited
output capacity. The Square Wave TIG 275 is also not
recommended for pipe thawing.

DUTY CYCLE AND TIME PERIOD

• Highly resistant to AC arc rectification.
• Thermostatically protected to prevent equipment
damage.
• No tungsten spitting within current range of electrode.
• Designed to make maintenance and servicing easy.

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

• 115 Volt Receptacle with 10 Amp Circuit Breaker.
Domestic and Canadian Models Only.
• 220 Volt European (Schuko) type Receptacle with 2
Amp Circuit Breaker. European Model Only.
• Low Voltage Trigger Circuit (18 VAC) for maximum
operator safety.
• Remote Receptacle for Amptrol or Arc Start Switch
connection.
• Gas Valve Inlet fitting conforms to Compressed Gas
Association (CGA) standards.

SQUARE WAVE TIG 275

B-6

OPERATION

CONTROLS AND SETTINGS
All operator controls and adjustments are located on the case front of the Square Wave TIG 275. Refer to Figure
B.1 and corresponding explanations following.
FIGURE B.1 - CONTROL PANEL
5

2
11

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Output Control Knob
AC Wave Balance Knob
Post Flow Knob
Down Slope Time Knob
Mode Switch
Trimmer Potentiometer
Digital Ammeter
Digital Voltmeter
Thermal Protection Light
Power Switch
Polarity Switch
Electrode Connection (Twist-Mate Connector)
Work Connection (Twist-Mate Connector)
Remote Control Amphenol
Water Solenoid (Optional)

12
13

1. Current Control This knob is used to set
the welding current from 5 to 315 amps. Read the
complete Operating Instructions section for more
information on Local and Remote setting of current.
2. AC Wave Balance Control This knob is
active in the AC TIG mode only. It is used to set the
amount of cleaning and/or penetration produced
during an AC TIG weld. Auto Balance™ automatically sets the AC Wave balance according to the
welding current. If manual adjustment is desired,
the balance can be adjusted from +0 (maximum
cleaning)
to +10 (maximum penetration).
Read the Advanced Features section for a complete explanation of the AC Wave Balance.
2
3. Post Flow Time Control This knob is active
in the TIG mode only. It adjusts the post flow time
from 5 to 50 seconds for shielding gas. It also
adjusts cooling water flow when the optional
K1621-1 Water Solenoid Kit is used.

4. Down Slope Time Control This knob is
active in 4-Step TIG mode only. It adjusts the time
(from 0.5 to 10 seconds) the welding output takes to
ramp down from the preset level to 25% ±10% of
that level.
5. Mode Switch - A three position toggle switch used
to select the welding mode. Refer to the WELDING
OPERATION section for more information on how
the machine functions in each of the following
modes:
Stick:
This mode is used for the stick electrode
(SMAW) welding process. In this position the only
active control is the output current control. The output
terminals are continuously energized.
2-Step TIG:
This mode is used for the TIG (GTAW)
welding process. An Arc Start switch must be used to
weld. The Down Slope Time has no effect in this mode.

4-Step TIG:
This mode is used for the TIG (GTAW)
welding process. An Arc Start switch must be used to
weld. All controls are active in this mode.
SQUARE WAVE TIG 275

B-7

OPERATION

6. Trimmer Potentiometers - Allows the meters to
be calibrated in the field.

WELDING OPERATION

7. Digital Ammeter - The ammeter displays actual
welding current during a weld cycle and displays
the peak current for approximately 5 seconds after
welding is complete. Otherwise the machine’s set
current is displayed. Read the complete Operating
Instructions section for more information on the
Ammeter.

TIG WELDING

8. Digital Voltmeter - This meter displays welding
voltage, as measured on the output studs of the
Square Wave TIG 275. After welding is complete,
the meter displays the welding voltage corresponding to the peak welding current and displays this
value for approximately 5 seconds

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

9. Thermal Protection Light A yellow light which
only lights when an over temperature situation
occurs. See the Maintenance Section for more
information on thermostatic protection.
10. Power Switch - Turns power “ON”

“OFF”
to the welder. When switched “ON” the
digital meters will illuminate, indicating that the
power is on.
11. Polarity Switch - Selects DC+,

Familiarize yourself with the Controls and Settings
Section before attempting operation of the Square
Wave TIG 275.

TIG WELDING GUIDELINES

or the TIG 4-Step
Weld Mode. TIG 2-Step is typically used with Hand or Foot Amptrols, with Remote
Current control. TIG 4-Step typically uses an Arc Start
switch and Local Current Control, because it provides
a very brief current upslope, and a .5 to 10 second
adjustable current downslope. TIG 4-Step also functions like a trigger interlock, making it unnecessary to
hold down the Arc Start switch during a weld. If remote
current control is desired in this mode, a device which
provides separate arc start and current control must be
used. Read the TIG Welding Sequence of Operation
sections for more details on 2-Step and 4-Step operation.
Recommended tungsten electrode sizes, stickouts,
currents, cup or nozzle sizes are shown in Table B.1.
SINCE WELDING APPLICATIONS CAN VARY, THIS
CHART IS INTENDED AS A GUIDE ONLY.

or DC- - welding polarity without reconnecting
leads. DO NOT SWITCH WHILE WELDING.
12. Twist Mate Electrode

B-7

and

13. Work Connections Easy to connect electrode and work connections. This style Electrode
Connection makes the gas and current connections for the TIG torch at the same time. (Adapter
plugs are provided with the machine.)
14. Remote Receptacle For Amptrol, Arc Start
Switch or Robotic Interface connection.
15. Optional Water Solenoid Connections -

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

SQUARE WAVE TIG 275

B-8

OPERATION
TABLE B.1 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES
AC
DCEN ( - )

Tungsten
Electrode
Diameter
in. (mm)

DCEP ( + )

Unbalanced Wave

Balanced Wave

(2)

Approximate Argon
Gas Flow Rate
C.F.H. (1/min.)

Pure
Tungsten

1%, 2%
Thoriated
Tungsten
Zirconiated

Pure
Tungsten

1%, 2%
Thoriated
Tungsten
Zirconiated

2-15
5-15
10-60

2-15
5-20
15-80

2-15
10-20
20-30

--5-20
20-60

3-8
5-10
5-10

(2-4)
(3-5)
(3-5)

3-8
5-10
5-10

(2-4)
(3-5)
(3-5)

#4, #5, #6

(3-5)

9-13

(4-6)

#5, #6

1%, 2%
Thoriated
Tungsten

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

2-15
5-20
15-80

(3)

1/16

(1.6)

70-150

10-20

50-100

70-150

30-80

60-120

5-10

3/32
1/8

(2.4)
(3.2)

150-250
250-400

15-30
25-40

100-160
150-210

140-235
225-325

60-130
100-180

100-180
160-250

15-23 (7-11)

5/32
3/16
1/4

(4.0)
(4.8)
(6.4)

400-500
500-750
750-1000

40-55
55-80
80-125

200-275
250-350
325-450

300-400
400-500
500-630

100-240
190-300
250-400

200-320
290-390
340-525

21-25 (10-12) 13-17 (6-8)
23-27 (11-13) 18-22 (8-10)
28-32 (13-15) 23-27(11-13)

(3)
(3)

(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or
pure helium shielding gasses.
(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure . . . . . . . . . . . . . . . EWP
1% Thoriated . . . . . . . . EWTh-1
2% Thoriated . . . . . . . . EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for
2% Thoriated Tungsten in AC and DC applications.
(3) DCEP is not commonly used in these sizes.

TIG WELDING SEQUENCE OF OPERATION
WELDING IN TIG MODE (2-STEP)
RELEASE
(STEP #2)

Aluminum

13-17 (6-8)

Stainless
Steel

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

TIG Torch
Nozzle
Size (4), (5)

#6, #7, #8

#8, #10

(4) TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:
#4 = 1/4 in.
(6 mm)
#5 = 5/16 in.
(8 mm)
#6 = 3/8 in.
(10 mm)
#7 = 7/16 in.
(11 mm)
#8 = 1/2 in.
(12.5 mm)
#10 = 5/8 in.
(16 mm)
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles,
which are less prone to breakage, but cannot withstand high temperatures and high duty cycles.

3. Turn the welder, gas supply and water supply (if
equipped), on. The digital ammeter/voltmeter displays will illuminate when the power is on. NOTE:
Cooling fan may not be “ON” when not welding.
(See MAINTENANCE Section)
4. Set the MODE switch to “2-STEP TIG”.

PRESET CURRENT

5. Set the peak current displayed on the digital ammeter with the output control knob.

PRESS
(STEP #1)

PREFLOW
(0.5 sec FIXED)

OPTIONAL
TIG PULSER

POSTFLOW
(0.5 to 10 sec. ADJUSTABLE

In 2-STEP mode an Arc Start switch or Amptrol must
be used. The switch or Amptrol is pressed to start the
weld. (Step 1) Output continues until the switch or
Amptrol is released. (Step 2)
1. Connect the Twist Mate plug to the receptacle located on the front of the machine. The connection locks
into place with a quarter turn making both the power
and gas connections. See the TIG TORCH CONNECTION section to install the Twist Mate plug on
your torch.
2. Connect an Arc Start Switch or an Amptrol to the
Remote Amphenol.

6. Select AC or DC- electrode polarity. See Table B.2.
TABLE B.2
RECOMMENDED POLARITY
SETTINGS FOR TIG WELDING
Type of Welding

Electrode
Polarity

Stainless Steel

DC-

Aluminum & Magnesium

Other Metals

DC-

SQUARE WAVE TIG 275

B-9

OPERATION

8. Set the Post Flow Time with the post flow knob.
Post flow control knob adjusts the time that the
shielding gas flows (and cooling water flow, if the
optional water solenoid is used) after the weld
cycle. Use short post flow times with low currents
and small tungstens, use long post flow times at
high output currents with large tungstens.
9. With the torch held safely away from everything,
press the Arc Start Switch or Amptrol and set the
gas flow meter. Release the switch or Amptrol. The
welder is now ready for welding.
10. Position the tungsten electrode at the start of the
weld at a 65˚ to 75˚ angle with the horizontal so
that the electrode is approximately 1/8" (4 mm)
above the work piece. Press the Arc Start Switch.
This opens the gas (and optional water solenoid)
valves to automatically purge air from the hose
and torch. After a 0.5 second preflow time, the
high frequency becomes available to strike the arc.
11. Hold the Arc Start Switch or Amptrol down until an
arc is established. If using an Amptrol, read the
Section on Hand and Foot Amptrol Operation.
Release the Arc Start Switch or Amptrol to stop
the arc and start the Post Flow timer. After the
Post Flow time has expired, the gas and (optional
water solenoid) valves will close. To make another weld, repeat steps 10 and 11.

B-9

(STEP #2) First Release: The output current ramps up
to the preset level in 0.5 seconds.
(STEP #3) Second Press: The output current ramps
down to 5 Amps or 25% +/- 10 % of the preset current
(whichever is greater). The time it takes to ramp down
can be adjusted from approximately 0.5 to 10 seconds
with the Down Slope Time control knob.
(STEP #4) Second Release: Output is turned off stopping the weld and starting the 5 to 50 seconds post
flow set with the Post Flow control knob.
1. Connect the Twist Mate plug to the receptacle located on the front of the machine. The connection
locks into place with a quarter turn making both the
power and gas connections. See the TIG TORCH
CONNECTION section to install the Twist Mate plug
on your torch.
2. Connect an Arc Start Switch to the Remote
Amphenol.
3. Turn the welder, gas supply and water supply (if so
equipped), on. The digital ammeter/voltmeter display will illuminate when the power is on. NOTE:
Cooling fan may not be “ON” when not welding.
(See MAINTENANCE section)
4. Set the MODE switch to “4-STEP TIG”.
5. Set the peak current displayed on the digital ammeter with the output control knob.

WELDING IN TIG MODE (4-STEP)
PRESS #2
(STEP #3)

6. Select AC or DC- electrode polarity. See Table B.2.
PRESET CURRENT
PRESS #1
(STEP #1)

RELEASE #1
(STEP #2)

START
CURRENT

RELEASE #2
(STEP #4)

CRATER CURRENT
DOWNSLOPE
(0.5 to 10 sec. ADJUSTABLE

PREFLOW
(0.5 sec. FIXED)

POSTFLOW
(5 to 50 sec. ADJUSTABLE)
OPTIONAL
TIG PULSER

In 4-STEP mode an Arc Start switch must be used.
The switch is pressed and then released to start the
weld cycle. Pressing and releasing the switch a second time ends the weld cycle. This eliminates the need
to continuously hold down the switch during the weld.
The process works as follows:
(STEP #1) First Press: Initiates a 0.5 second preflow
of shielding gas then starts the weld at a current equal
to 5 Amps or 25% +/- 10 % of preset current (whichever is greater).

7. If welding with AC polarity, set the AC Wave
Balance Knob to Auto Balance™. This gives the
optimum ratio between cleaning and penetration,
automatically adjusted for the output current. If
manual adjustment of the AC Wave Balance is
desired, adjust the wave balance to the desired settings. See the Advanced Features section for more
information on setting and using the AC Wave
Balance.
8. Set the Post Flow time with the Post Flow knob.
Post Flow time provides shielding gas flow (and
cooling water, if used) after the weld. Use short
Post Flow times with low currents and small tungstens and long Post flow times at high output currents and large tungstens.
9. Set the Downslope Time with the Downslope Time
Knob. This will adjust the time of the crater fill period.

SQUARE WAVE TIG 275

B-10

OPERATION

10. With the torch held safely away from everything,
press the Arc Start Switch and set the gas flow
meter. Release the switch. The welder is now ready
for welding.
11. Position the tungsten electrode at the start of the
weld at a 65˚ to 75˚ angle with the horizontal so that
the electrode is approximately 1/8" (4 mm) above the
work piece. Press the Arc Start Switch. This opens
the gas and water valves to automatically purge air
from the hose and torch. After a 0.5 second preflow
time, the high frequency becomes available to strike
the arc.
12. Hold the Arc Start Switch down until an arc is established. The arc will start at a low current value that is
equal to 25% +/- 10 % of the preset current established in Step 5 or 5 Amps, whichever is greater.
13. Release the Arc Start Switch and the current will
ramp up to the preset maximum current in 0.5 seconds and remain there indefinitely.
14. Press the Arc Start Switch a second time to initiate
the Down Slope time. The current will ramp down to
a crater fill level of 25% +/- 10 % of the preset current
or 5 Amps whichever is greater within the time set
with the Down Slope knob in Step 9.
15. Release the Arc Start Switch to stop the arc and start
the Post Flow timer. After the post flow time has
expired, the gas and optional water valves will close.
The make another weld, repeat steps 11 through 15.

HAND AND FOOT AMPTROL OPERATION
Both the Hand and Foot Amptrol work in a similar manner. They are meant to be used for remote current control. The TIG 2-Step mode must be selected when
using an Amptrol for remote current control.
For simplicity, the following explanation will refer only to
"Amptrols", meaning both Foot and Hand models. The
term "minimum" refers to a Foot pedal in the "up" position, as it would be with no foot pressure, or a Hand
Amptrol in the relaxed position, with no thumb pressure. "Maximum" refers to a fully depressed Foot
Amptrol, or a fully extended Hand Amptrol.
The Amptrol is capable of controlling the output current
from 5 amps to the preset current on the output control
knob. For example, if the preset is at 200 amps, the
Amptrol, when depressed just past its minimum position, will cause the Square Wave TIG 275 to weld at 5
amps. At the Amptrol's maximum position, the output
will be near 200 amps.
It is important to note that, for many applications, the
tungsten will not start an arc at only 5 amps. (Refer to

B-10

the TIG Welding Guidelines for recommended tungsten
currents.) To start an arc reliably, it is important to
depress the Amptrol far enough so that the machine
output current is near the tungsten operating range. In
the example above, a 3/32" tungsten may be used on
DC- to weld near 200 amps. To start the weld, the
operator may have to depress the Amptrol approximately 1/4 of the way down, or to nearly 50 amps, in
order to start the arc. Merely depressing the Amptrol to
its 5 amp minimum position will not start the arc.

ADVANCED TIG WELDING FEATURES
AC WAVE BALANCE AND AUTO BALANCE™
The AC Wave Balance feature is unique to the Square
Wave TIG 275. It is active only in AC TIG mode. It controls the amount of positive and negative current in the
AC output.
The Square Wave TIG 275 allows the operator to select
Auto Balance™. This selection provides automatic
adjustment of the AC Wave Balance; it is suitable for
most welding conditions. Auto Balance™ gives the
ideal amount of cleaning and penetration, based on the
welding current output.
Manual adjustment of the AC Wave Balance is also
possible. Manual Balance settings vary from 0 (maximum cleaning) to 10 (maximum penetration). A setting
of 3 yields a balanced output (equal amounts of cleaning and penetration). Use the following as a guide
when setting the Balance manually:
BALANCED (3): The amounts of positive and negative are the same.
CLEANING (0 to 2): Provides more positive current
than negative current. Since the positive current produces the "cleaning" or oxide removal
on aluminum, this setting is used for welding on
heavily oxidized aluminum.
PENETRATION (4 to 10): Provides more negative current than positive. The arc plasma will be more
concentrated and more easily directed to
where the heat is needed. Higher penetration
settings allow a given size of tungsten to carry
more current.
CAUTION: Use only the amount of cleaning required
because the greater amount of positive current will
heat the tungsten more and possibly cause it to melt or
"spit". Also, the arc is usually more flared and less stable with more cleaning current.
In general, use just enough "cleaning" to remove
oxides and to give good wetting of the puddle.

SQUARE WAVE TIG 275

B-11

OPERATION

STICK WELDING
1. Turn the welder “ON”. The digital ammeter/voltmeter
will illuminate when the power is on.
2. Set the Mode Switch to “STICK”. Set the output current displayed on the digital ammeter with the
Output Control Knob. No other functions or adjustments operate in the Stick Mode.
3. Select the desired DC+/AC/DC- electrode polarity.
4. Clamp the electrode in the electrode holder, start
the weld by lightly touching the electrode to the
work. Stop the weld by pulling the electrode away
from the work piece.

AUXILIARY POWER
60 HERTZ DOMESTIC MACHINES
The Square Wave TIG 275 machines rated for 60 Hz
operation provides 10 amps of 115 volt AC power at a
standard NEMA 5-15R receptacle, located on the
lower case back of the machine. This circuit is protected from shorts and overloading by a 10 amp circuit
breaker, located next to the receptacle. The auxiliary
circuit is intended for running water coolers and small
power tools, whose current draw is within the 10 amp
rating. Note that 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. If this situation occurs, the user
should refrain from using the Square Wave TIG 275
auxiliary for that equipment.

50/60 HERTZ EUROPEAN MACHINES
The Square Wave TIG 275 machines rated for 50/60Hz
operation provides 2 amps of 220 volt AC power at a
continental European (Schuko) type receptacle, located on the lower case back of the machine. This circuit
is protected from shorts and overloading by a 2 amp
circuit breaker, located above the receptacle. The auxiliary circuit is intended for running water coolers
whose current draw is within the 2 amp rating of the
receptacle. Note that some types of equipment, especially pumps and motors, have starting currents which
are significantly higher than their running currents.
These higher starting currents may cause the circuit
breaker to open. If this situation occurs, the user
should refrain from using the Square Wave TIG 275
auxiliary for that equipment.

SQUARE WAVE TIG 275

B-11

C-1

ACCESSORIES

ACCESSORIES INCLUDED WITH
MACHINE
K852-50 - Twist Mate Cable Plug for #2 to #1 Work
Lead.
K1622-1 - Twist Mate Adapter Kit for LA9 and LA17
Torches.
K1622-2 - Twist Mate Adapter Kit for LW18 and LW20
Torches.

C-1

OPTIONAL ACCESSORIES
K963-1, -2 - Hand Amptrol
K870 - Foot Amptrol
K814 - Arc Start Switch
K559-2 - Magnum® Cooler Mounting Bracket
K932-1 - Undercarriage When the undercarriage is
properly installed, the Square Wave TIG 275 lift bale is
nonfunctional. Do not attempt to lift the power source
with the undercarriage attached. The undercarriage is
designed for hand moving only; mechanized towing
can lead to personal injury and/or damage to the
Square Wave TIG 275.
K1619-1 - TIG Pulser Kit
K1620-1 - Power Factor Capacitor Kit
K1621-1 - Water Solenoid Kit
K1622-3 - Twist Mate Adapter Kit for LA26 Torch
K852-70 - Twist Mate Cable Plug for 1/0 to 2/0 Work
Lead
K852-95 - Twist Mate Cable Plug for 2/0 to 3/0 Work
Lead

SQUARE WAVE TIG 275

D-1

MAINTENANCE

SAFETY PRECAUTIONS

OVERLOAD PROTECTION
THERMOSTATIC PROTECTION

WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this maintenance.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this
equipment.
• Do not touch electrically hot
parts.

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

ROUTINE AND PERIODIC MAINTENANCE
Very little routine maintenance is necessary to keep
your Square Wave TIG 275 running in top condition.
No specific schedule can be set for performing the following items; factors such as hours of usage and
machine environment should be considered when
establishing a maintenance schedule.
1. Periodically blow out dust and dirt which may accumulate within the welder using an air stream.
2. Inspect welder output and control cables for fraying,
cuts, and bare spots.
3. Inspect the spark gap at regular intervals to maintain the recommended spacing. See the Service
Procedures Section for complete information on
spark gap settings.
4. The fan motor has sealed ball bearings which
require no maintenance.

This welder has thermostatic protection from excessive
duty cycles, overloads, loss of cooling, and high ambient temperatures. When the welder is subjected to an
overload or loss of cooling, a thermostat will open. This
condition will be indicated by the illumination of the yellow Thermostatic Protection Light on the case front
(see Figure 3). The fan will continue to run to cool the
power source. No welding is possible until the machine
is allowed to cool and the Thermostatic Protection
Light goes out.

FAN AS NEEDED (F.A.N.)
The Square Wave TIG 275 has the F.A.N. circuit feature, which means the cooling fan will operate only
while welding; then for about 6 minutes after welding
has stopped. The cooling fan will operate continuously if the yellow Thermostatic Protection Light in “ON”.
(See Design Features and Advantages Section)

SERVICE PROCEDURES
WARNING
Use extreme caution when working with the secondary
circuit of the high frequency transformer. Turn the input
power off using the disconnect switch or fuse box
before working inside the machine. This is particularly
important when working on the secondary circuit of the
high voltage transformer (T3) because the output voltage is dangerously high.
DO NOT APPLY POWER TO THE SQUARE WAVE
TIG 275 WITH THE SIDES AND ROOF REMOVED.
The case front and case back assemblies tend to lean
in towards the center assembly; there is a danger of a
short circuit when this occurs. If you must troubleshoot
the machine with power applied, do so with the roof in
place, and check for shorts before applying power.
-----------------------------------------------------------------------Operation of the Square Wave TIG 275 should be trouble-free for the life of the machine. Should a malfunction occur, however, the following procedures will be
useful to trained service personnel with experience in
repairing arc welding equipment.

SQUARE WAVE TIG 275

D-2

MAINTENANCE

COMPONENT LOCATION AND ACCESS

SPARK GAP ADJUSTMENT

Control PC Board:

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

Remove the left case side. Use a 3/8" Nut Driver or
other suitable tool.
Note: The Case side can be removed while roof is in
place, as long as the three screws which secure the
roof to the case side are removed. The PC Board is
mounted on left divider assembly and can be removed
with a phillips head screwdriver.

Display PC Board, Arc Starter/Bypass PC
Board:
Remove the roof and both case sides. Use a 3/8" Nut
Driver or other suitable tool. These PC Boards are
located on the inside case front of the machine.

Spark Gap Assembly,
Transformer:

High

To adjust the spark, first be sure that the input power to
the machine is ‘OFF’ AT THE DISCONNECT SWITCH
OR FUSE BOX. The high voltages developed in the
high frequency circuit can be lethal. Next, remove the
right case side. Use a 3/8" Nut Driver or other suitable
tool. Disconnect the two push on wires to the spark
gap blocks and pull back the dust shield. Check the
spark gap spacing with a feeler gauge. If adjustment is
required, pull off one of the two leads going to the aluminum spark gap blocks. Adjust the gap by loosening
the Allen head screw, reset the gap and tightening the
screw in the new position. Replace the dust shield and
the two leads removed earlier. Reinstall the case side.

Voltage

FIGURE D.1 SPARK GAP

Remove the right case side. Use a 3/8" Nut Driver or
other suitable tool. The high voltage transformer is
mounted to the base. The spark gap assembly is located on the inside case front.
.015 Spark Gap

Main Rectifier:
Remove the roof and both case sides. Next, remove
the case back assembly. Use a 3/8" Nut Driver or other
suitable tool. The main rectifier is mounted to the main
transformer, in front of the cooling fan.

RIGHT SIDE VIEW OF MACHINE

SQUARE WAVE TIG 275

E-1

TROUBLESHOOTING

E-1

HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
and machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function problems, TIG mode problems, TIG welding problems and Stick welding Problems.

Step 3. RECOMMENDED COURSE OF
ACTION
If you have exhausted all of the items in step
2. Contact your Local Lincoln Authorized
Field Service Facility.

Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.

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

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SQUARE WAVE TIG 275

E-2

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

RECOMMENDED
COURSE OF ACTION

GENERAL MACHINE TROUBLE
Machine will not turn on.

1. Input supply not "hot". Check input supply line voltage and fuses.
2. Input power switch (S1) faulty. Check
and replace.

No machine output.

1. Make sure the input Power Switch (S1) is
in the “ON” position.
2. A protective thermostat may be open.
An open thermostat disables machine
output. Allow machine to cool and thermostat will close. The yellow thermal
light (TL1) should be lit in this condition.
3. If the machine is not “hot” (i.e. you have
not been welding) and the thermostat
light is lit, the thermostat wiring or a thermostat may be faulty. Check for continuity between leads 313 and 314 at P3 on
the Control PC Board. If not present,
test each wire and thermostat individually.
4. The Control PC Board may be faulty.
See
PC
Board Troubleshooting
Procedures
5. Main Transformer (T1) may be faulty.

Control panel display does not func- 1. Check for loose connections at the
tion, but the output is normal.
Control PC Board (P4) or at the Display Contact your Local Lincoln Authorized
Field Service Facility for technical
Board (P20 & P21)..
2. The Display PC Board may be faulty. troubleshooting assistance.
See
PC
Board Troubleshooting
Procedures.
3. The Control PC Board may be faulty.
See
PC
Board Troubleshooting
Procedures.

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

1. Check leads 252 and 253 and their connections to the Polarity Switch (S2) and
to the Control PC Board connection (J6).
2. The Display PC Board may be faulty.
See
PC
Board Troubleshooting
Procedures.

E-3

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

RECOMMENDED
COURSE OF ACTION

GENERAL MACHINE TROUBLE
The Ammeter displays “000", but the 1. The shunt lead connections may be
open. Check the red lead (222) and
machine has output with no control.

white lead (221) twisted pair all the way
from the shunt back to the Control PC
board connector (J2).
2. The Control PC Board may be faulty.
See
PC
Board Troubleshooting
Procedures.

One of the meters is blank.

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

1. Check for loose connections at Control
PC Board (P4) and at the Display PC
Board (20 & 21)The Display.
2. The Display PC Board may be faulty.
See
PC
Board Troubleshooting
Procedures.
1. Is accessory defective? Plug it into a
known "hot" receptacle to see if it works.
2. Circuit Breaker CB may be open. Before
resetting the circuit breaker, find out why
it opened. See the Auxiliary Power section for more information.

Contact your Local Lincoln Authorized

Machine regularly overheats; thermostat (s) open.

1. Check for proper voltage at fan.
Field Service Facility for technical
If proper voltage is present, but fan is not
rotating or is rotating slowly, replace fan troubleshooting assistance.
motor.
If proper voltage is not present, but fan is
not rotating or is rotating slowly, the output fan circuit on the control PC Board
may be faulty.
2. Dirt and dust have clogged the cooling
channels inside the machine. Blow out
the machine with clean, dry compressed
air.
3. Are the duty cycles being exceeded?
Read the Instruction Manual thoroughly
for duty cycle information.
4. Is there adequate clearance around the
side and back of the machine, especially
near the intake and exhaust louvers? Do
not block the flow of cooling air during
operation.

E-4

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

RECOMMENDED
COURSE OF ACTION

GENERAL MACHINE TROUBLE
The machine makes a very loud 1. Diode D1 may be shorted. Check
Contact your Local Lincoln Authorized
buzzing noise in DC stick, or in DC
and replace.
TIG when the Arc Start Switch or 2. One of the main SCR’s may be Field Service Facility for technical
troubleshooting assistance.
Amptrol is pressed.
shorted. Check and replace.
The machine has output and the 1. Check and replace 5 Amp Fuse
meters are “ON” but there is no high
(F1) located below the Control PC
frequency present and the gas soleBoard on the right. (Fuse is prenoid does not function.
sent on European models only)
High frequency is present, but bad 1. Check and replace 5 Amp Fuse
starting at low currents.
(F2) located below the Control PC
(Approximately 15 Amps and below)
Board on the left. (Fuse is present
on European models only)

STICK WELDING TROUBLE
Stick electrode "Blasts Off" when 1. Weld current is set too high for
touched to the work piece.
electrode size. Reduce the preset
current.
2. One of the main SCR’s may be Contact your Local Lincoln Authorized
Field Service Facility for technical
shorted.
3. The Control PC Board may be troubleshooting assistance.
faulty.
See
PC
Board
Troubleshooting Procedures.
Cannot adjust AC Wave Balance.

1. AC Wave Balance Function is only
operational in the AC TIG mode.
2. The Control PC Board may be
faulty.
See
PC
Board
Troubleshooting Procedures.

Variable or sluggish welding arc.

1. Poor work or electrode connection.
2. Welding leads too small. Use
larger work and electrode leads
3. Welding current set too low.

E-5

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

RECOMMENDED
COURSE OF ACTION

TIG WELDING TROUBLE
Machine does not respond (no gas 1. Defective Arc Start Switch or
flow, no high frequency, no open cirAmptrol. Check for continuity
cuit voltage) when Arc Start Switch
between pins D and E on cable
or Amptrol is pressed. Thermal light
connector when Arc Start Switch
is not lit.
or Amptrol is pressed.
2. The Control PC Board may be
faulty.
See
PC
Board
Troubleshooting Procedures.
No gas or water flow (with optional
water solenoid) when Arc Start
Switch or Amptrol is pressed in the
TIG Weld Mode.

No High Frequency.

1. Gas supply is empty or not turned
on.
2. Pinched, disconnected, or leaking
gas or water hose.
3. Gas and/or water lines or solenoids are blocked with dirt. Clean
out and use filters to prevent reoccurrence.
4. Defective gas and/or water solenoid. Check and replace.
5. The Control PC Board may be
faulty.
See
PC
Board
Troubleshooting Procedures.
Contact your Local Lincoln Authorized
1. Spark gap is too large. Reset gap Field Service Facility for technical
per Periodic Maintenance Section troubleshooting assistance.
instructions.
2. Check gas solenoid operation. If it
is not working, check 115V circuit
from Main Transformer (T1).
Check Fuse (F1) on European
models only.
3. Defective high voltage transformer
(T2). Check and replace.
4. One or more of the following
components may be open: R5 or
C6. Check and replace.
5. The Control PC Board may be
faulty.
See
PC
Board
Troubleshooting Procedures.

E-6

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

RECOMMENDED
COURSE OF ACTION

TIG WELDING TROUBLE
Weak High Frequency.

1. Spark gap is too close. Reset
gap per Periodic Maintenance
Section instructions.
2. Work and electrode cables in
poor condition, allowing high frequency to "leak" to ground. Use
good quality cables, preferably
those with a high natural rubber
content, and as short as possible.
3. No shielding gas. Adjust gas
flow for a flow of 10 to 30 CFH
(4.7 to 14.1 1/min) for most applications. (High frequency will not
jump from the tungsten to work
without shielding gas).

Output quits momentarily; gas flow
and high frequency are also interrupted.

1. May be caused by high frequency interference. Is the machine
grounded properly, according to
the installation instructions? Are Contact your Local Lincoln Authorized
there other machines in the area Field Service Facility for technical
which may be strong sources of troubleshooting assistance.
high frequency? Make sure that
they are also properly installed
and grounded.
2. Some internal ground connections may have become loose.
Check that the screws which
mount the Control PC Board and
the Bypass Stabilizer PC Board
are tight. Also, all case parts
should be in place, and the case
screws should be tight.

E-7

TROUBLESHOOTING
BYPASS / STABILIZER PC BOARD

PC BOARD TROUBLESHOOTING
PROCEDURE
Before replacing a PC Board which is suspected of being
defective, visually inspect the PC Board in question for any
electrical or mechanical damage to any of the components or
conductors on the board, partially insulated molex pins or
connectors.
a. If there is no visible damage to the PC Board, install a new
one and see if this remedies the problem. If the problem
is remedied, reinstall the old PC Board to see if the problem still exists. If the problem no longer exists with old PC
Board:
1. Check the PC Board harness connector pins for
corrosion, contamination or looseness.
2. Check leads in the plug harness for loose or
intermittent connections.
b. If PC Board has visible electrical damage, before possibly
subjecting the new PC Board to the same cause of failure,
check for possible shorts, opens or grounds caused by:
1. Frayed or pinched lead insulation.
2. Poor lead termination, such as a poor contact or
a short to adjacent connection or surface.
3. Shorted or open control cable leads, or other
external leads.

The board is mounted between the output terminals. It
passes excess high frequency to ground before it can
reach the inside of the machine. For proper operation,
it must be securely grounded, by means of its ground
and mounting screws, to the case front. Failures of this
board should be very rare.

DISPLAY PC BOARD
The board is mounted directly to the front panel. The
Control P.C. Board supplies power and metering information to the board.

CONTROL PC BOARD
This board, located on the left divider assembly, is the
heart of the machine. All welding output is controlled
by this board. The Display board receives its information from the Control board as well. Very little external
diagnostic work can be performed on this board. If one
control or function of the machine does not appear to
be working, it is best to trace out the wiring associated
with that function all the way back to the Control board
with an ohmmeter. If all checks out there, verify that
the following voltages are present at the output of the
auxiliary leads at the main transformer, T1.
CONTROL PC BOARD
AUXILIARY LEAD VOLTAGES

4. Foreign matter or interference behind the PC
Boards.
c. If PC Board has visible mechanical damage, inspect for
cause, then remedy before installing a replacement PC
Board.
If there is damage to the PC Board or if replacing PC
Board corrects problem, return it to the local Lincoln
Electric Field Service Shop.

INPUT - BYPASS PC BOARD (EUROPEAN
MODELS ONLY)
This board is mounted to the case front and connects
to the input power at the line switch. It passes excess
high frequency to ground, protecting the machine and
power line. For proper operation it must be securely
grounded, by means of its ground and mounting
screws to the case front. The quick connect terminals
from the line switch must be fully seated. Failures of
this board should be very rare.

Main Transformer (T1)
Auxiliary Lead Number

Plug P8
Locations

Approximate
Voltage

209 to 210
201 to 204
231 to 232A
211A to 212

1 to 9
4 to 6
2 to 12
13 to 14

18 VAC
18 VAC
115 VAC
23 VAC

Often, replacement with a known good board is the
best service method. Remove the board that is suspected to be defective. Carefully look over the board,
checking for burnt traces or components. If none are
found, install the known good board. If the trouble goes
away, reinstall the suspected bad board to confirm that
the board was indeed at fault. If the problem is now
gone with the original board installed, the problem is
probably with one of the leads or connectors going to
the board.
Consult the Lincoln Service Department if further troubleshooting assistance is required.

N.A.

SV1

FAN

N.B.

CONTROL PC BOARD

R 222 (-)

CONNECT A TO LOW (H2)

208 VOLT CONNECTION

CONNECT A TO MID (H3)

230 VOLT CONNECTION

TO GROUND PER

235A

234A

J7A

236

238

SV2

254

255

275

A
B
C
D
E
F

B
C
D
E
F

277C

243

251

MODE SWITCH

AT MINIMUM

10K A-B

TERMINAL

236A

RECEPTACLE

OPTIONAL

TL1

BRASS

THERMAL LIGHT

2 STEP TIG

277
276

312

277B
245

275B

275C

4 STEP TIG

STICK

275A

L2
TOROID

TIG
REMOTE
OR
AMPTROL TM
PULSER

POSTFLOW CONTROL

270

B 242

REMOTE

246

J20

DOWNSLOPE CONTROL

250
H1

236B

237

115VAC

BALANCE CONTROL

248

CURRENT CONTROL

255
254

LOW

J21

MID

N.C.

HIGH

TOROID

253

252

276
243
277

248

245

251
242

246
312
275

249

THERMOSTAT

PRIMARY

316

THERMOSTAT

SECONDARY

L2 (V)

L1(U)

NATIONAL
ELECTRICAL CODE

THERMOSTAT

CHOKE

313

247

216

220A

220

217

218

SCR4

POS

BYPASS/
STABILIZER
PC BOARD

253

SWITCH

POLARITY

FRONT GANG

232C

211B

POS

232

J4 AND J20 (i.e. PIN 1 TO PIN 1).

N.C. NOT PRESENT ON EARLIER PC BOARDS.

N.B. ROBOTIC INTERFACE CONNECTION.

211

N.A. CONNECTION IS PIN TO PIN BETWEEN

ARC STARTER AS'BLY

GAP

SPARK

SCR3

SCR2

SCR1

R 222

W 221

232A
211A

NEG

L2 (V)

252

CONNECT A TO HIGH (H4)

315

H4 (460V)

W 201

IN AC POSITION)

NO
NC

OPEN
CLOSED
CLOSED

ELECTRICAL SYMBOLS PER E1537.

S2A

(REAR VIEW, SHOWN

A-C, D-E, B-F
B-D, C-E, A-F, G-H
B-D, A-E, C-F, G-H

X4
X5
23VAC

S
F

MICRO SWITCH

212

211

B 231

231B

115VAC

B 232
232B

W 204

18VAC

X10

R 210

W 209

H3 (230V)
H2 (208V)

POLARITY SWITCH
AC
DC+
DC-

NEG

L1(U)

275C

460 VOLT CONNECTION (AS SHOWN)

G3
217
220
G2
G1
218
G4
216

261
260

314

WIRING DIAGRAM - SQUARE WAVE TIG 275 (208/230/460/1/60)

W 221 (+)

247
220A
201
212
236
W 211A
W 204
B 232A
234
238
B 231
235
R 210
W 209

SQUARE WAVE TIG 275

D
E
C

(-)

F
B
A

(+)

277A

WIRING DIAGRAM
L10747

7-24-98

78VAC

F-1
F-1

IRON

FRONT

SV1

GAS VALVE

FAN

N.B.

CHOKE

235A

234A

J7A

SV2

236A

TOROID

253

252

276
243
277

248

245

251
242

246
312
275

249

WATER VALVE (OPTIONAL)

236

238

254

255

THERMOSTAT

PRIMARY

316

THERMOSTAT

SECONDARY

J20

J21

A
B
C
D
E
F

B
C
D
E
F

277C

243

251

275

RECEPTACLE

MODE SWITCH

BRASS

AT MINIMUM

10K A-B

TERMINAL

TIG
PULSER

OPTIONAL

TL1

THERMAL LIGHT

2 STEP TIG

312

277B
245

275B

275C

4 STEP TIG

STICK

275A

REMOTE
AMPTROL

276

277

TOROID

236B

237

115VAC

BALANCE CONTROL

248

CURRENT CONTROL

247

216

220A

220

217

POWER FACTOR
CAPACITORS (OPTIONAL)

218

BYPASS
PC BOARD

POSTFLOW CONTROL

270

B 242

N.C.

DOWNSLOPE CONTROL

POWER SWITCH

REMOTE

246

PC BOARD

DISPLAY

255
254

LOW

MID

HIGH

L2 (V)

RECONNECT PANEL

L2 (V)

L1(U)

NATIONAL
ELECTRICAL CODE

TO GROUND PER

THERMOSTAT

BACK

CASE

CONTROL PC BOARD

N.A.

CASE

R 222 (-)

BASE

W 221 (+)

PROTECTIVE BONDING CIRCUIT

CONNECT A TO LOW (H2)

220 VOLT CONNECTION

314

CONNECT A TO MID (H3)

313

380 VOLT CONNECTION

315

SCR4

POS

BYPASS/
STABILIZER
PC BOARD

253

SWITCH

POLARITY

FRONT GANG

ELECTRODE

POS

220VAC

211B

232

J4 AND J20 (i.e. PIN 1 TO PIN 1).

N.C. NOT PRESENT ON EARLIER PC BOARDS.

N.B. ROBOTIC INTERFACE CONNECTION.

WORK

N.A. CONNECTION IS PIN TO PIN BETWEEN

ARC STARTER AS'BLY

GAP

SPARK

SCR3

SCR2

SCR1

R 222

W 221

211A

232A

NEG

L1(U)

252

CONNECT A TO HIGH (H4)

H4 (415V)

H5 (440 V)

A-C, D-E, B-F
B-D, C-E, A-F, G-H
B-D, A-E, C-F, G-H

78VAC

LATCH

1 2 3

ELECTRICAL SYMBOLS PER E1537.

WIRING DIAGRAM
L10747-1

10-16-98

EXAMPLE: THIS IS PIN 7
0F CONNECTOR J5

COMPONENT VALUE
UNITS:
RESISTORS:
OHMS/WATTS
CAPACITORS:
MFD/VOLTS

VIEW OF CONNECTOR ON PC BOARD

1 2 3

CONNECTOR PIN NUMBERS:

U-BLUE
W-WHITE
Y-YELLOW

LEAD COLORING CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED

OPEN
CLOSED
CLOSED

POWER FACTOR CAPACITORS, 50/460
HIGH VOLTAGE CAPACITOR, .0015/12kV
PHASE SHIFT CAPACITOR 15uF/250VAC
CIRCUIT BREAKER, 2 AMP
FREE WHEELING DIODE
DIODE
FUSE, 5A FAST BLOW
FUSE, 5A FAST BLOW
OUTPUT INDUCTOR (CHOKE)
HI-FREQ PROTECTION CHOKE (TOROID)
HI-FREQ INDUCTORS
TOROID
CURRENT CONTROL POTENTIOMETER 10K
BALANCE CONTROL POTENTIOMETER 10K
POSTFLOW CONTROL POTENTIOMETER 10K
DOWNSLOPE CONTROL POTENTIOMETER 100K
PHASE SHIFT RESISTOR 200/100
HOLDING RESISTOR 50/225
RESISTOR 7.5/100
RESISTOR 1/25
INPUT POWER SWITCH
POLARITY SWITCH
MICROSWITCH ON POLARITY SWITCH
3 WAY MODE SWITCH
MAIN SCRs
GAS SOLENOID, 115VAC
WATER SOLENOID, OPTIONAL, 115VAC
MAIN TRANSFORMER
HIGH VOLTAGE TRANSFORMER
HI-FREQ TRANSFORMER
THERMAL LIGHT, LED

IN AC POSITION)

C1,C2
C5
C6
CB
D1
D2
F1
F2
L1
L2
L3,L4
L5
R1
R2
R3
R4
R5
R6
R7
R8
S1
S2
S2A
S3
SCR1,2,3,4
SV1
SV2
T1
T2
T3
TL1

MICRO-SWITCH

S2A

(REAR VIEW, SHOWN

REAR GANG

220VAC
X12

X11

23VAC

X4
X5

115VAC

18VAC

W X7

18VAC

MICRO SWITCH

212
52

B 231
211

W 204
B 232

R 210
W 201

H3 (380V)
H2 (220V)
H1
W 209
X10

POLARITY SWITCH
AC
DC+
DC-

211

NEG

415 VOLT CONNECTION (AS SHOWN)

WIRING DIAGRAM - SQUARE WAVE TIG 275 (220/380/415/1/50/60)

F
B
A

G3
217
220
G2
G1
218
G4
216

261
260

277A

(-)

247
220A
201
212
236
W 211A
W 204
B 232A
234
238
B 231
235
R 210
W 209

275C

(+)

SQUARE WAVE TIG 275

D
E
C

312

F-2
F-2

460 VOLT CONNECTION

N.A.

W 221 (+)

SV1

GAS VALVE

FAN

N.B.

CONTROL PC BOARD

R 222 (-)

CONNECT A TO LOW (H2)

TO GROUND PER

235A

234A

J7A

SV2

J20

J21

A
B
C
D
E
F

B
C
D
E
F

277C

243

B 242

275

251

MODE SWITCH

236A

RECEPTACLE

TIG
REMOTE
OR
AMPTROL TM
PULSER

AT MINIMUM

10K A-B

TERMINAL

BRASS

TOROID

TL1

THERMAL LIGHT

2 STEP TIG

312

4 STEP TIG

STICK

275A

277B
245

275B

275C

276

277

TOROID

OPTIONAL

POSTFLOW CONTROL

270

236B

237

115VAC

BALANCE CONTROL

248

CURRENT CONTROL

POWER FACTOR
CAPACITORS (OPTIONAL)

250

DOWNSLOPE CONTROL

N.C.

POWER SWITCH

REMOTE

246

PC BOARD

DISPLAY

255
254

LOW

MID

HIGH

L2 (V)

253

252

276
243
277

248

245

251
242

246
312
275

249

WATER VALVE (OPTIONAL)

236

238

254

255

THERMOSTAT

PRIMARY

316

THERMOSTAT

SECONDARY

RECONNECT PANEL

L2 (V)

L1(U)

NATIONAL
ELECTRICAL CODE

THERMOSTAT

CHOKE

313

CONNECT A TO HIGH (H4)

315

247

216

220A

220

217

218

SCR4

POS

115VAC

BYPASS/
STABILIZER
PC BOARD

253

SWITCH

POLARITY

FRONT GANG

232C

211B

ELECTRODE

POS

232

J4 AND J20 (i.e. PIN 1 TO PIN 1).

N.C. NOT PRESENT ON EARLIER PC BOARDS.

N.B. ROBOTIC INTERFACE CONNECTION.

WORK

211

N.A. CONNECTION IS PIN TO PIN BETWEEN

ARC STARTER AS'BLY

GAP

SPARK

SCR3

SCR2

SCR1

R 222

W 221

232A
211A

NEG

252

L1(U)

W 201

A-C, D-E, B-F
B-D, C-E, A-F, G-H
B-D, A-E, C-F, G-H

78VAC

LATCH

1 2 3

ELECTRICAL SYMBOLS PER E1537.

WIRING DIAGRAM
L10747-2

10-16-98

EXAMPLE: THIS IS PIN 7
0F CONNECTOR J5

COMPONENT VALUE
UNITS:
RESISTORS:
OHMS/WATTS
CAPACITORS:
MFD/VOLTS

VIEW OF CONNECTOR ON PC BOARD

1 2 3

CONNECTOR PIN NUMBERS:

U-BLUE
W-WHITE
Y-YELLOW

LEAD COLORING CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED

MICRO-SWITCH

OPEN
CLOSED
CLOSED

POWER FACTOR CAPACITORS, 50/460
BY-PASS CAPACITORS, .0047/3kV
HIGH VOLTAGE CAPACITOR, .0015/12kV
PHASE SHIFT CAPACITOR 15uF/250VAC
HI-FREQ PROTECTION CAPACITORS, .22/400
CIRCUIT BREAKER, 10 AMP
FREE WHEELING DIODE
DIODE
OUTPUT INDUCTOR (CHOKE)
HI-FREQ PROTECTION CHOKE (TOROID)
HI-FREQ INDUCTORS
TOROID
CURRENT CONTROL POTENTIOMETER 10K
BALANCE CONTROL POTENTIOMETER 10K
POSTFLOW CONTROL POTENTIOMETER 10K
DOWNSLOPE CONTROL POTENTIOMETER 100K
PHASE SHIFT RESISTOR 200/100
HOLDING RESISTOR 50/225
RESISTOR 7.5/100
RESISTOR 1/25
INPUT POWER SWITCH
POLARITY SWITCH
MICROSWITCH ON POLARITY SWITCH
3 WAY MODE SWITCH
MAIN SCRs
GAS SOLENOID, 115VAC
WATER SOLENOID, OPTIONAL, 115VAC
MAIN TRANSFORMER
HIGH VOLTAGE TRANSFORMER
HI-FREQ TRANSFORMER
THERMAL LIGHT, LED

IN AC POSITION)

C1,C2
C3,C4
C5
C6
C7,C8
CB
D1
D2
L1
L2
L3,L4
L5
R1
R2
R3
R4
R5
R6
R7
R8
S1
S2
S2A
S3
SCR1,2,3,4
SV1
SV2
T1
T2
T3
TL1

S2A

(REAR VIEW, SHOWN

REAR GANG

X4
X5
23VAC

S
F

MICRO SWITCH

212

211

B 231

231B

115VAC

B 232
232B

W 204

18VAC

X10

R 210

W 209

H2 (460V)

H4 (575V)

POLARITY SWITCH
AC
DC+
DC-

NEG

575 VOLT CONNECTION (AS SHOWN)

314

WIRING DIAGRAM - SQUARE WAVE TIG 275 (460/575/1/60)

F
B
A

G3
217
220
G2
G1
218
G4
216

261
260

277A

(-)

247
220A
201
212
236
W 211A
W 204
B 232A
234
238
B 231
235
R 210
W 209

275C

(+)

SQUARE WAVE TIG 275

D
E
C

312

F-3
F-3

40.65

20.00

28.00

3.57

15.37

4.00

24.06

3.57

.71

9.57

SQUARE WAVE TIG 275

27.65

17.50

19.15

22.89

A
M19118

33.40

F-4

DIMENSION PRINT
F-4

Now Available...12th Edition
The Procedure Handbook of Arc Welding

New Lessons in Arc Welding

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

Lessons, simply written, cover manipulatory techniques;
machine and electrode characteristics; related subjects, such
as distortion; and supplemental information on arc welding
applications, speeds and costs. Practice materials, exercises,
questions and answers are suggested for each
lesson.

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

528 pages, well illustrated, 6” x 9” size, bound in simulated,
gold embossed leather.
$5.00 postage paid U.S.A. Mainland

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

A must for all welders, supervisors, engineers and
designers. Many welding instructors will want to use the book as
a reference for all students by taking advantage of the low quantity discount prices which include shipping by
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$15.00 postage paid U.S.A. Mainland

Need Welding Training?
How To Read Shop Drawings
The book contains the latest information and application
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and draftsmen use the “short-cut” language of symbols to pass on
assembly and welding information to shop personnel.
Practical exercises and examples develop the reader’s ability
to visualize mechanically drawn objects as they will appear in
their assembled form.

The Lincoln Electric Company operates the oldest and
most respected Arc Welding School in the United States at its
corporate headquarters in Cleveland, Ohio. Over 100,000 students
have graduated. Tuition is low and the training is
“hands on”
For details write:

Lincoln Welding School
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199.

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

187 pages with more than 100 illustrations. Size 8-1/2” x 11”
Durable, cloth-covered board binding.
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BASIC COURSE
5 weeks of fundamentals

$700.00

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(ED-93)
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(JFLF-515)

Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
Titles:
New Lessons in Arc Welding
Procedure Handbook “Twelfth Edition”
How to Read Shop Drawings
Incentive Management
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Pipe Welding Charts

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● Do not touch electrically live parts or

WARNING
Spanish

AVISO DE
PRECAUCION
French

ATTENTION
German

WARNUNG
Portuguese

ATENÇÃO

● Keep flammable materials away.

● Wear eye, ear and body protection.

● Mantenga el material combustible

● Protéjase los ojos, los oídos y el

electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.

fuera del área de trabajo.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

cuerpo.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Mantenha inflamáveis bem guarda-

dos.

● Use proteção para a vista, ouvido e

corpo.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

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

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

remove fumes from breathing zone.
● Los humos fuera de la zona de res-

piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von

Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Strom vor Wartungsarbeiten

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

oder Innenschutzverkleidung in
Betrieb setzen!

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

● Mantenha-se afastado das partes

serviço.
● Não toque as partes elétricas nuas.

● Não opere com os paineis abertos

moventes.

WARNING
Spanish

AVISO DE
PRECAUCION
French

ATTENTION
German

WARNUNG
Portuguese

ATENÇÃO

ou guardas removidas.
Japanese

Chinese

Korean

Arabic

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

• 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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Creator                         : The Lincoln Electric Company
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Im609 SQUARE WAVE TIG 275 B

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