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USER SUPPLIED CONNECTORS
The Square Wave TIG 275 should be permanently
wired into the power system. No plugs or connectors
are necessary.
OUTPUT CONNECTIONS
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 elec-
trode 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
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 adequately-
sized welding cable. The Twist-Mate cable plug includ-
ed with the machine is designed to accept a welding
cable size of of #2 to #1. See Table A.1 and A.2 for rec-
ommended sizes and corresponding hardware.
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.
4. Slide the copper tube into the brass plug. Insert
skinned cable into the copper tube.
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 rub-
ber 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.
INSTALLATION
A-6 A-6
SQUARE WAVE TIG 275
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WARNING
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 (42.4mm
2
) 1/0 (53.5mm
2
) 2/0 (67.4mm
2
)
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
SEE
WELDING CABLE
TRIM
ABOVE
BOOT
COPPER TUBE
SET SCREW
(70-95 SIZE MAY
HAVE 2 SET
BRASS PLUG
SCREWS)