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Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation
. . . and thoughtful operation on your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And, most importantly, think before you act and be careful.
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PRECISION TIG 185
For use with machines having Code Number : 11105 thru 11109
SVM169-A
July, 2006
SERVICE MANUAL
Copyright © 2006 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
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.
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Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS may be dangerous
____________________________________________________
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.
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
PRECISION TIG 185
ii
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
SAFETY
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES can be dangerous.
5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon 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 ii
PRECISION TIG 185
iii
WELDING SPARKS can cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent the welding sparks from starting a fire.
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.
SAFETY
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 iii
PRECISION TIG 185
iv
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.
SAFETY 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
iv
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.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les
PRECISION TIG 185
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P499 Series
v
PRECISION TIG 185
Section A-1 TABLE OF CONTENTS
- INSTALLATION SECTION -
Section A-1
Installation ..............................................................................................................Section A
Machine Grounding and High Frequency Interference Protection ...........................A-4
Remote Control Connection........................................................................A-7
Stick Electrode Cable and Work Cable Connection ..........................................A-7
PRECISION TIG 185
A-2 INSTALLATION
TECHNICAL SPECIFICATIONS - PRECISION TIG 185 (K2345-1AND K2347-1,-2)
Standard Voltage
INPUT - SINGLE PHASE ONLY
Input Current at Rated Output
208/230/1/60 35A / 32A Effective and 70A / 64A Maximum
OUTPUT RANGE
Output Current
Range
Maximum Open
Circuit Voltage
Type of Output
7-185 Amps (AC)
5-185 Amps (DC)
(STICK AND TIG)
AC OCV: 75
DC OCV: 59
RATED OUTPUT
CC (Constant Current)
AC/DC
A-2
Duty Cycle
GTAW 15% Duty Cycle
100% Duty Cycle
SMAW 15% Duty Cycle
100% Duty Cycle
Amps
185A AC/DC
90A AC/DC (BAL)
70A AC (AUTO-BAL)
185A AC/DC125
90A AC/DC
Volts at Rated Amperes
15.2 V AC/DC
14.1 V AC/DC
13.8 V AC/DC
27.4 V AC/DC
23.6 V AC/DC
Chart gives max. rated Output Amps @% Duty Cycle (Based on a 10 minute cycle)
(Example; 110A@60% for AC/DC Stick and Balance TIG)
Using standard #8-3 input cable for protected
(1)
input supply
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
50 70 90 110 130
OUTPUT AMPS
150 170 190
(1)
Wiring and protection based on the 2002 U.S. National Electric Code:
Use a Super Lag type fuse or circuit breaker with a delay in tripping action.
Models with NEMA 6-50P plug may be used with a 50 amp protected 6-50R receptacle, or with a maximum 70 amp protected 6-50R receptacle if dedicated for the welder.
208/230v Model: AC/DC Stick & DC TIG
(AC TIG with #6-3 input cable)
460/575v Model: AC/DC Stick & AC/DC TIG
380/415v Model: AC/DC Stick &
DC/AC Auto-Bal.TIG
208/230v Model: AC TIG using 230v input
380/415v Model: AC TIG (Max. Penetration)
208/230v Model: AC TIG using 208v input
PRECISION TIG 185
A-3 INSTALLATION
TECHNICAL SPECIFICATIONS - CANADIAN (K2345-2), INTERNATIONAL K2346-1)
A-3
K2345-2 INPUT (at Rated Output)
Voltage/Phase/Freq.
Current Power Factor Idle Current
460/575/1/60 16 A/13 A Effective
32 A/26 A Max.
0.62 Min.
1.3 A/1.0 A Max.
Voltage/Phase/Freq.
380/400-415/1/50/60
N80
K2346-1 INPUT (at Rated Output)
Current
19 A/18 A Effective
39 A/37 A Max.
Power Factor
0.62 Min.
Idle Current
1.3 A/1.0 A Max.
Max. OCV.
74 V (AC)
59 V (DC)
OUTPUT RANGE
Weld Current
7-185 A (AC)
5-185 A (DC).
Output Type
CC (Constant Current)
AC or DC
RATED OUTPUT
Weld Current Process Duty Cycle*.
SMAW
15%
100%
GTAW
15%
100%
*
Based on a 10 minute cycle.
185 A AC/DC
90 A AC/DC
185 A AC/DC
90 A AC/DC (Auto-Bal.)
MODEL
Machine Only
(K2345-1,-2)
(K2346-1)
Ready-Pak
(K2347-1)
PHYSICAL DIMENSIONS
(2)
HEIGHT WIDTH DEPTH
20.71 in.
526 mm
14.48 in.
368 mm
25.62 in.
751 mm
20.71 in.
526 mm
14.48 in.
368 mm
25.62 in.
651 mm
Ready-PakW/Cart
(K2347-2)
31.24 in.
794 mm
(2) Dimensions are without Lift Eyebolt and Torch Holder
19.81 in.
503 mm
38.01 in.
966 mm
Weld Voltage (NEMA)
27.4 V
23.6 V
15.2 V
14.1 V
WEIGHT
Approx. 192 lbs.
87.1 kgs
Approx. 212lbs..
96.2 kgs.
Approx. 258lbs.
117.0 kgs.
PRECISION TIG 185
A-4
WARNING
INSTALLATION
SAFETY PRECAUTIONS
Read entire installation section before starting installation.
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this installation.
• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.
• Do not touch electrically hot parts.
• Always connect the SQUARE WAVE TIG 175 PRO to a power supply grounded per the National
Electrical Code and any local codes.
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SELECT SUITABLE LOCATION
Place the welder where clean cooling air can freely circulate in and out through the rear 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 shut-downs.
A-4
WARNING
• Use only Lincoln provided
T4550-5 1/2-13 x 1.00 eyebolt.
• Fully engage threads and torque eyebolt to 38 ft. lbs.
• Re-torque eyebolt to 38 ft. lbs.
before each lift.
• Lift only with equipment of adequate lifting capacity.
FALLING • Never lift welder with gas
EQUIPMENT cylinder attached.
cause injury. • Never lift welder above personnel.
• Lift only with equipment of adequate lifting
• Be sure machine is stable when lifting.
------------------------------------------------------------------------
An undercarriage, provided on the Ready-Pak w/Cart model, is also available to easily move the the unit.
Refer to the Accessories section of this manual.
Do not attempt to lift the power source with an undercarriage attached.
The undercarriage is designed for hand moving only; mechanized movement can lead to personal injury and/or damage to the Precision TIG 185.
GRINDING
Do not direct grinding particles towards the welder. An abundance of conductive material can cause maintenance problems.
TILTING
Each machine must be placed on a secure, level surface, either directly or on a recommended undercarriage. The machine may topple over if this procedure is not followed.
STACKING
ENVIRONMENTAL RATING
Square Wave TIG 185 cannot be stacked.
LIFTING AND MOVING
The PRECISION TIG 185 power source carries an
IP21 environmental rating. It may be used in normal industrial and commercial environments. Avoid using it in environments which have falling water such as rain.
The Precision TIG 185 models are provided with an
Eyebolt used for lifting the unit with a hoist. To install; remove the plug button from the case top and screw the Eyebolt securely into the threaded bracket beneath the case top per the below instructions and warnings provided on the case top decal. Save the removed plug button (LE part No.T10397-2) to cover the hole when the lift Eyebolt is removed.
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.
MACHINE GROUNDING AND HIGH FRE-
QUENCY INTERFERENCE PROTECTION
This welder must be grounded! See your local and national electrical codes for proper grounding methods.
PRECISION TIG 185
A-5 INSTALLATION
6. Keep cover and all screws securely in place.
The high frequency generator, being similar to a radio transmitter, may cause 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.
Radiated interference can develop in the following four ways:
A-5
7. Electrical conductors within 50 ft (15.2m) of the welder should be enclosed in grounded rigid metallic conduit or equivalent shielding, wherever possible. Flexible metallic conduit is generally not suitable.
1. Direct interference radiated from the welder.
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.
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.
INPUT CONNECTIONS
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.
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.
208/230 volt models have a NEMA 6-50P plug attached to the #8-3 input power cord and a NEMA 6 -
50R receptacle is included with the Ready-Pak models. Other voltage models have an input power cord but no plug or receptacle.
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.
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:
Have a qualified electrician provide input power supply to the receptacle or cord in accordance with all local and national electrical codes. Use a single phase line or one phase of a two or three phase line. Choose an input and grounding wire size according to local or
national codes. Refer to the Technical Specifications
page at the beginning of this section. Fuse the input circuit with the recommended super lag fuses or delay type 1 circuit breakers. Using fuses or circuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush currents even if not welding at high currents. 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.
1Also 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.
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 along pipe system can result in re-radiation, effectively making these members radiating antennas.
PRECISION TIG 185
A-6 INSTALLATION
INPUT RECONNECT PROCEDURE
On multiple input voltage welders, be sure the machine is connected per the following instructions for the voltage being supplied to the welder.
CAUTION
Failure to follow these instructions can cause immediate failure of components within the welder and void machine’s warranty.
-----------------------------------------------------------------------
Multiple voltage models are shipped connected for the highest voltage. To change this connection refer to the following instructions.
WARNING
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.
------------------------------------------------------------------------
For the lowest rated voltage connection (Refer to figure A.1):
1. Remove the sheet metal left side cover.
2. Disconnect lead H3 from the power switch and insulate with the insulation from the H2 lead.
3. Connect lead H2 to the power switch where H3 was connected.
4. Tighten connections.
5. Replace sheet metal cover and all screws
For the highest rated voltage connection (Refer to figure A.1):
The machine is normally shipped connected for the highest rated voltage, however verify the following:
1. Remove the sheet metal left side cover.
2. Disconnect lead H2 from the power switch and insulate with the insulation from the H3 lead.
3. Connect lead H3 to the line switch where H2 was connected.
4. Tighten connections.
5. Replace sheet metal cover and all screws.
INPUT LEADS
L1 & L2
LEAD H1
(DO NOT
REMOVE)
FOR LOWEST RATED VOLTAGE
: H2 CONNECTED
FOR HIGHEST RATED VOLTAGE
: H3 CONNECTED
BACK VIEW OF LINE SWITCH
FIGURE A.1 Reconnect Leads
OUTPUT CONNECTIONS
A-6
ELECTRODE/GAS
OUTLET
RECEPTACLE
(TWIST-MATE)
WORK CABLE & CLAMP
FIGURE A.2 Location of Output Connections
CONNECTIONS FOR TIG (GTAW) WELDING
TIG TORCH CONNECTION
Refer to Included Equipment in the Operation Section of this manual for TIG welding equipment which is included with the PRECISION TIG 185.
PRECISION TIG 185
A-7 INSTALLATION
A PTA-17 Twist-Mate TIG welding torch with cable and connector is supplied with the Ready-Pak Models and
available for other models (See Accessories
Section).
Turn the Power Switch “OFF”. Connect the torch cable
Twist-Mate quick connect plug into the Electrode/Gas
Output Receptacle on the front of the welder and turn it clockwise until it is tight. This is a Twist-Mate quick connect terminal and also provides the gas connection for the shielding gas to the torch.
REMOTE CONTROL CONNECTION
A-7
A cylinder is loaded by leaning it slightly sideways and rocking it up on the platform, being careful not to allow the Under-Storage Cart to roll. Secure the cylinder in
place with the provided chain. Unload by following these steps in reverse.
WARNING
To avoid receiving a high frequency shock, keep the TIG torch and cables in good condition.
------------------------------------------------------------------------
WORK CABLE CONNECTION
A remote control receptacle is provided on the case front of the welder for connecting a remote control to to the machine. A Foot Amptrol™, foot activated remote control, is included with the PRECISION TIG 185
Ready-Pak models and available separately for other
models. Refer to the Optional Accessories
section of this manual for other available remote controls.
CONNECTIONS FOR STICK (SMAW)
WELDING
A work cable with attached work clamp is factory connected to the PRECISION TIG 185. To minimize high
frequency interference, refer to Machine Grounding and High Frequency Interference Protection
section of this manual for the proper procedure on grounding the work clamp and work piece.
SHIELDING GAS CONNECTION
An adjustable gas pressure regulator with flow gage and hose is supplied with the PRECISION TIG 185
Ready-Pak Models and available separately for other
Section). Obtain the necessary inert shielding gas (usually argon). Connect the cylinder of gas with the pressure regulator and flow gage. Install the gas hose between the regulator and gas inlet (located on the rear of the welder). The gas inlet has a 5/16-18 right hand female thread;
CGA#032.
STICK ELECTRODE CABLE AND WORK
CABLE CONNECTION
Refer to Field Installed Options in Accessories Section of this manual for STICK welding equipment which is available for use with the PRECISION TIG 185. An electrode holder with Twist-Mate cable and Twist-Mate connector are available separately for use with the
PRECISION TIG 185. (See Accessories
Section).
Turn the Power Switch “OFF”. Connect the Twist-Mate quick connect plug into the Electrode/Gas Output
Receptacle and turn it clockwise until it is tight. The work cable and work clamp are factory connected.
The available Under-Storage Cart features a low platform that simplifies loading and unloading of gas cylinders.
WARNING
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.
------------------------------------------------------------------------
PRECISION TIG 185
A-8 NOTES A-8
PRECISION TIG 185
Section B-1 TABLE OF CONTENTS
- OPERATION SECTION -
Section B-1
Operation ................................................................................................................Section B
PRECISION TIG 185
B-2
SAFETY PRECAUTIONS
OPERATION B-2
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
Read and understand this entire section before operating the machine.
INPUT POWER
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 at the arc, or both, to remove fumes and gases from breathing zone and general area.
------------------------------------------------------------------------
WELDING SPARKS can cause fire or explosion
• Keep flammable material away.
• Do not weld on containers that have held combustibles.
POSITIVE OUTPUT
NEGATIVE OUTPUT
DIRECT CURRENT
PROTECTIVE
GROUND
WARNING OR
CAUTION
DO NOT SWITCH
WHILE WELDING
------------------------------------------------------------------------
ARC RAYS can burn.
• Wear eye, ear and body protection.
------------------------------------------------------------------------
Observe additional Safety Guidelines detailed in the beginning of this manual.
------------------------------------------------------------------------
PRECISION TIG 185
B-3
PRODUCT DESCRIPTION
OPERATION
RECOMMENDED EQUIPMENT/INTERFACE
(See Installed Options in Accessories Section for more details) The Precision TIG 185 is a member of our field acclaimed Precision TIG family of industrial arc weld ing power sources. Premium features include:
B-3
The Precision TIG 185 will be available as a basic
Machine (Only) and in two Factory-Configured Welding
Packages:
1. Precise constant current output.
2. Full range square wave AC/DC TIG (GTAW) weld-ing.
3. Enhanced version of the patented Micro-
Start™Technology for its lower Minimum(5 amps) to higher Maximum (185 amps) output control range.
4. Built-in high frequency stabilization for DC TIG starting and continuous AC TIG welding.
5. AC/DC Stick (SMAW capability.) A new undercarriage (with gas bottle rack) is available for field installation, or is included with an available Ready-
Pak TIG Welding Package. The Precision TIG patented convenient built-in storage provisions for welding components and cable management.
The Precision TIG 185 also provides advanced features such as:
• Digital Meter
• Presettable control, adjustable Auto Balance™
• Fan As Needed (F.A.N.)
• Timers for fixed Preflow and variable Postflow shielding gas.
• Built-in, easy to set single knob Pulse TIG control with a "blinking" light to indicate the pulse frequency setting.
• Auto-Sense remote control selection.
• Tool-less Twist-Mate electrode cable connection.
• Built-in work clamp cable permanently attached.
1. Machine(Only) (K2345-1)
2. Ready-Pak (K2347-1)
3. Ready-Pak w/Cart (K2347-2)
Basic module will also be available as with Domestic,
Canadian and International input voltages for user configuration, with optional accessories.
Select Machine 208/230/1/60 Machine with 6 NEMA 6-50P
Plug Cable and Receptacle (K2345-1)
460/575/1/60 Machine only with cable (K2345-2)
380/400/415/1/50/60 Machine only with cable (K2346-1)
Torch Starter Kit Air Cooled System: Water Cooled System:
(Select one) TIG-Mate TIG-Mate 20
Water Cooler
Torch Starter Kit*
Not Applicable
Torch Starter Kit*
115V 50/60Hz
Cool-Arc 40*
K2348-(*) Under-Storage
Cart (Optional )
Optional Remote
Trigger Device
(Select one)
Arc Start Switch*
Foot Amptrol*
Start Pedal Foot Amptrol*
Hand Amptrol*
*
For “Part Numbers” or “K Numbers” see Accessories Section.
EQUIPMENT LIMITATIONS
Four models are available for 60Hz. with Domestic and
Canadian input voltages, as well as an International model with 50/60Hz voltages.
The Precision TIG machines are protected from over loads beyond the output ratings and duty cycles, per the Specifications in the Installation Section, with
Thermostat protection of the output power coils and rectifiers.
RECOMMENDED PROCESSES AND
EQUIPMENT
The PRECISION TIG 185 machine uses Twist-Mate output terminals, therefore stud connection adapters
(such as LECO. S19257-series) cannot be used for torch connection.
RECOMMENDED PROCESSES
The Precision TIG 185 is recommended for the TIG
(GTAW) and Stick (SMAW) welding processes within its output capacity range of 5 amps DC,or 7 amps AC, to 185 amps AC/DC. It is compatible with most
Magnum TIG accessories, as well as many industry standard items, such as TIG torches (adapted for
Twist-Mate), hoses, and water coolers.
If a Precision Tig 185 is powered from an engine generator which doesn’t have sufficient capacity, the AC
Balance control and the Output control will not provide full range of control.
WELDING CAPABILITY(Duty Cycle)
PROCESS LIMITATIONS
The Precision TIG machines are not recommended for arc gouging due to it's limited output capacity, and are also not recommended for pipe thawing.
The PRECISION TIG 185 is rated at 185 amps, 27 volts, at 15% duty cycle on a ten minute basis. It is capable of higher duty cycles at lower output currents.
See rated output graph, on specification sheet located in the Installation Section. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools.
PRECISION TIG 185
B-4 OPERATION
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the front of the PRECISION TIG 185. Refer to Figure B.1
and corresponding explanations.
FIGURE B.1 - CONTROL PANEL
13
4
3
9 5
1. POWER SWITCH
2. POLARITY SWITCH
3. MODE SWITCH
4. AC BALANCE CONTROL
5. MAXIMUM OUTPUT CONTROL (AMPS)
6. DIGITAL METERS
7. POST FLOW TIME
8. PULSE TIG CONTROL
9. THERMAL SHUTDOWN LIGHT
10. REMOTE RECEPTACLE
11. ELECTRODE/GAS OUTPUT
RECEPTACLE
12. WORK CABLE
13. REMOVABLE LIFT EYEBOLT
B-4
8
6
7
1
2
11
10
CONTROL FUNCTIONALITY
1. POWER SWITCH – Input line switch turns input power ON or OFF, as indicated by the on or off status of the front panel digital display (See Item 6).
2. POLARITY SWITCH – The rotary power switch has
3-positions for DC+, AC and DC- selections for the electrode output stud welding polarity.
CAUTION
• Do not switch the polarity switch while welding or damage may result to the machine.
------------------------------------------------------------------------
3. MODE SWITCH – The push button switch allows selection of the two machine welding modes as indicated by colored mode lights:
• STICK mode – Top position Red light.
• TIG mode – Bottom position Green light.
4. AC BALANCE CONTROL – The AC Balance
Control permits adjustment of the AC TIG wave balance adjustment from Max. Penetration (80% negative wave) at full CW rotation setting, to Max.
Cleaning (60% positive wave) at CCW rotation, and includes:
12
• Auto Balance position indicated by the Green panel light turning on.
This setting position feature automatically provides the proper amount of cleaning and penetration for normal
AC TIG welding.
5. MAXIMUM OUTPUT CONTROL – Presets the output welding current over the rated output range of the machine:
• With a Remote Current Control (Amptrol) connected to the Remote Receptacle (See item 10), this knob sets the Maximum output current level set table with the remote Amptrol.
• For Pulse TIG (See Item 8) this knob sets the Peak
Pulse level, with the Remote Amptrol (if used).
6. DIGITAL METER – A 3 digit LED meter is used to display the preset output current level before welding, and actual output level while welding:
• A lit display indicates input power is turned on.
(See Item 1.)
7. POST FLOW TIME – Sets the TIG mode shielding gas post flow time over the range of about 1 to 30 seconds after the arc is shut off.
Note: Gas preflow time is fixed at 0.5 second only in
TIG mode, but no preflow time will occur if the arc is restarted during Post Flow time, since shielding gas would not have stopped flowing.
PRECISION TIG 185
B-5 OPERATION
8. PULSE TIG CONTROL – The Pulse TIG feature built into the Precision TIG 185 is simplified to be a single knob control which sets the Pulse Frequency over the peak pulses/sec. range of about 0.1 to 20 pulses per second:
• Full CCW (min.) setting of the control knob shuts off Pulse TIG (0.0 pps).
• Peak Pulse level is set by the Max. Output Control and the Remote Amptrol (if used).
• Background Current level is typically optimized at a fixed 50% of Peak Pulse level setting.
• Peak Pulse % On-time is typically optimized at a fixed50%.
A Green light "blinks" with each Peak Pulse to indicate the Pulse TIG Control setting before and during welding.
OPERATING STEPS
WELDING IN TIG MODE
1. Connect the TIG torch and cable Twist-Mate quick connect plug to the Electrode/Gas output receptacle. This receptacle also contains an integral gas connection for the torch. Connect the work clamp to the work piece.
2. Set the TIG/STICK switch to “TIG”.
B-5
3. Set the Polarity Switch to DC- for welding steel or stainless steel; or to AC for welding aluminum.
4. Connect the Foot Amptrol to the Remote Control
Connector.
9. OVER TEMPERATURE LIGHT If the welder overheats due to blocked air flow, high ambient air temperature, or exceeded duty cycle, an internal thermostat will open disabling the welding output and this yellow light will illuminate. The cooling fans will continue to run to cool the unit during this time.
The light will go out when the unit cools and the thermostat resets. Once the light goes out, the machine will again become available to weld.
5. Turn on the cylinder gas valve and adjust the flow regulator to obtain desired flow.
6. Turn the power switch to “ON”. NOTE: There will be a 15 second gas flow when the power is turned on.
7. Preset the Output Control on the control panel to the maximum desired amps, as read on the digital meter.
10. REMOTE RECEPTACLE – Provides for connection of remote control and/or arc start switch only in
TIG Mode: ( There is no remote output control capability when stick welding.
• Plugging a remote current control (Amptrol) into this receptacle automatically switches the output control from the panel Max Output Control (See
Item 5) to the remote control.
• The connected remote control will then control the output current between the Min. range of the machine and the setting of the panel Max Output
Control.
• Switching Mode Switch (See Item 3) to Stick will automatically disable the connected remote control and switch the output control back to the Max
Output panel control.
8. Depress the Foot Amptrol to energize the torch and establish an an arc with the work piece. The digital meter reads the actual amps while welding.
NOTE: When the TIG/STICK switch is set to “TIG”, depressing the remote control will start a 0.5 second gas pre-flow before energizing the TIG torch. When the remote control is released the TIG torch is de-energized and gas flow will continue for the time set by the
Post Flow Time control. When the polarity switch is set to DC, the TIG Arc Starter will turn on and off automatically to start and stabilize the arc. In AC the TIG Arc
Starter will turn on with the output and remain on continuously until the remote control is released.
PULSE TIG CONTROL
11. ELECTRODE/GAS OUTPUT RECEPTACLE -
This quick connect Twist-Mate receptacle provides electrical connection to the electrode holder and cable for Stick welding and a combined electrical and gas connection for the TIG torch when TIG welding.
12. WORK CABLE - This work cable is factory connected to the welder and is connected to the work piece to complete the welding circuit. Refer to
Machine Grounding and High Frequency
Interference Protection in the Installation section of this manual for the proper procedure on grounding the work clamp and work piece to minimize high frequency interference.
Use this knob to set the frequency or the number of pulses per second(pps), from 0.1pps to 20pps.
• This setting adjusts heat output and bead shape for travel speed. Thinner plate that is welded with faster travel speed will require higher frequency than thicker plate with slower travel speed. 2-3pps is a typical starting point.
PRECISION TIG 185
B-6
REMOTE CONTROL OPERATION
OPERATION
A Foot Amptrol ™is included with the PRECISION TIG
185 Ready-Pak models and availiable for other models
(See Accessories Section) for remote current control while TIG welding. An optional Hand Amptrol may also be used. An optional Arc Start Switch may be used to start and stop the welding if no remote control of the current is desired. Refer to the Accessories Section of this manual.
Both the Hand and Foot Amptrol work in a similar manner. 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.
B-6
BENEFITS OF THE PRECISION TIG 185 DESIGN
In AC TIG welding of aluminum, the positive portion of the AC wave provides cleaning (removal of aluminum oxide) of the work piece. This is desirable on materials with a heavy oxide coating. However the positive portion may also cause the electrode to overheat at high currents causing “tungsten spitting”. The negative portion of the AC wave offers no cleaning action but concentrates more heat on the work.
The AC waveform of the PRECISION TIG 185 optimizes cleaning and heating of the work. The result is the capability to weld through the complete range in AC
TIG or DC- TIG requiring only one electrode, a 3/32”
2% thoriated tungsten.
When the welder is in TIG modes activating the
Amptrol energizes the electrode terminal and varies the output welding current from its minimum value of 5
Amp (DC) or 7 Amp (AC), to the maximum value set by the Current Control on the control panel. This helps eliminate accidental high current damage to the work piece and/or tungsten, and provides a fine control of the current. When the welder is in the stick mode a remote control has no effect and is not used.
It is important to note that, in some cases, the tungsten will not start an arc at the minimum current because the tungsten may be too large or cold. 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. For example, a 3/32” tungsten may be used on DC- to weld over the full range of the machine.
To start the arc, the operator may have to turn the current control up and depress the Amptrol approximately
1/4 of the way down. Depressing the Amptrol to its minimum position may not start the arc. Also if the current control is set too low, the arc may not start. In most cases, a large or cold tungsten will not readily establish an arc at low currents. This is normal. In Direct Current mode the PRECISION TIG 185 will start a 3/32”, 2% thoriated tungsten electrode at 15 amperes provided the electrode tip is properly grounded and not contaminated.
PRECISION TIG 185
B-7
WELDING IN STICK MODE
OPERATION
1. Put the electrode holder and cable quick connect plug into the electrode output receptacle. Turn clockwise until tight. Connect the work clamp to the work piece.
2. Set the TIG/STICK switch to “STICK”.
3. Set the Polarity Switch to the weld mode desired for the type of electrode being used (most commonly
DC+).
4. Place the electrode in the electrode holder.
5. Turn the power switch to “ON”.
B-7
6. Adjust the Current Control to the desired amps.
7. Strike an arc and weld.
NOTE: When the TIG/STICK switch is set to “STICK” the output is always on when the power switch is on. A remote control has no effect on the welding current and the gas flow and high frequency TIG arc starter are disabled.
WARNING
• In Stick Mode the output terminal and electrode will be electrically hot whenever the power switch is turned on.
-----------------------------------------------------------------------
RECOMMENDED ELECTRODE AMPERAGE RANGES - PRECISION TIG 185
ELECTRODE TYPE
The PRECISION TIG 185 is rated from 5-185 Amps.
SMAW Process
Fleetweld 5P, Fleetweld 5P+ E6010
POLARITY
DC+
Welding Amp Range for Stick Electrode Size
3/32" 1/8" 5/32"
40 - 70 75 - 130 90 - 175
Fleetweld 180
Fleetweld 37
Fleetweld 47
Excalibur
E6011
E6013
E7014
E7018
DC+
DC+
DC-
DC+
40 - 80
70 - 95
75 - 95
85 - 110
55 - 110
100 - 135
100 - 145
110 - 160
105 - 135
145 - 180
135 - 200
130 - 200
Blue Max Stainless
Red Baron Stainless
DC+
DC+
40 - 80
40 - 70
75 - 110
60 - 100
Mild steel procedures are based on recommended procedures listed in C2.10 8/94 and the maximum rating of the PRECISION TIG 185
Blue Max procedures are based on C6.1 6/95
Red Baron Procedure are based on ES-503 10/93
95 - 150
90 - 140
Electrode Polarity DC-
Electrode Tip Preparation Sharpened
GTAW Process
AC
Balled
Electrode Type
Tungsten Size (in.)
.010
.020
.040
1/16
3/32
EWTh-1, EWCe-2
EWTh-2, EWLa-1
EWG
Up to 15 A.
Up to 15 A.
Up to 80 A.
Up to 150 A.
Up to MAX. A.
EWP
Up to 10 A.
Up to 15 A.
Up to 40 A.
Up to 100 A.
Up to 160 A.
EWZr
EWTh-1, EWTh-2
EWCe-2, EWLa-1
EWG
Up to 15 A.
Up to 20 A.
Up to 60 A.
Up to 130 A.
1/8 X Up to MAX. A.
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
X
Aluminum
3-8
5-10
5-10
C.F.H. (l/min.)
(2-4)
(3-5)
(3-5)
Stainless
3-8
Steel
5-10
5-10
(2-4)
(3-5)
(3-5)
5-10 (3-5) 9-13 (4-6)
Up to MAX. A.
13-17 (6-8) 11-15 (5-7)
15-23 (7-11) 11-15 (5-7)
Pure ..................................EWP ........green
+1% Thoria .......................EWTh-1 ...yellow
+2% Thoria .......................EWTh-2 ...red
+2% Ceria.........................EWCe-2...orange
TRI-MIX OF ELEMENTS.............EWG.........gray
+1.5% Lanthana ...............EWLa-1 ...black
+0.15 to 0.40% Zirconia....EWZr .......brown
Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.
Approximate Argon
Gas Flow Rate
PRECISION TIG 185
B-8 NOTES B-8
PRECISION TIG 185
Section C-1 TABLE OF CONTENTS
- ACCESSORIES SECTION -
Section C-1
Accessories ............................................................................................................Section C
PRECISION TIG 185
C-2
FACTORY INSTALLED OPTIONS
ACCESSORIES
2. Precision TIG 185 Ready-Pak w/Cart (K2347-2)
C-2
The Precision TIG 185 will be available in two Factory-
Configured Welding Packages:
1. Precision TIG 185 Ready-Pak (K2347-1)
• 208/230/1/60 Machine (K2345-1)
• 9 ft. (2.7m) Input Cable with NEMA 6-50P Plug*
• NEMA 6-50R Receptacle
• Integrated 10 ft.(3.1m)Work Lead w/Clamp*
• Gas Regulator with 10 ft.(3.1m). Hose
• PTA-17 12.5”(318mm) Ultra=Flex Torch with
3/32”(2.4mm)Electrode and Parts
• Foot Amptrol (K870)
• TIG Slide Rule ( WC332)*
• GTAW Book (JFLF-834)*
• Lift Eyebolt*
The Precision TIG 185 will also be available as Basic models with Domestic input voltages for user-configuration with optional accessories: (See Table C.1)
TABLE C.1
Select Machine
208/230/1/60 Machine with 9 ft.(2.7m) NEMA 6-50P Plug Cable and Receptacle (K2345-1)
460/575/1/60 Machine only with Cable (K2345-2)
380/400-415/1/50-60 Machine only with Cable (K2346-1)
Water Cooled System Air Cooled System Optional
Torch Starter Kit
(Select one)
K2267-1 TIG-Mate 20 Torch Starter Kit
Includes:
• 200A PTW-20 12.5 ft.(3.81m) Torch
• KP510 Parts Kit
• Regulator & Hose
• K1622-4 Twist Mate Torch Adapter
• Water Hose & Hose Coupler
• Work Cable & Clamp (Not required for
Precision TIG 185)
K2266-1 TIG-Mate Torch Starter
Kit Includes:
• 150A PTA-17 12.5 ft.(3.81m) Torch.
• KP508 Parts Kit.
• Regulator & Hose.
• K1622-1 Twist Mate Torch Adapter.
• Work Cable & Clamp (Not required for Precision
TIG 185)
Not Applicable K1813-1 115V 50/60Hz Cool-Arc 40 Water Cooler
Optional Under-
Storage Cart
• 208/230/1/60 Machine (K2345-1)
• 9 ft.(2.7m) Input Cable with NEMA 6-50P Plug*
• NEMA 6-50R Receptacle
• Integrated 10 ft.(3.1m) Work Lead w/Clamp*
• Gas Regulator with 10 ft.(3.1m) Hose
• PTA-17 12.5 ft.(3.8m) One cable Superflex Torch with
3/32”(2.4mm) Electrode and Parts
• Foot Amptrol (K870)
• TIG Slide Rule (WC332)*
• GTAW Book (JFLF-834)*
• Lift Eyebolt*
• Under-Storage Cart (K2348-1)
* Included with K2345-1 Machine Only model.
Optional Remote
Trigger Device
(Select one)
K2348-1
K814 Arc Start Switch
K870 Foot Amptrol
K870-1 Start Pedal Foot Amptrol
K963-3 Hand Amptrol
PRECISION TIG 185
C-3
FIELD INSTALLED OPTIONS
ACCESSORIES
The following Options/Accessories are available for the
Precision TIG 185:
C-3
• Magnum “Pro-Torch™ TIG Torch” assemblies and
Accessories.
Requires Twist-Mate Adapter:
K1622-1 for PTA-9/-17
K1622-3 for PTA-26
K1622-4 for PTW water cooled torch • K2348-1 Under-Storage Cart
Includes a front magnetic latch storage drawer and rear storage bin on a single bottle undercarriage.
(L12225 Installation Instructions included)
• Harris #3100211 Harris Argon Flow Regulator
(Includes 10 ft.(3.1m) hose.)
• K2374-1 Electrode Holder and Cable
200 amp Electrode Holder with 10 ft.(3.1m) cable and Twist-Mate connector.
• K870 Foot Amptrol
Single pedal foot activation of arc start switch and output control, with 25 ft.(7.6m) plug cable.
• K870-1 Start Pedal Foot Amptrol
Independent start pedal on control pedal provides two-stage foot action to easily feel start switch closure at minimum output level for enhanced arc start and crater-fill control. Provided with adjustable, or removable , heel stop and 25 ft.(7.6m) plug cable.
• K963-3 Hand Amptrol
Fastens to torch for convenient thumb activation of arc start switch and output control, with 25 ft.(7.6m) plug cable:
• K814 Arc Start Switch
Needed for TIG welding without an Amptrol. Includes
25 ft.(7.6m) plug cable, and attaches to torch for convenient finger control.
• TIG-Mate Torch Starter Kits:
Includes Torch with Twist-Mate adapter and accessories listed below:
K2266-1 TIG-Mate Torch Starter Kit Includes:
• 150A PTA-17 12.5 ft.(3.8m) Torch
• KP508 Parts Kit
• Regulator & Hose
• K1622-1 Twist Mate Torch Adapter
• Work Cable & Clamp (Not required for Precision
TIG 185)
K2267-1 TIG-Mate 20 Torch Starter Kit Includes:
• 200A PTW-20 12.5 ft.(3.8m) Torch
• KP510 Parts Kit
• Regulator & Hose
• K1622-4 Twist Mate Torch Adapter
• Water Hose & Hose Coupler
• Work Cable & Clamp
(Not required for Precision TIG 185)
PRECISION TIG 185
C-4 NOTES C-4
PRECISION TIG 185
Section D-1 TABLE OF CONTENTS
- MAINTENANCE SECTION -
Section D-1
Maintenance ...........................................................................................................Section D
PRECISION TIG 185
D-2
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
MAINTENANCE
• 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
1. Disconnect power supply lines to machine before performing periodic maintenance.
D-2
WARNING
Use extreme caution when working with circuit of the high frequency. The high voltages developed can be lethal. Turn the input power off using the disconnect switch or fuse box before working inside machine. This is particularly important when working on the secondary circuit of the high voltage transformer (T3) because the output voltage is dangerously high.
-----------------------------------------------------------------------
Refer to figure D.1. Note in highly dirty environments where there is an abundance of conductive contaminants, use a low pressure air stream or a firm piece of paper to clean the spark gap. Do not disturb the factory setting.
To check the spark gap:
- Turn off input power as specified above.
- Remove the right side panel from the machine, the spark gap box is located on the lower right side.
- Check the spark gap with a feeler gauge.
If adjustment is needed:
- Adjust the gap by loosening the allen head screw in one of the aluminum blocks, near the front of the unit and tighten the screw in the new position.
If the gap is correct:
- Replace the wraparound.
2. Periodically clean the inside of the machine with a low pressure air system. Be sure to clean the following components thoroughly.
• Main Transformer
• Electrode/Gas Output Receptacle
• Polarity Switch
• Rectifier Assembly
• Arc Starter/Spark Gap Assembly
• PC Boards
• Fan Blades
8. Inspect gas hose and inlet fitting for cracks or leaks.
9. Replace any unreadable labels or decals.
10. Verify that the machine and welding circuit is properly grounded.
FIGURE D.1 SPARK GAP
3. Inspect welder output and control cables for fraying, cuts, and bare spots.
4. Keep TIG torch and cables in good condition.
5. Clean air louvers to ensure proper air flow and cooling.
6. The fan motor has sealed ball bearings which require no maintenance.
7. SPARK GAP ADJUSTMENT
The spark gap is set at the factory to a gap of 0.020
See Figure D.1. This setting is adequate for most applications. Where less high frequency is desired, the setting can be reduced to 0.015 inches (0.4mm).
.020 Spark Gap
FAN MOTOR OR FAN BLADE REPLACEMENT
When installing a new fan blade or fan motor be sure to maintain proper shaft spacing per Figure D.2 below.
.30
FIGURE D.2
PRECISION TIG 185
D-3 MAINTENANCE
FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.
1. Case Front Assembly
2. Case Back Assembly
3. Arc Starter & Bypass Assembly
4. Center Assembly
5. Cover Assembly
6. Cart Base Assembly
7. Upper Cylinder Support Assembly
8. TIG Torch & Cable Assembly
9. Foot Amptrol Assembly (Pedal)
5
7
D-3
4 2
1
9
3
6
PRECISION TIG 185
D-4 NOTES D-4
X
Section E-1 TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
Section E-1
Theory of Operation ...............................................................................................Section E
FIGURE E.1 – PRECISION TIG 185 BLOCK LOGIC DIAGRAM
BY-PASS
BOARD
POLARITY
SWITCH
INPUT
POWER
SWITCH
BYPASS
ASBLY
H1
MAIN
TRANSFORMER
X1 AC DC+
SCR
BRIDGE
C
H
O
K
E
HI-FREQUENCY
TRANSFORMER
H2
H3
X2
AC DC-
SHUNT
F
E
E
D
B
A
C
K
HIGH VOLTAGE
TRANSFORMER
CIRCUIT
115VAC
FAN
18VAC
18VAC
115VAC
CONTROL
BOARD
POWER
"ON"
DIGITAL
DISPLAY
WORK
ELECTRODE
MODE
SWITCH
REMOTE
RECEPTACLE
THERMAL
LIGHT
GAS
VALVE
THERMO-
STATS
OUTPUT
CONTROL
AUTO
BALANCE
LED
PULSE
FREQ.
LED
TIG
LED
STICK
LED
AC
PULSE
BALANCE
CONTROL
CONTROL
POSTFLOW
CONTROL
X
E-2 THEORY OF OPERATION
GENERAL DESCRIPTION
The PRECISION TIG 185 is a member of our field acclaimed Precision TIG family of industrial arc welding power sources. Premium features include:
E-2
3. Enhanced version of the patented MicroStartTM
Technology for its lower Minimum (5amps) to higher Maximum (185 amps) output control range.
1. Precise constant current output.
4. Built-in high frequency stabilization for DC TIG starting and continuous AC TIG welding.
2. Full range square wave AC/DC TIG (GTAW) welding.
5. AC/DC Stick (SMAW capability.)
FIGURE E.2 Main Transformer and Input Power
BY-PASS
BOARD
POLARITY
SWITCH
INPUT
POWER
SWITCH
BYPASS
ASBLY
H1
MAIN
TRANSFORMER
X1 AC DC+
SCR
BRIDGE
C
H
O
K
E
HI-FREQUENCY
TRANSFORMER
H2
H3
X2
AC DC-
SHUNT
F
E
E
D
B
A
C
K
HIGH VOLTAGE
TRANSFORMER
CIRCUIT
115VAC
FAN
18VAC
18VAC
115VAC
CONTROL
BOARD
POWER
"ON"
DIGITAL
DISPLAY
WORK
ELECTRODE
MODE
SWITCH
REMOTE
RECEPTACLE
THERMAL
LIGHT
GAS
VALVE
THERMO-
STATS
OUTPUT
CONTROL
AUTO
BALANCE
LED
PULSE
FREQ.
LED
TIG
LED
STICK
LED
INPUT POWER CIRCUIT
AC
PULSE
BALANCE
CONTROL
CONTROL
POSTFLOW
CONTROL
The desired single-phase input power is connected to the TIG 185 through an input power switch located in the front panel of the machine. The machine can be configured for either 230VAC or 208VAC input voltage by connecting the appropriate lead (H2 or H3) to the input power switch. When the input power switch is turned “ON” the input voltage is applied directly to the primary of the main transformer.
incorporated in the main transformer. The 115VAC winding supplies power to the fan motor and also, through the control board, powers the gas solenoid valve and the high voltage transformer. The 18VAC winding provides power to the trigger circuitry. The other 18VAC winding is rectified and regulated to a
15VDC supply which operates the circuitry on the control board.
The main transformer changes the high voltage, low current input power to a low voltage, high current output which is available at the main secondary winding
(X1 and X2). In addition three auxiliary windings are
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
PRECISION TIG 185
E-3 THEORY OF OPERATION
FIGURE E.3 Control Board and Output Feedback Control.
BY-PASS
BOARD
POLARITY
SWITCH
INPUT
POWER
SWITCH
BYPASS
ASBLY
H1
MAIN
TRANSFORMER
X1
AC DC+
SCR
BRIDGE
C
H
O
K
E
HI-FREQUENCY
TRANSFORMER
H2
H3
X2
AC DC-
SHUNT
F
E
E
D
B
A
C
K
HIGH VOLTAGE
TRANSFORMER
CIRCUIT
FAN
18VAC
18VAC
115VAC
CONTROL
BOARD
115VAC
POWER
"ON"
DIGITAL
DISPLAY
MODE
SWITCH
REMOTE
RECEPTACLE
WORK
ELECTRODE
THERMAL
LIGHT
GAS
VALVE
THERMO-
STATS
OUTPUT
CONTROL
E-3
AC
PULSE
BALANCE
CONTROL
CONTROL
POSTFLOW
CONTROL
AUTO
BALANCE
LED
PULSE TIG
FREQ.
LED
LED
STICK
LED
OUTPUT RECTIFICATION AND
FEEDBACK CONTROL
The AC output from the main transformer secondary is rectified and controlled through the SCR bridge.
Output current is sensed at the shunt as a low voltage signal and fed back to the control board. The control board compares the commands of the mode switch, output control, AC balance control, pulse control, postflow control, or remote control with the feedback information. The appropriate SCR gate firing signals are created by the control board and sent to the SCR bridge. The control board controls the firing of the
SCRs, which control the output of the machine. See
SCR Operation . The control board monitors the ther-
mostats, and also controls the gas solenoid valve, thermal light, auto balance LED, pulse frequency LED, TIG
LED, stick LED, and the digital display.
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
PRECISION TIG 185
E-4 THEORY OF OPERATION
FIGURE E.4 High Voltage/High Frequency Circuit.
BY-PASS
BOARD
POLARITY
SWITCH
INPUT
POWER
SWITCH
BYPASS
ASBLY
H1
MAIN
TRANSFORMER
X1
FAN
H2
H3
X2
18VAC
18VAC
115VAC
HI-FREQUENCY
TRANSFORMER
AC DC+
SCR
BRIDGE
AC DC-
SHUNT
F
E
E
D
B
A
C
K
CONTROL
BOARD
C
H
O
K
E
HIGH VOLTAGE
TRANSFORMER
CIRCUIT
115VAC
POWER
"ON"
DIGITAL
DISPLAY
MODE
SWITCH
REMOTE
RECEPTACLE
THERMAL
LIGHT
GAS
VALVE
THERMO-
STATS
OUTPUT
CONTROL
HIGH VOLTAGE / HIGH
FREQUENCY CIRCUIT
The control board passes the 115VAC voltage to the primary of the high voltage transformer. The secondary of the high voltage transformer is coupled to a spark gap generator and also to the high frequency transformer. The high frequency transformer transfers the high frequency “spark” to the electrode terminal which is coupled to the TIG torch.
E-4
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
PRECISION TIG 185
E-5 THEORY OF OPERATION
DC WELDING OUTPUT
E-5
When the polarity switch is placed in either DC position, the AC voltage from the main transformer secondary is applied to the SCR bridge. The SCR bridge and choke circuits are connected in a conventional full wave bridge and filter configuration, resulting in a controlled DC output. Since the choke is in series with the negative leg of the bridge and also in series with the welding load, a filtered DC is applied to the machine output terminals.
PRIMARY
1Ø
CHOKE
G
G
G
G
FIGURE E.5 DC Welding Current Generation.
ELECTRODE
DC
WORK
PRECISION TIG 185
E-6 THEORY OF OPERATION
AC WELDING OUTPUT
E-6
Rotating the polarity switch to the AC position changes the welding power circuit. One lead (X1) of the main transformer secondary is connected to the machine output work terminal. The other secondary lead (X2) is connected to one of the AC connections on the SCR bridge. The electrode terminal is connected to the other
AC side of the bridge. The choke is now electrically across the negative and positive SCR bridge connections.
With the ability of the choke to store energy and the SCRs to turn on at the appropriate times, an AC square wave is developed and applied to the output terminals.
PRIMARY
1Ø
G
G CHOKE
G
G
ELECTRODE
FIGURE E.6 AC Square Wave Welding Current Generation.
WORK
PRECISION TIG 185
E-7
SCR OPERATION
THEORY OF OPERATION
A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load.
An SCR acts very much like a switch. When a gate signal is applied to the SCR it is turned ON and there is current flow from anode to cathode. In the ON state the SCR acts like a closed switch. When the SCR is turned OFF there is no current flow from anode to cathode thus the device acts like an open switch. As the name suggests, the SCR is a rectifier, so it passes current only during positive half cycles of the AC supply. The positive half cycle is the portion of the sine wave in which the anode of the SCR is more positive than the cathode.
E-7 between gate and cathode, the voltage between these terminals must be slightly greater than 0.6V. Once the
SCR has fired it is not necessary to continue the flow of gate current. As long as current continues to flow from anode to cathode the SCR will remain on. When the anode to cathode current drops below a minimum value, called holding current, the SCR will shut off.
This normally occurs as the AC supply voltage passes through zero into the negative portion of the sine wave.
If the SCR is turned on early in the positive half cycle, the conduction time is longer resulting in greater SCR output. If the gate firing occurs later in the cycle the conduction time is less resulting in lower SCR output.
When an AC supply voltage is applied to the SCR, the device spends a certain portion of the AC cycle time in the on state and the remainder of the time in the off state. The amount of time spent in the ON state is controlled by the Gate.
An SCR is fired by a short burst of current into the gate.
This gate pulse must be more positive than the cathode voltage. Since there is a standard PN junction
INPUT
ANODE
CATHODE
OUTPUT
GATE
GATE
NOTE: AS THE GATE
PULSE IS APPLIED
LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.
FIGURE E.7 SCR Operation
PRECISION TIG 185
E-8
PROTECTIVE CIRCUITS
THEORY OF OPERATION
Protective circuits are designed into the PRECISION
TIG 185 to sense trouble and shut down the machine before the trouble damages the internal machine components. Both thermal protection and current overload are included. Fan as needed (F.A.N.) Fan runs for 5 seconds at power-up and stops at idle 8 minutes after welding.
OVERLOAD PROTECTION
E-8 by excessive output or duty cycle and the fan is operating normally, the power may be left on, and the reset should occur within a 15 minute period. If the fan is not functioning properly or the air intake louvers are obstructed, then the input power must be removed and the fan problem or air obstruction corrected.
THERMAL PROTECTION
The machine is electronically protected from producing excessively high output currents. The output is limited to 200 amps.
9. OVER TEMPERATURE LIGHT- If the welder overheats due to blocked air flow, high ambient air temperature, or exceeded duty cycle, an internal thermostat will open disabling the welding output and this yellow light will illuminate. The cooling fans will continue to run to cool the unit during this time. The light will go out when the unit cools and the thermostat resets.
Once the light goes out, the machine will again become available to weld.
Once the machine cools sufficiently the thermostats are self-resetting. If the thermostat shutdown is caused
PRECISION TIG 185
Section F-1 TABLE OF CONTENTS
- TROUBLESHOOTING & REPAIR SECTION -
Section F-1
Troubleshooting & Repair Section ........................................................................Section F
PC Board Troubleshooting Procedures and Replacement...........................................F-3
Test Procedures
Oscilloscope Waveforms
Normal Open Circuit Voltage Waveform-AC TIG Mode .......................................F-29
Normal Open Circuit Voltage Waveform-DC TIG Mode.......................................F-30
Normal Open Circuit Voltage Waveform-AC Stick Mode.....................................F-31
Normal Open Circuit Voltage Waveform-DC Stick Mode ....................................F-32
Typical Output Voltage Waveform-Machine Loaded AC TIG Mode.....................F-33
Typical Output Voltage Waveform-Machine Loaded DC TIG Mode ....................F-34
Typical Output Voltage Waveform-Machine Loaded AC Stick Mode ..................F-35
Typical Output Voltage Waveform-Machine Loaded DC Stick Mode ..................F-36
Abnormal Open Circuit Voltage-DC TIG Mode One SCR not Functioning..........F-37
Replacement Procedures
SCR Bridge Assembly Removal and Replacement .............................................F-39
High Voltage Transformer Removal and Replacement ........................................F-49
Main Transformer and Output Choke Removal and Replacement ......................F-53
PRECISION TIG 185
F-2 TROUBLESHOOTING & REPAIR
CAUTION
F-2
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 three main categories: Feeding
Problems and Welding Problems.
Step 3. PERFORM COMPONENT TESTS. The last column, labeled “Recommended Course of
Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.
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.
All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the referred to test points, components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
WARNING
HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment.
• Perform all voltage and waveform checks with high frequency circuit OFF. Perform High
Frequency Disable Procedure.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
PRECISION TIG 185
F-3 TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.
CAUTION
Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:
1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.
2. Check for loose connections at the PC board to assure that the PC board is properly connected.
3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:
PC board can be damaged by static electricity.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
- Remove your body’s static charge before opening the staticshielding bag. Wear an anti-static wrist strap. For safety, use a 1
Meg ohm resistive cord connected to a grounded part of the equipment frame.
- If you don’t have a wrist strap, touch an un-painted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.
F-3
- Remove the PC board from the static-shielding bag and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can’t be installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers, don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.
4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.
5. Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.
a. If the original problem does not reappear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.
6. Always indicate that this procedure was followed when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.
- Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.
PRECISION TIG 185
F-4
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING & REPAIR
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-4
Observe Safety Guidelines detailed in the beginning of this manual.
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine is dead. No output - No fan
1. Make sure that the input power switch is in the "ON" position and the machine is plugged in.
1. Check the input power switch and associated wires for loose or faulty connections.
2. Check the input voltage at the machine. Input voltage must match the rating plate and voltage connection. Refer to
in the
Installation section of this manual.
3. Blown or missing fuses in the input line.
The fan runs normally. No output from the machine in either Stick or
TIG modes.
1. Check for proper input voltages per nameplate and voltage reconnect configuration.
1. Check for loose or faulty connections on the heavy current carrying leads. (polarity switch, output choke output terminals etc.)
2. Check to make sure the polarity switch is in the proper position and functioning correctly.
3. Perform the
4. Check current control R1 for proper operation. Normal resistance is 10,000 ohms. Also check associated leads for loose or faulty connections.
5. The control board may be faulty.
Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
PRECISION TIG 185
F-5
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING & REPAIR
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-5
Observe Safety Guidelines detailed in the beginning of this manual.
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Fan runs - No output from machine in either Stick or TIG modes and the yellow light on the control panel is on.
1. The welding application may have exceeded the recommended duty cycle. Allow the unit to run until the fan cools the unit and the yellow light goes out.
1. One of the thermostats may be faulty. Check or replace. See wiring diagram.
2. The air louvers may be blocked.
Remove air obstruction and allow unit to cool.
2. Check for loose or faulty wires on the thermostats and associated circuitry. See wiring diagram.
The machine does not respond (no gas flow, no high frequency and no open circuit voltage) when the arc start switch or Amptrol is activated fan is working normally.
1. Make certain the machine is in the TIG mode.
2. The Amptrol may be defective.
Check for continuity(zero ohms) between pins "D" and "E" on cable connector when the
Amptrol is depressed.
1. Check the continuity (zero ohms) of the leads between the remote receptacle and plug J5 on the control board. See wiring diagram.
3. The control board may be faulty.
Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
PRECISION TIG 185
F-6
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING & REPAIR
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-6
Observe Safety Guidelines detailed in the beginning of this manual.
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine regularly over heats - thermostat opens. Yellow light on front panel glows. The fan runs but the machine has no output.
Machine regularly over heats - thermostat opens. Yellow light on front panel glows. The fan runs but the machine has no output.
1. The thermostat(s) may be faulty.
Check or replace.
2. The control board may be faulty.
The machine does not have output in the Stick mode. The machine operates correctly in the TIG mode.
The machine does not have output in the Stick mode. The machine operates correctly in the TIG mode.
1. Check the Stick/TIG switch(S3) and associated leads. See wiring diagram.
2. The control board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
PRECISION TIG 185
F-7
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING & REPAIR
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-7
Observe Safety Guidelines detailed in the beginning of this manual.
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine welds at a very low output regardless of the current control setting.
1. If welding in the TIG mode the remote control device may be defective.
1. Check the polarity switch and associated leads.
2. Make certain the input line voltage is correct for the machine reconnect configuration.
2. Check the interior connections of the heavy current carrying leads.
3. Perform the SCR Bridge Test .
3. Check the welding cables and or torch for loose or faulty connections.
5. Check the current control for proper operation. Normal resistance is 10k ohms. See wiring diagram.
6. The control board may be faulty.
The machine welds at a very high output regardless of the current control setting.
1. If welding in the TIG mode the remote control device may be defective.
1. Perform the SCR Bridge Test .
3. Check the current control for proper operation. Normal resistance is 10k ohms. See wiring diagram.
4. The control board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
PRECISION TIG 185
F-8
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING & REPAIR
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-8
Observe Safety Guidelines detailed in the beginning of this manual.
RECOMMENDED
COURSE OF ACTION
TIG MODE PROBLEMS
Machine output is intermittently lost.
Gas flow and high frequency are also interrupted.
1. The problem may be caused by high frequency interference.
Make sure that the machine is grounded properly according to the installation instructions. If there are other high frequency sources in the area, make certain that they are grounded properly.
1. Check for loose or faulty connection on the leads between the remote receptacle and plug J5 on the control board. See wiring diagram.
2. Check the plugs on the control board for loose connections.
2. Make sure the Amptrol is operating properly.
3. The control board may be faulty.
3. Check to make sure that the input voltage is correct for the machine reconnect configuration.
in the Installation section of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
PRECISION TIG 185
F-9
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING & REPAIR
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-9
Observe Safety Guidelines detailed in the beginning of this manual.
RECOMMENDED
COURSE OF ACTION
TIG MODE PROBLEMS
The arc "flutters" when TIG welding.
1. The tungsten electrode may be too large in diameter for the current setting.
1. Check the polarity switch for proper operation and loose or faulty lead connections. See wiring diagram.
2. The tungsten tip may not be
"sharp" enough.
2. Perform the SCR Bridge Test .
3. The gas shielding may be insufficient. Increase the gas flow and or reduce the tungsten stickout beyond the gas cup.
3. Check for loose or faulty connections at the shunt. ( leads #221 and #222 ).
4. Check for contaminated gas or leaks in the gas line, torch, or connections.
4. Check components R3 and C4 in the high voltage transformer primary circuit. Replace if necessary. See wiring diagram.
5. The control board may be faulty.
Replace.
5. If a helium blend is used as a shielding gas then reduce the percentage of helium.
The arc "pulsates" when AC TIG welding.
1. Make sure the gas and procedure are correct for the process being used.
1. Check the micro switch S2A on the polarity switch. It may be stuck closed. See wiring diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
PRECISION TIG 185
F-10
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING & REPAIR
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-10
Observe Safety Guidelines detailed in the beginning of this manual.
RECOMMENDED
COURSE OF ACTION
TIG WELDING PROBLEMS
Black areas along weld bead.
1. Clean any oily or organic contamination from the work piece.
1. This may be a welding procedure problem.
2. Tungsten electrode may be contaminated. Replace or sharpen.
Contact The Lincoln Electric Service
Department, 1-888-935-3877.
3. Check for contaminated gas or leaks in the gas line, torch, or associated connections.
4. The gas shielding may be insufficient. Increase gas flow: reduce tungsten stickout beyond the gas cup.
Weak high frequency - machine has normal welding.
1. Check for loose or faulty connections at the torch and/or welding cables.
1. Make sure that 115VAC is being applied to the primary of the high voltage transformer (T3). See wiring diagram.
2. The gas shielding may be insufficient. Increase gas flow: reduce tungsten stickout beyond the gas cup.
2. Check for any open or arcing high frequency component.
Replace as required.
(Examples: C3, R3, C4)
3. Check spark gap operation and setting. Normal is (0.015").
this manual.
section of
4. The work and electrode cables may be in poor condition allowing the high frequency to "leak off".
Use good quality cables with a high natural rubber content, such as Lincoln Stable Arc Cable.
Cables should be as short as possible.
3. If spark is weak at the spark gap, check or replace the high frequency circuit.
(Examples: T3, L3, L4).
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
PRECISION TIG 185
F-11
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING & REPAIR
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-11
Observe Safety Guidelines detailed in the beginning of this manual.
RECOMMENDED
COURSE OF ACTION
TIG WELDING PROBLEMS
High frequency "spark" is present at tungsten electrode, but operator is unable to establish a welding arc.
Machine has normal open circuit
in the Installation
Chapter.
1. The torch may be faulty. Check or replace.
2. The current control may be set too low.
3. The tungsten electrode may be contaminated. Replace or sharpen.
1. This may be a welding procedure problem.
Contact The Lincoln Electric Service
Department 1-888-935-3877.
4. The electrode may be too large for the process.
5. If a helium blend is being used as a shielding gas, then reduce the percentage of helium.
6. Check the welding cables for loose or faulty connections.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
PRECISION TIG 185
F-12
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING & REPAIR
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-12
Observe Safety Guidelines detailed in the beginning of this manual.
RECOMMENDED
COURSE OF ACTION
TIG WELDING PROBLEMS
No high frequency. Machine is in the TIG mode and has normal output.
1. If the machine location is in a highly dirty environment with conductive contaminants, check and clean the spark gap with a low pressure air stream per the maintenance instructions.
1. Check the high voltage transformer (T3). The normal resistance of the secondary winding of the high voltage transformer is
12.5k ohms.
2. Check spark gap operation and setting. Normal is (0.020").
section of this manual.
WARNING
ELECTRIC SHOCK CAN
KILL. When 115VAC is applied to the primary of
T3. A very high voltage is developed on the secondary winding.
For assistance call the Lincoln
Electric Service Department 1-888-
935-3877.
------------------------------------------------
2. Check the values of R3, and C4.
3. Perform the T1 Transformer Test.
4. The control board may be faulty.
Replace.
No gas flow when Amptrol is activated in the TIG mode. Machine has normal output - fan runs.
A "click" can be heard indicating that the gas solenoid valve is operating.
1. The gas supply is either empty or not turned on.
1. Possible gas supply problems.
2. The flow regulator may be set too low.
Consult your local welder/gas distributor.
3. Check the gas hose for kinks or blockages.
4. Check the filter screen inside gas inlet fitting to solenoid valve.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
PRECISION TIG 185
F-13
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING & REPAIR
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-13
Observe Safety Guidelines detailed in the beginning of this manual.
RECOMMENDED
COURSE OF ACTION
TIG WELDING PROBLEMS
When AC TIG welding, the arc is erratic and there is a loss of "cleaning" of the work piece.
1. The tungsten electrode may be too small for the process. Use a larger diameter tungsten or a pure tungsten.
1. Check components R3 and C4 in the high voltage transformer primary circuit.
2. If a helium blend is used as a shielding gas, then reduce the percentage of helium.
2. Perform the SCR Bridge Test .
The end of the tungsten electrode melts away.
1. The welding current is too high for the electrode type and or
in the
Operation Section.
1. This may be a welding procedure problem.
Contact The Lincoln Electric Service
Department 1-888-935-3877.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
PRECISION TIG 185
F-14
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING & REPAIR
POSSIBLE AREAS OF
MISADJUSTMENT(S)
F-14
Observe Safety Guidelines detailed in the beginning of this manual.
RECOMMENDED
COURSE OF ACTION
STICK WELDING PROBLEMS
Stick electrode "Blasts Off" when arc is struck.
1. Weld current may be set too high for electrode size. Reduce current control setting, or use a larger diameter electrode.
1. Perform the SCR Bridge Test .
2. The control board may be faulty.
Replace.
The stick electrode "sticks" in the puddle.
1. The weld current may be set too low. Increase the current control setting or use a smaller diameter electrode.
Variable or sluggish welding arc when welding in the Stick mode.
1. Check work and electrode cables for loose or poor connections.
1. Check the polarity switch for excessive wear or faulty connections.
2. The weld cables may be too small or too long to permit the desired current to flow.
2. Check interior connection of the heavy current carrying leads.
3. The weld current may be set too low.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
PRECISION TIG 185
F-15 TROUBLESHOOTING & REPAIR
HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will disable the high frequency circuit. The technician will then be able to take voltage measurements without the possibility of high frequency damage to his test equipment.
MATERIALS NEEDED
3/8” Nutdriver
5/64” Allen type wrench
.020” feeler gauge
F-15
WARNING
HIGH VOLTAGE IS STILL PRESENT IN THE HIGH FREQUENCY CIRCUIT.
----------------------------------------------------------------------------------------------------------------------------
PRECISION TIG 185
F-16 TROUBLESHOOTING & REPAIR
HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE
PROCEDURE
1. Remove input power to the TIG185 machine.
2. Using the 3/8” nutdriver remove the right side panel.
3. Locate the Spark Gap Assembly at the right side of the machine. See
Figure F.1.
4. With the 5/64” Allen type wrench loosen the set screw holding the upper electrode in place.
5. Increase the distance between the electrodes to at least 3/8” by sliding one electrode away from the other electrode. Secure the one electrode in this position.
6. This should disable the high frequency circuit. Visually check to make sure high frequency sparking is
NOT present before connecting any test equipment to the TIG 185 machine.
7. When voltage testing and scope measurements are complete reset the spark gap electrodes to .020” air gap. Tighten the set screw using the
5/64” Allen wrench.
F-16
FIGURE F.1 SPARK GAP ASSEMBLY
LEFT SIDE OF MACHINE
PRECISION TIG 185
F-17 TROUBLESHOOTING & REPAIR
T1 TRANSFORMER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the correct voltage is being applied to the primary of the
T1 transformer and also if the correct voltages are being induced on the secondary windings of the transformer.
MATERIALS NEEDED
Volt/Ohm Meter
Precision TIG 185 Wiring Diagrams
3/8” nutdriver
F-17
PRECISION TIG 185
F-18 TROUBLESHOOTING & REPAIR
T1 TRANSFORMER TEST (continued)
TEST PROCEDURE
1. Remove main supply power to the machine.
4. Carefully apply the correct input power making certain the reconnect configuration at the input switch is correct for the input voltage applied.
Turn the TIG 185 ON.
2. Using the 3/8” nutdriver remove the case wrap-around cover.
3. Locate plugs J3 and J4 on the control board. See Figure F.2.
5. Using the voltmeter carefully test for the correct transformer secondary voltages per Table F.1.
F-18
FIGURE F.2 - Plugs J3 & J4 on Control Board
PRECISION TIG 185 CONTROL BOARD
PIN 7 (LEAD #209)
PIN 8 (LEAD #210)
PIN 3 (LEAD #204)
PIN 4 (LEAD #201)
PIN 3 (LEAD #232)
PIN 2 (LEAD #260)
PRECISION TIG 185
F-19 TROUBLESHOOTING & REPAIR
T1 TRANSFORMER TEST (continued)
6. If all of the secondary voltages are correct the T1 transformer is functioning properly.
leads for broken or loose connections between plugs J3, J4 and the T1 transformer.
A. If all of the secondary voltages are missing or incorrect make certain that the correct input voltage is being applied to the correct primary leads. See Table F.1.
7. Replace case wrap-around cover.
B. If the correct input voltage is being applied to the primary leads and any or all of the secondary voltages are incorrect the T1 transformer may faulty. See
F-19
TABLE F.1 T1 TRANSFORMER VOLTAGE
TEST POINTS
SECONDARY WINDINGS
PLUG J3 PIN 8 (LEAD #210)
TO
PLUG J3 PIN 7 (LEAD #209)
PLUG J3 PIN 4 (LEAD #201)
TO
PLUG J3 PIN 3 (LEAD #204)
PLUG J4 PIN 2 (LEAD #260)
TO
PLUG J4 PIN 3 (LEAD #232)
X1 TO X2
PRIMARY WINDINGS
H1 TO H2
H1 TO H3
ACCEPTABLE VOLTAGES
SECONDARY VOLTAGES
18VAC
18VAC
CHECK DURING FIRST 5 SECONDS OF POWER UP
115VAC
80 VAC
PRIMARY VOLTAGES
208VAC
230VAC
NOTE: If the input voltages vary the secondary voltages will vary accordingly.
PRECISION TIG 185
F-20 NOTES F-20
PRECISION TIG 185
F-21 TROUBLESHOOTING & REPAIR
STATIC SCR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure is a quick check to determine if an SCR is shorted or “leaky”. See machine waveform section for normal and abnormal SCR waveforms.
MATERIALS NEEDED
Volt/Ohm Meter (Analog)
Precision TIG 185 Wiring Diagrams
3/8” nutdriver
SCR Heat Sink Assembly Drawing
F-21
PRECISION TIG 185
F-22 TROUBLESHOOTING & REPAIR
STATIC SCR TEST (continued)
TEST PROCEDURE
1. Remove main supply power to the
TIG 185 and remove the case wraparound cover.
2. Locate and remove plug J2 from the control board. See Figure F.3.
Figure F.3 - Plug J2 Location on Control Board
PLUG J2 REMOVED
PRECISION TIG 185 CONTROL
F-22
PRECISION TIG 185
F-23 TROUBLESHOOTING & REPAIR
STATIC SCR TEST (continued)
3. Using an analog ohmmeter test the resistance from anode to cathode of
SCR1. Reverse the meter leads and check from cathode to anode of
SCR1. See Figure F.4. If a low resistance is indicated in either direction
SCR1 is faulty. Replace SCR Bridge
4. Repeat Step #3 testing SCR2, SCR3 and SCR4.
5. The further check the SCR’s functions use an SCR tester and proceed
F-23
FIGURE F.4 SCR TEST POINTS
SCR1 ANODE
SCR2 CATHODE
SCR3 CATHODE
SCR4 ANODE
SCR1 CATHODE/SCR2 ANODE
SCR3 ANODE/SCR4 CATHODE
PRECISION TIG 185
F-24 NOTES F-24
PRECISION TIG 185
F-25 TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the device is able to be gated “ON” and conduct current from anode to cathode.
MATERIALS NEEDED
An SCR tester as outlined in this procedure.
Precision TIG 185 Wiring Diagrams
3/8” nutdriver
F-25
PRECISION TIG 185
F-26 TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST (continued)
TEST PROCEDURE
1. Remove main supply power to the
TIG 185 machine.
2. Locate and remove plug J2 from the
3. Perform test procedure as outlined in
Figure F.5. Repeat test for all four
4. Construct the circuit outlined in Figure
F.5. One 6V lantern battery can be used. Resistor values are ±10%. The voltmeter scale should be low, approximately 0-5 or 0-10 volts.
5. Battery Test - Check the battery by shorting leads (A) and (C) and then close switch SW-1. Re-place battery if voltage is less than 4.5 volts.
F-26
FIGURE F.5 ACTIVE SCR TEST SETUP
SW1
R2
V R1
SW2
6volt
Lantern
Battery
SCR under test
A
C
G
To test SCRs construct the circuit outlined above.
Resistor values are plus or minus ten percent. The voltmeter scale should be low, approximately 0-5 or
0-10 volts DC.
R1= 4 ohms /10 watts
R2= 3 ohms/ 10 watts
PRECISION TIG 185
F-27 TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST (continued)
SCR1 ANODE
SCR2 CATHODE
SCR3 CATHODE
SCR4 ANODE
F-27
SCR1 CATHODE/SCR2 ANODE
SCR3 ANODE/SCR4 CATHODE
FIGURE F.6 SCR GATE LOCATIONS
PLUG J2
3
SCR3 SCR4
4
SCR1 SCR2
1 2
S24018-4 (INSERTION SIDE)
SCR GATE LEADS/TEST POINTS
6. Connect SCR into the test circuit as shown (A) lead to anode (C) lead to cathode and (G) lead to the gate.
7. Close switch SW-1 (switch SW-2 should open), voltmeter should read zero. If the voltmeter reads higher than zero the SCR is shorted.
8. With switch SW-1 closed, close switch SW-2 for two seconds and release. The voltmeter should read 3 to 6 volts before and after switch SW-
2 is released. If the voltmeter does not read, or reads only while SW-2 is depressed, the SCR or battery is defective (repeat Battery Test
Procedure above).
9. Open switch SW-1, disconnect the gate lead (G) and reverse the (A) and
(C) leads on the SCR. Close switch
SW-1. The voltmeter should read zero. If the voltage is higher than zero, the SCR is shorted.
10. Replace SCR Bridge Assembly if any SCRs do not pass the test in
11. Replace plug J2 into the control board.
12. Replace the case wrap-around cover.
PRECISION TIG 185
F-28 NOTES F-28
PRECISION TIG 185
F-29 TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
AC TIG MODE
CAUTION
HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment.
• Perform all voltage and waveform checks with high frequency circuit OFF.
• Perform High Frequency Disable Procedure.
____________________________________________________________________
F-29
0 V
50 V
This is the typical AC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time.
Note: Scope probes connected at machine output terminals: (+) probe to electrode, (–) probe to work.
2 ms
SCOPE SETTINGS
Volts/Div. ...............................50 V/Div.
Horizontal Sweep .................2 ms/Div.
Coupling .........................................DC
Trigger .....................................Internal
PRECISION TIG 185
F-30 TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
DC TIG MODE
CAUTION
HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment.
• Perform all voltage and waveform checks with high frequency circuit OFF.
• Perform High Frequency Disable Procedure.
____________________________________________________________________
F-30
0 V
50 V
This is the typical DC (+) output voltage waveform generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time.
Note: Scope probes connected at machine output terminals: (+) probe to electrode, (–) probe to work.
2 ms
SCOPE SETTINGS
Volts/Div. ...............................50 V/Div.
Horizontal Sweep .................2 ms/Div.
Coupling .........................................DC
Trigger .....................................Internal
PRECISION TIG 185
F-31 TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
AC STICK MODE
CAUTION
HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment.
• Perform all voltage and waveform checks with high frequency circuit OFF.
• Perform High Frequency Disable Procedure.
____________________________________________________________________
F-31
0 V
50 V
This is the typical AC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time.
Note: Scope probes connected at machine output terminals: (+) probe to electrode, (–) probe to work.
2 ms
SCOPE SETTINGS
Volts/Div. ...............................50 V/Div.
Horizontal Sweep .................2 ms/Div.
Coupling .........................................DC
Trigger .....................................Internal
PRECISION TIG 185
F-32 TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
DC STICK MODE
CAUTION
HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment.
• Perform all voltage and waveform checks with high frequency circuit OFF.
• Perform High Frequency Disable Procedure.
____________________________________________________________________
F-32
0 V
50 V
This is the typical DC (+) output voltage waveform generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time.
Note: Scope probes connected at machine output studs: (+) probe to electrode, (–) probe to work.
2 ms
SCOPE SETTINGS
Volts/Div. ...............................50 V/Div.
Horizontal Sweep .................2 ms/Div.
Coupling .........................................DC
Trigger .....................................Internal
PRECISION TIG 185
F-33 TROUBLESHOOTING & REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
AC TIG MODE
F-33
CAUTION
HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment.
• Perform all voltage and waveform checks with high frequency circuit OFF.
• Perform High Frequency Disable Procedure.
____________________________________________________________________
0 V
10 V
MACHINE LOADED TO 180 AMPS AT
16VDC.
This is the typical AC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 10 volts and that each horizontal division represents 2 milliseconds in time.
The machine was loaded with a resistance grid bank. The grid load meters read 180 amps and 16VDC
Note: Scope probes connected at machine output terminals: (+) probe to electrode, (–) probe to work.
2 ms
SCOPE SETTINGS
Volts/Div. ...............................10 V/Div.
Horizontal Sweep .................2 ms/Div.
Coupling .........................................DC
Trigger .....................................Internal
PRECISION TIG 185
F-34 TROUBLESHOOTING & REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
DC TIG MODE
F-34
CAUTION
HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment.
• Perform all voltage and waveform checks with high frequency circuit OFF.
• Perform High Frequency Disable Procedure.
____________________________________________________________________
0 V
10 V
MACHINE LOADED TO 180 AMPS AT
16VDC.
This is the typical DC (+) output voltage waveform generated from a properly operating machine. Note that each vertical division represents 10 volts and that each horizontal division represents 2 milliseconds in time.
The machine was loaded with a resistance grid bank. The grid load meters read 180 amps and 16VDC
Note: Scope probes connected at machine output terminals: (+) probe to electrode, (–) probe to work.
2 ms
SCOPE SETTINGS
Volts/Div. ...............................10 V/Div.
Horizontal Sweep .................2 ms/Div.
Coupling .........................................DC
Trigger .....................................Internal
PRECISION TIG 185
F-35 TROUBLESHOOTING & REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
AC STICK MODE
F-35
CAUTION
HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment.
• Perform all voltage and waveform checks with high frequency circuit OFF.
• Perform High Frequency Disable Procedure.
____________________________________________________________________
0 V
10 V
MACHINE LOADED TO 180 AMPS AT
26VDC.
This is the typical AC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 10 volts and that each horizontal division represents 2 milliseconds in time.
The machine was loaded with a resistance grid bank. The grid load meters read 180 amps and 26VDC
Note: Scope probes connected at machine output terminals: (+) probe to electrode, (–) probe to work.
2 ms
SCOPE SETTINGS
Volts/Div. ...............................10 V/Div.
Horizontal Sweep .................2 ms/Div.
Coupling .........................................DC
Trigger .....................................Internal
PRECISION TIG 185
F-36 TROUBLESHOOTING & REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
DC STICK MODE
F-36
CAUTION
HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment.
• Perform all voltage and waveform checks with high frequency circuit OFF.
• Perform High Frequency Disable Procedure.
____________________________________________________________________
0 V
10 V
MACHINE LOADED TO 180 AMPS AT
26VDC.
This is the typical AC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 10 volts and that each horizontal division represents 2 milliseconds in time.
The machine was loaded with a resistance grid bank. The grid load meters read 180 amps and 26VDC
Note: Scope probes connected at machine output terminals: (+) probe to electrode, (–) probe to work.
2 ms
SCOPE SETTINGS
Volts/Div. ...............................10 V/Div.
Horizontal Sweep .................2 ms/Div.
Coupling .........................................DC
Trigger .....................................Internal
PRECISION TIG 185
F-37 TROUBLESHOOTING & REPAIR
ABNORMAL OPEN CIRCUIT VOLTAGE - DC TIG MODE
ONE OUTPUT SCR NOT FUNCTIONING
CAUTION
HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment.
• Perform all voltage and waveform checks with high frequency circuit OFF.
• Perform High Frequency Disable Procedure.
____________________________________________________________________
F-37
0 V
50 V
This is NOT the typical DC (+) output voltage waveform. One output SCR is not functioning. Note the “gap”in the waveform. One
SCR gate was disconnected to simulate an open or non-functioning output SCR. Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time.
Note: Scope probes connected at machine output terminals: (+) probe to electrode, (–) probe to work.
2 ms
SCOPE SETTINGS
Volts/Div. ...............................50 V/Div.
Horizontal Sweep .................2 ms/Div.
Coupling .........................................DC
Trigger .....................................Internal
PRECISION TIG 185
F-38 NOTES F-38
PRECISION TIG 185
F-39 TROUBLESHOOTING AND REPAIR
SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the SCR assembly
MATERIALS NEEDED
5/16” nutdriver
3/8” nutdriver
Needle nose pliers
7/16” Wrench
3/8” Wrench
Slot head screwdriver
Dow Corning 340 Heat Sink compound
F-39
PRECISION TIG 185
F-40 TROUBLESHOOTING AND REPAIR
SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
PROCEDURE
1. Remove input power to the TIG 185 machine.
2. Using the 3/8” nutdriver remove the case wrap-around cover.
loosen the input cable strain relief to allow movement of case back.
4. Using the 3/8” nutdriver remove the two lower screws from the case back.
See Figure F.7.
5. With the 5/16” nutdriver remove the two screws holding the case back to the internal divider panel. See Figure
F.7.
6. Remove the gas hose from the gas solenoid valve.
7. Carefully pull the case back and fan assembly away to allow access to the SCR Bridge Assembly. Support the case back so as not to stress the fan motor leads. It is not necessary to disconnect the fan motor leads.
8. Using the 5/16” nutdriver remove the two screws holding the front panel
assembly to the base. See Figure
F-40
FIGURE F.7 CASE BACK MOUNTING SCREWS
REAR PANEL
MOUNTING
SCREWS
PRECISION TIG 185
F-41 TROUBLESHOOTING AND REPAIR
SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
FIGURE F.8 FRONT PANEL MOUNTING SCREWS
F-41
FRONT PANEL
MOUNTING
SCREWS
9. Remove plug J2 from the control
remove plug and lead harness from internal divider panel.
10. Carefully slide the internal divider panel away a few inches to allow access to the SCR bridge assembly.
11. Using the 7/16” wrench disconnect the diode pigtail connection from the
polarity switch lead. See Figure
. Cut any necessary cable ties
and remove insulating sleeving.
Note placement of sleeving and cable ties for reassembly.
12. Using the 7/16” wrench remove the
X2 secondary transformer lead from the left side AC SCR heat sink.
13. With the 7/16” wrench remove the shunt from the SCR bridge left side negative heat sink.
14. Using the 7/16” wrench remove the polarity switch lead from the right side AC SCR heat sink.
15. Using the 7/16” wrench remove the positive lead from the right side positive heat sink.
PRECISION TIG 185
F-42 TROUBLESHOOTING & REPAIR
SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
FIGURE F.9 PLUG J2 ON CONTROL BOARD
PLUG J2 REMOVED
F-42
PRECISION TIG 185 CONTROL
DIODE
PIGTAIL
CONNECTION
FIGURE F.10 DIODE PIGTAIL CONNECTION TO POLARITY SWITCH LEAD.
PRECISION TIG 185
F-43 TROUBLESHOOTING & REPAIR
SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
16. With the 3/8” wrench remove the four mounting screws holding the
SCR bridge assembly to the main transformer frame. Note insulator placement.
17. Carefully remove the SCR bridge assembly from the TIG 185 cutting any necessary cable ties.
REPLACEMENT PROCEDURE
1. Carefully place the new SCR bridge assembly in position in the TIG 185.
2. Using the 3/8” wrench install the four mounting screws taking special care that the insulators are in the correct positions.
USE DOW CORNING 340 HEAT SINK
COMPOUND ON ALL ALUMINUM
CONNECTIONS
3. Assemble the positive lead to the right side positive heat sink.
4. Assemble the lead from the polarity switch to the right side AC heat sink.
Note: Also connect lead #216
5. Assemble the shunt to the SCR bridge left side negative heat sink.
6. Assemble the X2 secondary transformer lead to the left side AC SCR heat sink. Note: Also connect lead
#217
7. Assemble the diode pigtail lead to
the polarity switch lead. See Figure
and secure with cable ties. Position with harness and secure with cable ties.
9. Position the internal divider panel and secure with the screws previously removed.
10. Install the J2 plug into the control board and position the harness in the internal divider panel.
11. Position and install the case back and secure with the screws previously removed.
12. Install the gas hose onto the solenoid valve.
13. Tighten the input cable strain relief.
14. Assemble the case wrap-around cover.
F-43
8. Replace any previously removed cable ties.
PRECISION TIG 185
F-44 NOTES F-44
PRECISION TIG 185
F-45 TROUBLESHOOTING & REPAIR
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the polarity switch.
MATERIALS NEEDED
3/8” Nutdriver
1/2” Wrench
7/16” Wrench
Phillips head screwdriver
5/64” Allen type Wrench
Needle nose pliers
Slot head screwdriver (2 required)
Wiring diagram
F-45
PRECISION TIG 185
F-46 TROUBLESHOOTING & REPAIR
POLARITY SWITCH
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
REMOVAL PROCEDURE
1. Remove the input power to the TIG
185 machine.
2. Using the 3/8” nutdriver remove the case wrap-around cover.
3. Using the 3/32” Allen type wrench remove the output control knob.
4. Using the Phillips head screwdriver remove the screw from the polarity switch handle.
5. With the 2 slot head screwdrivers carefully pry the polarity switch handle from the shaft.
6. Remove the five plastic snap rivets holding the name plate to the case front. These can be removed by gently prying at the rivet between the name plate and the case front.
7. Remove the name plate.
8. With the 1/2” wrench remove the
“positive” flex lead from the polarity switch. See wiring diagram. Label lead and connection point for reassembly.
9. With the 1/2” wrench remove the
“AC” flex lead from the polarity switch. This lead connects to the AC plate on the SCR bridge. See wiring diagram. Label lead and connection point for reassembly.
10. Using the 1/2” wrench remove the flex lead from the rear gang of the polarity switch. This lead connects to the D1 diode on the SCR bridge.
See wiring diagram. Label lead and connection point for reassembly.
11. Using the 1/2” wrench remove the flat copper lead from the polarity switch. This lead connects to the high frequency transformer coil and the by-pass board. See wiring diagram. Label lead and connec-
PRECISION TIG 185 tion point for reassembly.
12. Using the 1/2” wrench remove the other flat copper lead from the polarity switch. This lead connects to the lower terminal on the by-pass board and the “work” lead. See wiring diagram. Label lead and connection point for reassembly.
13. Using the 1/2” wrench remove the choke lead from the polarity switch.
See wiring diagram. Label lead and connection point for reassembly.
14. With the 1/2” wrench remove the X1 secondary lead from the polarity switch. See wiring diagram. Label lead and connection point for reassembly.
15. With the 7/16” wrench remove the two nuts and washers that hold the polarity switch to the front panel.
16. Carefully rotate the polarity switch assembly to gain access to the micro-switch.
17. Carefully unsolder the two leads
(#311 and #312) from the microswitch located on the polarity switch assembly. See wiring diagram.
Label leads and connection points for reassembly.
18. Carefully remove the polarity switch assembly from the machine.
F-46
F-47 TROUBLESHOOTING & REPAIR
POLARITY SWITCH
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
REPLACEMENT PROCEDURE
1. Carefully position the new polarity switch in position on the front panel.
Make certain the micro-switch is assembled to the polarity switch correctly.
2. Solder leads #311 and #312 to the micro -switch.
3. Assemble and tighten the two nuts and washers that hold the polarity switch to the front panel.
4. Assemble the X1 secondary lead to the polarity switch. Make certain washers are in place and the nut is tight.
5. Assemble the choke lead to the polarity switch. Make certain washers are in place and the nut is tight.
6. Assemble the flat copper leads to the polarity switch. Make certain they are connected to the proper terminals and the nuts are tightened.
7. Assemble the flex lead from diode
D1 to the rear gang of the polarity switch. Make certain washers are in place and the nut is tight.
8. Assemble the flex lead from the AC bridge plate to the polarity switch.
Make certain washers are in place and the nut is tight.
9. Assemble the “positive” flex lead to the polarity switch. Make certain washers are in place and the nut is tight.
10. Clear the leads and check for
“shorted” or “grounded” leads.
11. Position the name plate and fasten to the front with the previously removed snap rivets.
12. Assemble the polarity switch handle in place with the Phillips head screw and check for correct switch operation.
13. Using the Allen type wrench replace the output control knob.
14. Replace the case wrap-around cover.
F-47
PRECISION TIG 185
F-48 NOTES F-48
PRECISION TIG 185
F-49 TROUBLESHOOTING & REPAIR
HIGH VOLTAGE TRANSFORMER
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the high voltage transformer.
MATERIALS NEEDED
3/8” Nutdriver
Phillips head screwdriver
Needle nose pliers
Wire cutters
F-49
PRECISION TIG 185
F-50 TROUBLESHOOTING & REPAIR
HIGH VOLTAGE TRANSFORMER
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
REMOVAL PROCEDURE
1. Remove input power to the TIG 185 machine.
2. Using the 3/8” nutdriver remove the case wrap-around cover.
3. With the needle nose pliers remove the two secondary leads from the quick-connects on the high frequency arc starter board assembly. See Figure F.11.
4. Disconnect the in-line splice quick connect from one primary lead to lead #231A.
Cut any necessary cable ties.
5. Remove the lead splice from the other primary lead that is connected to lead #236 and the C4 capacitor. See wiring diagram. Cut any necessary cable ties.
remove the front mounting screws from the base of the high voltage transformer.
Take note of insulator placement for reassembly. NOTE: On some machines the mounting screw configuration may be different.
7. With phillips head screwdriver loosen the two rear mounting screws.
8. Carefully slide the transformer forward and remove from the TIG 185 machine.
F-50
FIGURE F.11 SECONDARY LEADS AT HIGH FREQUENCY STARTER BOARD
PRECISION TIG 185
TRANSFORMER
SECONDARY
LEADS
F-51 TROUBLESHOOTING & REPAIR
HIGH VOLTAGE TRANSFORMER
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
REPLACEMENT PROCEDURE
1. Carefully position the new high voltage transformer in place in the two rear mounting insulators. See Figure
F.12.
2. Install the front mounting insulators and mounting screw.
3. Using the phillips head screwdriver tighten all four mounting screws making certain the insulators are positioned correctly.
4. Reconnect the two primary leads.
5. Reconnect the two secondary leads to the high frequency arc starter board assembly.
6. Replace any previously removed cable ties.
cover.
F-51
FIGURE F.12 HIGH VOLTAGE TRANSFORMER MOUNTING INSULATORS
SLOTTED REAR
MOUNTING INSULATORS
FRONT MOUNTING
INSULATORS
NOTE: On some machines the mounting screw configuration may be different.
PRECISION TIG 185
F-52 NOTES F-52
PRECISION TIG 185
F-53 TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the main transformer and choke assembly.
MATERIALS NEEDED
3/8” Nutdriver
1/2” Wrench
Wire cutters
F-53
PRECISION TIG 185
F-54 TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
REMOVAL PROCEDURE
1. Remove input power to the TIG 185 machine.
2. Perform the SCR Bridge Assembly
3. Unsolder the two 115VAC leads and leads B231 and B232 from the main transformer leads. Label leads for reassembly. See wiring diagram.
4. Unsolder leads W201 and W204 from the main transformer leads.
Label leads for reassembly. See wiring diagram.
5. Unsolder leads R209 and U210 from the main transformer leads. Label leads for reassembly. See wiring diagram.
6. Using the 1/2” wrench remove the shunt assembly from the choke lead.
7. With the 3/8” wrench remove the H1,
H2 or H3 lead from the input power switch. See wiring diagram. Label the leads and connection points for reassembly. Cut any necessary cable ties.
8. Remove plug J3 from the control board and push through the interior divider panel.
9. Using the 1/2” wrench remove the choke lead from the polarity switch.
See wiring diagram. Label lead and connection point for reassembly.
10. With the 1/2” wrench remove the X1 secondary lead from the polarity switch. See wiring diagram. Label lead and connection point for reassembly.
11. With the 1/2” wrench remove the four nuts and lock washers from the transformer mounting bolts at the base of the machine.
12. Carefully hoist the transformer/ choke assembly clear of the base.
Clear all leads.
F-54
PRECISION TIG 185
F-55 TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (Continued)
REPLACEMENT PROCEDURE
1. Position the new transformer/choke assembly onto the base and mounting bolts.
2. Assemble the four nuts and washers to the mounting bolts on the base of the machine.
3. Assemble the X1 secondary lead to the polarity switch.
4. Assemble the choke lead to the polarity switch.
5. Install the J3 plug into the control board.
6. Assemble the H1, H2 or H3 lead onto the input power switch. Insulate and secure the unused lead (H2 or H3).
7. Assemble the shunt assembly to the choke lead.
8. Solder leads R209 and U210 to the main transformer leads. See wiring diagram. Insulate connections.
9. Solder leads W201 and W204 to the main transformer leads. See wiring diagram. Insulate connections.
10. Solder the two 115VAC leads and leads B231 and B232 to the main transformer leads. See wiring diagram. Insulate connections.
11. Replace any previously removed cable ties. Clear leads and check for “shorts” or “grounds”.
F-55
PRECISION TIG 185
F-56 NOTES F-56
PRECISION TIG 185
F-57 TROUBLESHOOTING AND REPAIR
RETEST AFTER REPAIR
F-57
Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested.
Input Volts/Hertz
208/60
230/60
INPUT IDLE AMPS
Maximum Idle Amps
2.50 Amps
3.00 Amps
OPEN CIRCUIT VOLTAGES
Stick Mode OCV
TIG Mode OCV
AC 70 - 80VAC
DC 55 - 65VDC
AC 70 - 80VAC
DC 60 - 70VDC
MAXIMUM ACCEPTABLE OUTPUT VOLTAGE -
AT MINIMUM OUTPUT SETTINGS
DC TIG Mode 6 Amps @ 12 Volts
MINIMUM ACCEPTABLE OUTPUT VOLTAGE -
AT MAXIMUM OUTPUT SETTINGS
DC TIG Mode 200 Amps @ 29 Volts
RECOMMENDED METERS FOR MACHINE OUTPUT TESTS
VOLTMETER: AC and DC True RMS Meter - Fluke 8922A or equivalent
AMMETER: Columbia Type AX AC or DC Tong Ammeter
IMPORTANT: IF OTHER TYPE METERS ARE USED RESULTS MAY NOT BE ACCURATE.
PRECISION TIG 185
F-58 NOTES F-58
PRECISION TIG 185
Section G-1 TABLE OF CONTENTS
- ELECTRICAL DIAGRAMS SECTION -
Section G-1
Electrical Diagrams ...............................................................................................Section G
PRECISION TIG 185
G-2
WIRING DIAGRAM - ENTIRE MACHINE - (G4549)
ELECTRICAL DIAGRAMS G-2
C2
C1
VOLTAGE RECONNECTION
SEE RATING PLATE FOR SPECIFIC VOLTAGES
230 or 400-415 or 575 VOLT CONNECTION
(AS SHOWN & AS SHIPPED FROM FACTORY)
H1 and H3 (HIGH) TO POWER SWITCH.
H2 NOT CONNECTED; INSULATE.
208 or 380 or 460 VOLT CONNECTION
H1 and H2 (LOW) TO POWER SWITCH.
H3 NOT CONNECTED; INSULATE.
C1 AND C2 MUST ALWAYS BE CONNECTED
ACROSS TRANSFORMER PRIMARIES
380V AND ABOVE
G
B
(L1)
W
(L2)
CONNECT GREEN LEAD TO GROUND PER
NATIONAL AND LOCAL ELECTRICAL CODE
CONNECT BLACK AND WHITE LEADS
TO SUPPLY CIRCUIT
208V/230V ONLY TO GROUND PER
NATIONAL ELECTRIC CODE
INPUT PLUG (208V/230V ONLY)
G
W
(L2)
B
(L1)
S1
POWER
SWITCH
S4
CHOKE
H3
H2
H1
313
314
10K A-B
AT MINIMUM
OPTIONAL
REMOTE
AMPTROL TM
A
B
C
D
E
F
A
B
C
D
E
REMOTE
RECEPTACLE
L5
AC
240
FRONT
GANG
D
A
C
E F
B
X1
POS
S2
POLARITY
SWITCH
AC
DC+
DC-
POLARITY SWITCH MICRO SWITCH
A-C, D-E, B-F
B-D, C-E, A-F, G-H
B-D, A-E, C-F, G-H
OPEN
CLOSED
CLOSED
REAR GANG
H
MICRO-SWITCH
NO
NC
312A
G
DC
S2A 311A
(REAR VIEW,
SHOWN IN AC POSITION)
284 285
312
311
4 3 2 1
J4
12 11 10 9 8 7 6 5 4 3 2 1
J3
AUTO
BALANCE
LED
G
AC
BALANCE
CONTROL
8 7 6 5 4 3 2 1
J2
MODE
SWITCH
G
TIG LED
R
STICK LED
236
236A
R3
C4
A
C
B
D
E
1
2
3
4
5
6
J5
PULSE
FREQ
LED
PULSE
CONTROL
G
POSTFLOW
CONTROL
DIGITAL
DISPLAY
THERMAL
LED Y
OUTPUT
CONTROL
CONTROL PC BOARD
J6
J1
1
2
W 221
R 222
1
2
3
4
L4
237
115VAC
T2
231A
H3 (HIGH)
H2 (LOW)
201
TRIGGER
204
209
POWER
210
H1
X3
18VAC
X4
X5
18VAC
X6
X1
78VAC
X2
T1
X8
115VAC
X7
232
231
L1
R4
245 244
R5
P7
J7
4 3 2 1
W 221
R 222
217
G3
216
216A
SHUNT
G4
G1
G2
POS
220
220A
SCR1
AC
SCR2
218
218A
( )
+
220A 218A
260 231A
115VAC
FAN
SCR3
X2
SCR4
_
( )
D1
DC
235
231
GAS VALVE
SV1
WORK
ELECTRODE
285
284
L3 L2
ARC
STARTER
AS'BLY
239 238
SPARK
GAP
T3
C3
BYPASS/
STABILIZER
PC BOARD
284A
R2
284B
R1
285A 285B
C1,C2
C3
C4
C5,C6
CB1
D1
L1
L2,L3
L4,L5
R1,R2
R3
R4,R5
S1
S2
S2A
BY-PASS CAPACITORS, .0047/250VAC
HIGH VOLTAGE CAPACITOR, .0025/10kV
PHASE SHIFT CAPACITOR, 15/250VAC
BY-PASS CAPACITORS, .22/400VDC
CIRCUIT BREAKER, 10A
FREE WHEELING DIODE
OUTPUT INDUCTOR (CHOKE)
HIGH FREQUENCY INDUCTORS
RF TOROID CHOKES
HOLDING RESISTORS, 100/100W
PHASE SHIFT RESISTOR, 200/100W
MICRO START RESISTORS, 12/100W
INPUT POWER SWITCH
POLARITY SWITCH
MICROSWITCH ON POLARITY SWITCH
S4 MAIN CHOKE THERMOSTAT
SCR1,2,3,4 MAIN POWER SCR'S
SV1
T1
GAS SOLENOID VALVE, 115VAC
MAIN TRANSFORMER
T2
T3
HIGH VOLTAGE TRANSFORMER
HIGH FREQUENCY TRANSFORMER
LEAD COLORING CODE:
B-BLACK
G-GREEN
R-RED
W-WHITE
COMPONENT VALUE
UNITS:
RESISTORS:
OHMS/WATTS
CAPACITORS:
MFD/VOLTS
CONNECTOR PIN NUMBERS:
1 2 3 7
EXAMPLE: THIS IS PIN 7
OF CONNECTOR J4
8
J4
14
LATCH
VIEW OF CONNECTOR ON PC BOARD
ELECTRICAL SYMBOLS PER E1537.
G4549 B
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
PRECISION TIG 185
G-3 ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE - (G4588)
8 G458
CHANGE DETAIL: RELEASED FROM X A.02
TYPICAL OCV
65V IN DC
75V IN AC
ENGINEERING CONTROLLED
MANUFACTURER:
No
POWER-UP SEQUENCE
METER AND MODE DISPLAY THE PREVIOUS OUTPUT
CONTROL AND MODE SETTINGS. FAN RUNS FOR 5
SECONDS. IF MODE IS TIG, GAS FLOWS FOR A TIME
SET BY THE POSTFLOW KNOB. OUTPUT IS HOT IF
MODE IS STICK. IN TIG MODE OUTPUT IS COLD UNTIL
TRIGGER IS CLOSED
METER, ENCODER, SWITCH, LEDs,
AND ALL POTENTIOMETERS ARE
MOUNTED ON PC BOARD
OUTPUT CONTROL &
MODE SETTINGS ARE
MEMORIZED AT POWER
- DOWN AND RECALLED
AT POWER - UP
+15V
DISPLAY PRESET AT IDLE
ACTUAL AMP WHEN WELDING
NO HOLD FUNCTION
S1
MODE
+5Vref
TOGGLE BETWEEN TIG &
STICK.
HI-FREQ, GAS, BALANCE
CONTROL, PULSE
FREQUENCY, &
MICRO-START CIRCUIT
ARE DISABLED IN STICK
A
C
OUTPUT CONTROL
(ENCODER)
5 - 185A IN DC
7 - 185A IN AC
B
A1
+5Vref
DET_REM
REM_SENSE
REM_POT
From Auto Loc/Rem
+5V
3 DIGIT
METER
(DISP1)
METER
INTERFACE
+5Vref
FIRE_SCR
PHASE_FIRE
Iarc
SETPOINT
AC/DC
BG
+15V +5V +24V
SCR
GATING & SNUBBER
+15V PHASE
MICRO-START
CIRCUIT
(DISABLED IN STICK)
+15V -15V
OUTPUT REGULATOR
+24V +5Vref
INTERFACE
5J2
6J2
3J2
8J2
2J2
1J2
4J2
7J2
11J3
10J3
9J3
12J3
1J1
2J1
5J3
SCR1 GATE
SCR2 GATE
SCR3 GATE
SCR4 GATE
G1
G2
G3
G4
SCR3,SCR2 CATHODE
SCR1 CATHODE
SCR4 CATHODE
218
217
216
SCR1,SCR4 ANODE 220
BACKGROUND AC INPUT
BACKGROUND ( - )
BACKGROUND ( + )
BACKGROUND AC INPUT
TOROID
SHUNT (+)
W 221
SHUNT (-)
R 222
CURRENT FEEDBACK
DETERMINE IF HI-FREQ IS
CONTINUOUS OR START
ONLY, MIN. CURRENT, AND
BALANCE CONTROL
MICRO SWITCH INPUT
216A
245
244
240
Rear of machine attached to base, below fan
R4
12/100 EACH
220A
G4
G3
G2
220
R5
BACKGROUND RESISTORS
G1
217
218
218A
IN-LINE CONNECTOR J7
Inside sleeving at top left side of
Main Rectifier
311
TWISTED PAIRS
216
4
3
2
1
On top of Main
Transformer
216A
Top rear
SEE CONNECTION DETAIL
G4
G3
G2
SCR4
-
D1
FREE WHEELING DIODE
G1
SCR1
MAIN SCR
RECTIFIER
SCR2
SCR3
15 - 20 OHM
GATE-CATHODE
RESISTANCE TYP.
+
DC
Lower left side of
Polarity Switch
R 222(-)
W 221(+)
OUTPUT
INDUCTOR
240
311
SHUNT
400A/200mV
AC
CLOSED
IN DC N.C.
312
MICRO SWITCH CLOSED IN DC
OPEN IN AC
Right Side of SCR Bridge
Rectifier. Top of Machine behind Choke.
L1
Right side of Machine above Choke Coil.
Gang A
Gang D
DC+
DC-
CBW
Gang C
Gang G
Gang B
AC
CBW
DC
+
CBW
DC-
AC
Gang H
DC
-
AC
DC
+
CBW CBW
DC
-
AC
DC
+
X2
80 VAC
X1
MAIN
TRANSFORMER
T1
H3
CBW = CONNECTED
BY SWITC H
THESE CONNECTIONS
ARE MASE BY POLARITY
SWITCH, THEY ARE NOT
PHYSICAL LEADS
Center of machine
H2
HIGH
LOW
BYPASS ASSEMBLY
C1
Attached to Power Switch
.0047/ 250VAC
POWER SWITCH
C2
W
S1
L1
H1
L2 B
G
RECONNECT IS DONE AT
POWER SWITCH
Front Panel Left side
VOLTAGE RECONNECTION
SEE RATING PLATE FOR SPECIFIC VOLTAGES
230 or 400-415 or 575 VOLT CONNECTION
(AS SHOWN & AS SHIPPED FROM FACTORY)
H1 and H3 (HIGH) TO POWER SWITCH.
H2 NOT CONNECTED; INSULATE.
208 or 380 or 460 VOLT CONNECTION
H1 and H2 (LOW) TO POWER SWITCH.
H3 NOT CONNECTED; INSULATE.
MAX. PENETRATION
BALANCE
MAX. CLEANING
AUTO
R1
10K
Polling signal
Hi = Local
Remote control
THERMOSTAT
INTERFACE
+24V +5Vref
6J3
2J3
1J3
THERMOSTAT INPUT
DISABLE OUTPUT & HI-FREQ
IF THERMOSTAT OPEN
312
314
313
Gang E
284
Gang F
S2
POLARITY SWITCH
Front Panel Center
SEE CONNECTION DETAIL
285
C1 AND C2 MUST ALWAYS BE CONNECTED
ACROSS TRANSFORMER PRIMARIES
BALANCE CONTROL IS
DISABLED IN STICK AND
DC TIG
CHOKE TSTAT
(NORMALLY CLOSED
OPEN AT 135C TYP.)
Inside hi-freq box on right side of machine near front
+5Vref
PULSE FREQUENCY IS
DISABLED IN STICK
20 HZ
PULSE FREQUENCY R2
0.1 HZ
OFF
10K
+5Vref
30 S
POSTFLOW
R3
10K
1 S
+5V
DATA
SCLK
XRES
MICRO-
PROCESSOR
PHASE
TRIGGER
+15V
+5Vref
115V CIRCUIT
TRIAC & OPTO-TRIAC
DRIVER
1J6
2J6
3J6
4J6
PROGRAMMING CONNECTOR
FOR SOFTWARE UPGRADE
Left side of Machine near front
In Front of main transformer,
Attached to Base
Inside hi-freq box on right side of machine near front
HI-FREQ OFF IN STICK
START ONLY IN DC TIG
CONTINUOUS IN AC TIG
BYPASS/STABILIZER
PCB
(SCHEMATIC S22530)
(PCB AS'BLY L10121-1)
284A 285A
100/100
R2
284B
HOLDING RESISTORS
285B
R1
100/100
Right side of machine, front of gas solenoid, attached to Base
SCR
HEATSINK
FARTHEST LEFT
SCR (VIEWED
FROM FRONT)
TO0 COPPER BAR
BOTTOM
COPPER
BAR
W 222
ALUMINUM BAR
FARTHEST RIGHT SCR
(VIEWED FROM
FRONT)
7 GA. FLEX LEAD
HI-FREQ BYPASS CONNECTION
FROM BOTTOM LEFT
MOUNTING HOLE TO SHEET
METAL
LED 1
STICK
(RED)
NEXT TO MODE SWITCH
LED 4
AUT0BALANCE
(GREEN)
NEXT TO BALANCE POT.
OFF IN STICK AND DC TIG
AUTO LOCAL/REMOTE
STICK MODE: ALWAYS LOCAL
TIG MODE: REMOTE IF PLUGGED
LOCAL IF UNPLUGGED
RECEPTACLE
Left front
U A
10K N
R
B
B
C
W
D
E
F
TOROID
TM
OPTIONAL AMPTROL REMOTE
CONTROL AND ARC START SWITCH
3J5
2J5
5J5
6J5
AUTO
LOCAL/
REMOTE
CONTROL
RF
CHOKES
1J5
TO MICRO
PROCESSSOR
+15V
-15V
LED INTERFACE
LED 3
TIG
(GREEN)
NEXT TO MODE SWITCH
LED 5
FREQUENCY
(GREEN)
NEXT TO PULSE
FREQUENCY POT.
OFF IN STICK, BLINKS AT
FREQUENCY RATE
POSTFLOW
+5V
TRIGGER
INTERFACE
J1 2 PIN
J5
LED 2
THERMAL
(YELLOW)
NEXT TO METER
4 PIN (WHITE)
PROGRAMMING
CONNECTOR
J6
MICRO-PROCESSOR
OUTPUT CONTROL
+5Vref
(GREEN)
X1
SOFTWARE
VERSION LABEL
TRIGGER
TO MICRO
PROCESSOR
FREQUENCY
6 PIN
+24V
+15V
+5V
+5Vref
-15V
+15V
(GREEN)
MODE
+5V
(GREEN)
BALANCE
4J4
1J4
3J4
2J4
LED 6
THERMAL
(YELLOW)
NEXT TO METER
TWO THERMAL LEDs TO
LIGHT THROUGH
BACK-LIT THERMAL
SYMBOL
+5V
TO MICRO PROCESSOR
AND SCR GATING
PHASE
PHASE
DETECTOR
POWER SUPPLY
J2
8 PIN
J3
12 PIN
J4
4 PIN
7J3
8J3
4J3
3J3
HI-FREQ (115VAC)
GAS (115VAC)
115VAC IN
FAN (115VAC)
232
260
235
236
DO NOT REVERSE LEADS
209 & 210, USED FOR SCR
PHASE TIMING
209
210
X5
18VAC
CONTROL BOARD SUPPLY
X6
201
18VAC
TRIGGER CIRCUIT
204
X3
X4
AUX. WINDINGS OF
MAIN TRANSFORMER T1
T1
HIGH VOLTAGE
TRANSFORMER
T2
200/100
R3
237
236B
C4
15/250
5.5 OHMS
TYP.
115V
S
F
14.5 KOHMS
TYP.
5000V
Rear Panel
Right Side
235
232
GAS
SOLENOID
(115VAC)
SV1
Right front side of
Main Transformer
L2
12.5 OHM TYP.
12.5 OHM TYP.
L3
HI-FREQ CIRCUIT
231
435 OHMS TYP.
115VAC
12 OHMS TYP.
260
ARC STARTER ASSEMBLY
FAN
238
239
C3
SPARK
GAP .020
.0015/12KV
HIGH FREQ.
TRANSFORMER
ELECTRODE
Right front
FAN RUNS FOR 5 S AT POWER-UP
STOPS AT IDLE 8 MINUTES
AFTER WELDING.
TYP. RPM:
1600 RPM 60Hz
1340 RPM 50Hz
Between SCR Bridge halves behind choke.
T3
232
Mounted to front side of hi-freq box on right side of machine near front.
Center front
WORK
Right rear side of Main
Transformer
X7
115VAC
X8
T1
240
Gang D
Rear gang H
Gang C
Gang E
6 GA. FLEX LEADS
DC
AC
DC+
DC-
POLARITY SWITCH
A-C, D-E, B-F
B-D, C-E, A-F, G-H
B-D, A-E, C-F, G-H
Gang A
LEAD COLOR CODE:
B-BLACK OR GRAY
G-GREEN
O-ORANGE
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
OUTPUT INDUCTOR
285
Gang F
Rear gang G
UNUSED TERMINAL
311 gang B
MOUNTING HOLE
MICRO SWITCH
X1
312
GANG LOCATIONS ARE
VIEWED FROM REAR OF
SWITCH
MICRO SWITCH
OPEN
CLOSED
CLOSED
SCR BRIDGE AND POLARITY SWITCH CONNECTION DETAIL
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
1 2 6
7 12
LATCH
VIEW OF CONNECTOR ON PC BOARD
HI-FREQ BYPASS
CONNECTION
CONTROL PCB MAIN COMPONENT & DIANOSTIC LED LAYOUT
(VIEWED FROM COMPONENT SIDE) CONTROL PC BOARD
SCHEMATIC G4550-
ASSEMBLY G4551-
Front Panel Top
COMPONENT LOCATION DESCRIPTIONS ARE AS VIEWED
FROM FRONT OF MACHINE UNLESS STATED
OTHERWISE
THE INFORMATION ON THIS
PRINT IS FOR REFERENCE
ONLY. COMPONENTS AND
CIRCUITRY MAY BE DIFFERENT
FROM AN ACTUAL MACHINE.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: Precision Tig 185
DRAWN BY: Jbarto Reference
ENGINEER:
APPROVED:
TNguyen
Approve
SCALE:
NONE
SUBJECT:
MATERIAL
DISPOSITION:
UF
MACHINE SCHEMATIC
APPROVAL
DATE: 02/20/2004
PROJECT
NUMBER:
CRM36191
DOCUMENT
NUMBER:
G4588
DOCUMENT
REVISION:
A
G-3
PRECISION TIG 185
G-4
SCHEMATIC - CONTROL PC BOARD - (G4550-1B4-1)
ELECTRICAL DIAGRAMS G-4
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PRECISION TIG 185
G-5
SCHEMATIC - CONTROL P.C. BOARD - (G4550-1B4-2)
ELECTRICAL DIAGRAMS G-5
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PRECISION TIG 185
G-6
SCHEMATIC - CONTROL P.C. BOARD - (G4550-1B4-3)
ELECTRICAL DIAGRAMS G-6
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PRECISION TIG 185
G-7 ELECTRICAL DIAGRAMS G-7
PC BOARD ASSEMBLY - CONTROL - (G4551-1)
51-1 G45
CHANGE DETAIL: REVISED IDENTIFICATION CODE, SCHEMATIC REFERENCE, BUY PART NUMBER AND ITEM 40.
ENGINEERING CONTROLLED
MANUFACTURER: Yes
6.00
N.G.
5.83
5.13
N.B.
LED4
R116
C68
D31
X13
N.F.
TP3
R94
C49
D28
S1
LED1
LED3
X
X
X
X
X X X X X X
R1
X
X X X X X
X
X
X
X
X
X3
D41
R95
X6
X14
DZ5
Q2
D4
Q11
Q13
DZ6
TP4
Q14
Q15
X2
X4
R205
R206
R207
N.C.,N.D.
PT185
CONTROL
D40
TP1
TP2
X1
J1
R214
D6
TP5
C50
R213
N.C.
X
X
X
X
X X X X X X
R2
X
X X X X X
X
X
X
X
X
T1
T2
OCI1
C95
R161
X9
DISP1
LED5
R73
R76
LED2
LED6
N.C., N.D., N.H. (3 PLACES)
OPPOSITE COMPONENT SIDE
R10
C7
R46
R52
C31
R19
R64
R35
C20
R40
R47
Q10
X7
TP7
X11
D16
X12
TRI1
OCI2
5.01
Q7
Q12 D20
R72
R199
TRI2
OCI3
D2
R20
D3
R36
R41
D5
R54
D8
R74
R77
C51
X10
TRI3
OCI4
C46
N.J.
N.C.
R105
R110
TRI4
OCI5
D23
D32
C94
Q16
D35
N.C.
X
X
X X X X X
X
X
X
X A1
X X X X X
X
X
X
X
X
X
X X X X X X
R3
X
X X X X X
X
X
X
X
X
D12
D9
D15
C47
R141
R151
R155
R158
R163
R168
R175
R179
MOV4
MOV5
R142
R152
R156
R159
R164
R169
R176
R180
N.K.
R92
C48
C54
C69
C70
C73
C86
D13
D10
R160
R157
R165
R93
C96
C99
1
N.C., N.D.
N.E.
N.K.
N.K.
N.C.
N.A.
ITEM
1
2
3
REQ PART NO.
DESCRIPTION
1
1
G4551-B
S25864-4
PRECISION TIG 185 CONTROL PCB BLANK
PSOC SOFTWARE
AS NEEDED E2861 SEALANT
FOR ITEMS BELOW, REFER TO ELECTRONIC COMPONENTS DATABASE FOR CURRENT SPECIFICATIONS
ITEM REFERENCES
4 A1
5 C1,C3,C29,C39,C41-
C43,C58,C60,C78,C84,
C89-C92,C94-C95,C103-
C104,C109-C110
QTY PART NUMBER
1 M17789-4
21 S25020-2SMT
DESCRIPTION
ENCODER,INCREMENTAL,2-BIT,PEC12
CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%,X7R,S0805
6
7
C2,C10,C35,C111
C4,C23,C38
C5,C20,C45 8
9 C6-C7,C9,C12,C17-
C18,C24,C30-
C32,C34,C44,C53,C59
10 C8,C13,C25-C26
11 C11,C14,C19,C21-
C22,C33,C48,C50-
C52,C55-
C56,C62,C64,C66,C68,
C74-C76,C79-
C83,C85,C93,C98,C100
,C105,C107-C108,C112
12 C15,C63
13 C16,C40,C113
14 C27,C36-C37
15 C28
16 C46,C49
17 C47
18 C54,C69-
C70,C73,C86,C96,C99,
C101,C106
19 C57,C61,C65
20 C67,C77
21 C71-C72,C87-C88,C102
22 C97
23 DISP1
24 DZ1,DZ8,DZ10
25 DZ2-DZ3
26 DZ4
27 DZ5-DZ6
28 DZ7,DZ9
29 D1-D3,D5,D7-D8,D21-
D22
30 D4,D6,D16,D18-
D20,D28,D31-
D32,D35,D40-D41
31 D9-D15,D17,D23,D29-
D30,D33-D34,D36-D39
32 D24-D27
33 J1
34 J2
35 J3
36 J4
37 J5
38 J6
39 LED1
40 LED2,LED6
41 LED3-LED5
42 LED7-LED9
43 L1-L5
44 MOV1
45 MOV2-MOV5
46 MOV6-MOV8
47 OCI1
48 OCI2-OCI5
49 Q1,Q6
50 Q2-Q3,Q5,Q7,Q9-
Q10,Q12-Q13,Q15-Q18
51 Q4,Q8,Q11,Q14
52 R1-R3
4 S25020-9SMT
3 S25024-2SMT
3 S25020-12SMT
14 S25020-10SMT
4 S20500-17
32 S25020-3SMT
2 S25020-4SMT
3 S25020-14SMT
3 S25020-7SMT
1 S25020-24SMT
2 S13490-199
1 S13490-179
9 T11577-52
3 S13490-197
2 S25020-5SMT
5 T11577-58
1 S13490-181
1 S17395-11
3 S25046-4SMT
2 S25046-3SMT
1 S25046-1SMT
2 S25045-1SMT
2 S25044-3SMT
8 S25040-1SMT
12 S25040-5SMT
17 S25040-2SMT
4 S25040-10SMT
1 S24020-2G
1 S24020-8
1 S24020-12
1 S24020-4
1 S24020-6
1 S18248-4
1 T13657-2
2 T13657-14
3 T13657-3
3 S25080-2SMT
5 T12218-9
1 T13640-16
4 T13640-25
3 T13640-18
1 S15000-34SMT
4 S15000-16
2 S25051-11SMT
12 S25050-1SMT
4 S25050-2SMT
3 T10812-116
CAPACITOR,SMD,CERAMIC,47pF,50V,5%,COG,S0805
CAPACITOR,SMD,TANTALUM,1.0MF,35V,10%,S3528
CAPACITOR,SMD,CERAMIC,100pF,100V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,4700pF,50V,10%,XR7,S0805
CAPACITOR,PPMF,0.1MF,630V,5%,BOX
CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X7R,S0805
CAPACITOR,SMD,CERAMIC,820pF,50V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,330pF,100V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,0.22MF,50V,20%,X7R,S1812
CAPACITOR,SMD,CERAMIC,1.0MF,25V,10% ,X7R,S1206
CAPACITOR,ALEL,220,25V,20%,LOW-ESR
CAPACITOR,ALEL,1000,35V,20%
CAPACITOR,CD,.0047/.005,1400V,20%
CAPACITOR,ALEL,82,35V,20%,LOW-ESR
CAPACITOR,SMD,CERAMIC,2700pF,50V,5%,X7R,S0805
CAPACITOR,CD,.0047,3000V,20%
CAP,ALEL,22,63V,20%
LED,DISPLAY,7-SEGMENT,CC,3-DIGIT
ZENER DIODE,SMD,0.5W,12V,5%,SOD-123
ZENER DIODE,SMD,0.5W,18V, 5%,SOD123
ZENER DIODE,SMD,0.5W,5.1V, 5%,SOD123
ZENER_DIODE,SMD,225mW,12V,5%,SOT-23
ZENER DIODE,SMD,3W,12V,5%, SMB
DIODE,SMD,1A,400V,FAST RECOVERY,DO-214BA
DIODE,SMD,DUAL,0.200A,70V,UFR
DIODE,SMD,1A,400V,DO-214BA/AC
DIODE,SMD,3A,400V,D0-214AB
CONNECTOR,MOLEX,MINI,PCB,2-PIN,GOLD
CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,12-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,4-PIN
LED,T-1,3/4,RED,HLMP-3003
LED,T-1,3/4,AMBER,HIGH-INTENSITY
LED,T-1,3/4,GREEN,HLMP-3502
LED,SMD,GREEN,CLEAR,S1206
CHOKE,RF,390UH,5%, 225MA,CONFORMAL
MOV,150VRMS,80J,20MM
MOV,130VRMS,90J,20MM
MOV,320VRMS,150J,20MM
IC,SMD,OPTOCOUPLER,HMA124
OPTOCOUPLER,TRIAC,DRIVER,ZVC,3083
TRANSISTOR,SMD,NMF,DPAK,TO-252,48A,100V(SS)
TRANSISTOR,SMD,NPN,0.5A,40V,SOT-23,MMBT4401LT1
TRANSISTOR,SMS,PNP,SOT23,0.5A, 40V,MMBT4403LT1
POT,SINGLE-TURN,0.25W,10K,10%
CAPACITORS = MFD / VOLTS
RESISTORS = OHMS
NOTES:
N.A.
N.B.
N.C.
N.D.
N.E.
N.F.
N.G.
N.H.
N.J.
N.K.
THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY, SEE E2454 BEFORE
HANDLING.
PROGRAM X1 WITH ITEM 2.
KEEP FREE OF ENCAPSULATION MATERIAL.
SEAL COMPONENT BY APPLYING ITEM3 AS SHOWN SO THAT ENCAPSULATION MATERIAL
DOES NOT GET INSIDE COMPONENT.
KEEP FREE OF ENCAPSULATION MATERIAL (.50 DIA. MIN.) ON BOTH SIDES OF BOARD.
KEEP MOUNTING HOLES FREE OF ENCAPSULATION MATERIAL (5 PLACES).
COVER MOLEX WITH TAPE.
HAND TIGHT MOUNTING WASHER AND MOUNTING NUT TO POTENTIOMETER BUSHING.
WHEN ASSEMBLING DISPLAY, SPACE DISPLAY OFF THE BOARD .125+/- .010 MEASURED
FROM BOTTOM OF DISPLAY TO PC BOARD SURFACE.
SQUEEZE COMPONENTS TOGETHER BEFORE ENCAPSULATION.
N.A.,N.B.
N.A.
R180
73 R48,R199,R209,R213-
R214
74 R59,R136
75 R62
76 R63,R120
77 R65-R66,R94-
R95,R130,R137
78 R67
79 R70,R117,R119,R121,R
204
80 R71
81 R78
82 R80,R83
83 R87-R89,R99-
R102,R205-R207
84 R93
85 R105,R110
86 R114,R216
87 R115
88 R116,R153-R154
89 R118
90 R123,R133
91 R124-
R125,R127,R171,R181,
R189
92 R126,R138
93 R129
94 R134
95 R140
96 R144,R146,R148,R150,
R186,R190,R192-R193
97 R151-R152,R155-
R156,R158-R159,R163-
R164,R168-R169,R175-
R176
98 R161
99 R172-R174,R178
100 R183
101 R201
102 S1
103 TP1-TP7
104 TRI1,TRI3
105 TRI2,TRI4
106 T1-T2
107 X1
108 X2
109 X3-X4,X14
110 X5
111 X6
112 X7
113 X8
114 X9
115 X10
116 X11
117 X12
118 X13
53 R4,R49-R50,R68-
R69,R72,R107,R122,R1
32,R162,R184
54 R5,R16-R17,R30-
R32,R51,R60-
R61,R92,R194-
R195,R208,R212,R215
55 R6
56 R7,R9,R111-
R113,R135,R143,R145,
R147,R149,R191,R196-
R198,R200,R202
57 R8,R34,R203
58 R10-R11,R52-R53,R90-
R91,R103-R104
59 R12-R15,R26-R29,R42-
R45,R55-R58
60 R18
61 R19,R64,R157,R160,R1
65,R170
62 R20,R36,R41,R54
63 R21
64 R22
65 R23,R79
66 R24
67 R25,R75
68 R33,R38
69 R35,R84,R108-
R109,R139,R166
70 R37,R85,R106
71 R39,R81-
R82,R98,R128,R131,R1
67,R177,R182,R185,R1
87-R188,R210-R211
72 R40,R46-R47,R73-
R74,R76-R77,R86,R96-
R97,R141-R142,R179-
11 S25000-1002SMT
15 S25000-1001SMT
1 S25000-1500SMT
16 S25001-1001SMT
3 S25000-6812SMT
8 S25004-1R00SMT
16 S25003-1210SMT
1 S25000-5622SMT
6 S25001-47R5SMT
4 S25003-15R0SMT
1 S25000-7681SMT
1 S25000-4752SMT
2 S25000-2213SMT
1 S25001-2210SMT
2 S25006-10R0SMT
2 S25008-1002SMT
6 S25001-1000SMT
3 S25000-3322SMT
14 S25000-4751SMT
14 S25001-4751SMT
5 S25000-2210SMT
2 S25000-4750SMT
1 S25000-1000SMT
2 S25000-8251SMT
6 S25008-4751SMT
1 S25000-1003SMT
5 S25000-3321SMT
1 S25000-1004SMT
1 S25001-1002SMT
2 S25000-1212SMT
10 S25000-47R5SMT
1 S25000-2671SMT
2 S25003-47R5SMT
2 S25000-6811SMT
1 S25000-2212SMT
3 S25003-2002SMT
1 S25001-4752SMT
2 S25000-2211SMT
6 S25003-2000SMT
2 S25001-1213SMT
1 S25000-2001SMT
1 S25000-6813SMT
1 S25000-3323SMT
8 S25001-2670SMT
12 S25001-1821SMT
RESISTOR,SMD,METAL FILM,1/10W,10.0K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,1.00K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,150OHMS,1%,S0805
RESISTOR,SMD,1K,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,68.1K,1%,S0805
RESISTOR,SMD,1W,1.00OHMS,1%
RESISTOR,SMD,1W,121OHMS,1%
RESISTOR,SMD,METAL FILM,1/10W,56.2K,1%,S0805
RESISTOR,SMD,47.5OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,1W,15.0OHMS,1%
RESISTOR,SMD,METAL FILM,1/10W,7.68K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,47.5K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,221K,1%,S0805
RESISTOR,SMD,221OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,METAL_FILM,1/2W,10OHMS,1%,S2010
RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.5%,S0805
RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,33.2K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,4.75K,1%,S0805
RESISTOR,SMD,4.75K,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,221OHMS,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,475OHMS,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,100OHMS,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,8.25K,1%,S0805
RESISTOR,SMD,PREC,MF,1/10W,4.75K,0.5%,S0805
RESISTOR,SMD,METAL FILM,1/10W,100K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,3.32K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,1.00M,1%,S0805
RESISTOR,SMD,10K,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,12.1K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,47.5OHMS,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,2.67K,1%,S0805
RESISTOR,SMD,1W,47.5OHMS,1%
RESISTOR,SMD,METAL FILM,1/10W,6.81K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,22.1K,1%,S0805
RESISTOR,SMD,1W,20.0K,1%
RESISTOR,SMD,47.5K,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,2.21K,1%,S0805
RESISTOR,SMD,1W,200OHMS,1%
RESISTOR,SMD,121K,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,2.00K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,681K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,332K,1%,S0805
RESISTOR,SMD,267OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,1.82K,1/4W,1206,1%,TR
1 S25001-7500SMT
4 S25001-1211SMT
1 S25000-1502SMT
1 S25001-2211SMT
1 T13381-16
RESISTOR,SMD,750OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,1.21K,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,15.0K,1%,S0805
RESISTOR,SMD,2.21K,1/4W,1206,1%,TR
SWITCH,PUSHBUTTON,SPST,GREEN,W/BLACK EXTENDER
7 TESTPT_FUNTIONAL FUNCTIONAL TEST POINT
2 S18395-27 TRIAC,T220,8A,800V,WITH S18104-3HS
2 S15161-27
2 T12737-2
1 S25073-3SMT
TRIAC,T220,8A,800V
TRANSFORMER,PULSE,3-WINDING,1:1:1
IC,SMD,CMOS,PSOC,8-BIT,CY8C26643,TQFP44(SS)
1 S15128-27SMT
3 S15128-28SMT
1 S18395-8
1 S15128-10SMT
1 M15102-4SMT
1 S15128-5SMT
1 S25072-2SMT
1 S15018-21SMT
IC,OP-AMP,SINGLE,PRECISION,LT1097S8
IC,OP-AMP,SMT,QUAD,HIGH-PERF,33074ADT
REGULATOR,HEAT-SINKASBLY,S15128-6,S18104-3
IC,SMD,VOLTAGE REF,ADJ, PRECISION,431I,SOIC-8
IC,ARRAY,DRIVER,PERIPHERAL,NPN,DARLINGTON
IC,VOLT REG,SMD,FIXED,3-T,(+),1A,5V
IC,SMD,ACT,BUFFER,OCTAL,3-STATE,TSSOP-20(SS)
IC,SMD,CMOS,DRIVER,MOSFET,4451, SOIC-8(SS)
1 S17900-24SMT
1 S25065-3SMT
1 S15018-11SMT
IC,SMD,CMOS,GATE,NAND,2-INPUT,QUAD,SCHM(SS)
IC,SMD,CMOS,INVERTER,SCHMITT,HEX,VHC14(SS)
IC,SMD,CMOS,SWITCH,ANALOG,QUAD,201(SS)
BUY AS:
G 4 5 5 1 - 1 B 4
.23
0
TP6
Q17
D36
D38
DZ10
D37
D39
C106
C101
N.K.
ENCAPSULATE WITH HUMISEAL (2 COATS)
1A27LU PER E1844 OR WITH EQUIVALENT AS
APPROVED BY LINCOLN ELECTRIC CO.
PART NUMBER IDENTIFICATION CODE
BUY PER E3867
TEST PER E4127-C
P.C. BOARD BLANK REFERENCE INFORMATION
BUY COMPLETE AS G4551-B
SEE ELECTRONIC FILE FOR INFORMATION
N.K.
8.81
SCHEMATIC REFERENCE G4550-1B4
.21
0 9.00
COMPONENT SIDE
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING
DESIGN INFORMATION
DRAWN BY:
ENGINEER: Trang Nguyen
APPROVED: jbarto
-
REFERENCE:
G4407-1
SCALE:
1:1.25
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
PRECISION TIG 185
CONTROL PC BOARD ASSEMBLY
11/29/2005
PROJECT
NUMBER:
CRM37680
DOCUMENT
NUMBER:
G4551-1
DOCUMENT
REVISION:
D
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
PRECISION TIG 185
SVM ERROR REPORTING FORM
We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you.
If you discover new or different “Problems or Symptoms” that are not covered in the three column troubleshooting chart, please share this information with us. Please include the machine’s code number and how the problem was resolved.
Thank You,
Technical Services Group
Lincoln Electric Co.
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 04/06
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