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tig 185
Operator Manual
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Lincoln tig 185 Operator Manual

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PRECISION TIG 185
This manual covers equipment which is no longer in production by The Lincoln Electric Co. Specications and availability of optional features may have changed.
IM832-A
December, 2006
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought­ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most
importantly, think before you act and be careful.
11105, 11106, 11107 11108, 11109
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• Sales and Service through Subsidiaries and Distributors Worldwide •
IP 21S
OPERATOR?S MANUAL
Copyright © 2006 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
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
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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
i
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.d. Keep all equipment safety guards, covers and devices in
position 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 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.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding 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.
and in good repair.Keep hands, hair, clothing and
to perform required maintenance. Remove
1.f. Do not put your hands near the engine fan.
Do idler by pushing on the throttle control rods while the engine is running.
arc or when the engine is running.
not attempt to override the governor or
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ʻ95
ii
SAFETY
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.
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.
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.
5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
Do not weld in locations near chlorinated hydrocarbon
5.c.
coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating prod­ucts.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employerʼs safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
vapors
AUG 06
to
iii
SAFETY
iii
WELDING SPARKS can cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f. free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode if damaged.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturerʼs recommendations.
Mar ʻ95
iv
SAFETY
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 LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions pour le porte-électrode sʼapplicuent aussi au pistolet de soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de nʼimporte quelle partie du corps.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer des risques dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de soudage. Se protéger avec des vêtements de protection libres de lʼhuile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.
LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ʻ93
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SAFETY
v
vi
SAFETY
vi
Thank You
for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
viivii
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
viii
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications ................................................................................................A-1,A-2
Safety Precautions ...............................................................................................................A-3
Select Suitable Location................................................................................................A-3
Grinding.........................................................................................................................A-3
Stacking ........................................................................................................................A-3
Tilting.............................................................................................................................A-3
Lifting and Moving .........................................................................................................A-3
Tilting.............................................................................................................................A-3
Environmental Rating....................................................................................................A-3
Machine Grounding and High Frequency Interference Protection................................A-3, A-4
Input Connections .........................................................................................................A-4
Input Reconnect Procedure ..........................................................................................A-5
Output Connections..............................................................................................................A-5
Connections For Tig (GTAW) Welding..........................................................................A-5
Tig Torch Connections ..................................................................................................A-5
Work Cable Connections ..............................................................................................A-5
Shielding Gas Connection.............................................................................................A-6
Remote Control Connection..........................................................................................A-6
Connections For Stick (SMAW) Welding .............................................................................A-6
Stick Electrode Cable and Work Cable Connection......................................................A-6
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Graphic Symbols ..................................................................................................................B-1
Product Description ..............................................................................................................B-1
Recommended Processes and Equipment...................................................................B-2
Recommended Processes.. ..........................................................................................B-2
Process Limitations ......................................................................................................B-2
Recommended Equipment/Interface.............................................................................B-2
Equipment Limitations...................................................................................................B-2
Welding Capability................................................................................................................B-2
Controls and Settings ...................................................................................................B-3, B-4
Operating Steps ...................................................................................................................B-4
Welding in TIG Mode ....................................................................................................B-4
Pulse TIG Mode ............................................................................................................B-4
Remote Control Operation ............................................................................................B-5
Benefits of the Precision TIG 185 .................................................................................B-5
Welding in Stick Mode..........................................................................................................B-6
________________________________________________________________________________
Accessories.....................................................................................................Section C
Factory Installed Options.......................................................................................C-1
Field Installed Options...........................................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Maintenance........................................................................D-1
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting ..................................................................................E-2 THRU E-7
________________________________________________________________________
Diagrams .........................................................................................................Section F
Wiring Diagram ......................................................................................................F-1
Dimension Print......................................................................................................F-2
________________________________________________________________________
Parts List .................................................................................................P499,P210,P66
viii
A-1
U s i n g s t an d ard #8-3 input cable for protected
(1)
input supply
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
50 70 90 110 130 150 170 1 90
208/230v Model: 208/230v Model: AC/DC Stick & DC AC/DC Stick & DC TIGTIG (AC (AC TIG with #6-3 input cable)TIG with #6-3 input cable) 460/575v Model: 460/575v Model: AC/DC Stick & AC/DC Stick & AC/DC AC/DC TIGTIG 380/415v Model: 380/415v Model: AC/DC Stick & AC/DC Stick & DC/AC DC/AC Auto-Bal.TIGAuto-Bal.TIG
208/230v Model: 208/230v Model: AC AC TIG using 230v inputTIG using 230v input 380/415v Model: 380/415v Model: AC AC TIG (Max. Penetration)TIG (Max. Penetration)
208/230v Model: 208/230v Model: AC AC TIG using 208v inputTIG using 208v input
OUTPUT AMPS
OUTPUT % DUTY CYCLE

INSTALLATION

A-1
TECHNICAL SPECIFICATIONS - PRECISION TIG 185 (K2345-1AND K2347-1,-2)
INPUT - SINGLE PHASE ONLY
Standard Voltage
Input Current at Rated Output
208/230/1/60
35A / 32A Effective
and 70A / 64A Maximum
OUTPUT RANGE
Output Current
Range
7-185 Amps (AC) 5-185 Amps (DC)
Maximum Open
Circuit Voltage
(STICK AND TIG)
AC OCV: 75 DC OCV: 59
RATED OUTPUT
Duty Cycle
GTAW 15% Duty Cycle
100% Duty Cycle
70A AC (AUTO-BAL)
SMAW 15% Duty Cycle
100% Duty Cycle
Chart gives max. rated Output Amps @% Duty Cycle (Based on a 10 minute cycle) (Example; 110A@60% for AC/DC Stick and Balance TIG)
Amps
185A AC/DC
90A AC/DC (BAL)
185A AC/DC125
90A AC/DC
Type of Output
CC (Constant Current)
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
(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.
PRECISION TIG 185
A-2
INSTALLATION
A-2
TECHNICAL SPECIFICATIONS - CANADIAN (K2345-2), INTERNATIONAL K2346-1)
K2345-2 INPUT (at Rated Output)
Voltage/Phase/Freq.
460/575/1/60
Voltage/Phase/Freq.
380/400-415/1/50/60
N80
Max. OCV.
74 V (AC) 59 V (DC)
Current
16 A/13 A Effective
32 A/26 A Max.
Power Factor
0.62 Min.
K2346-1 INPUT (at Rated Output)
Current
19 A/18 A Effective
39 A/37 A Max.
Power Factor
0.62 Min.
OUTPUT RANGE
Weld Current
7-185 A (AC)
5-185 A (DC).
RATED OUTPUT
Idle Current
1.3 A/1.0 A Max.
Idle Current
1.3 A/1.0 A Max.
Output Type
CC (Constant Current)
AC or DC
Process Duty Cycle*.
SMAW
15%
100%
GTAW
15%
100%
* Based on a 10 minute cycle.
MODEL HEIGHT WIDTH DEPTH WEIGHT
Machine Only
(K2345-1,-2)
(K2346-1)
Ready-Pak
(K2347-1)
Ready-PakW/Cart
(K2347-2)
(2)
Dimensions are without Lift Eyebolt and Torch Holder
20.71 in. 526 mm
20.71 in. 526 mm
31.24 in. 794 mm
Weld Current
185 A AC/DC
90 A AC/DC
185 A AC/DC
90 A AC/DC (Auto-Bal.)
PHYSICAL DIMENSIONS
14.48 in. 368 mm
14.48 in. 368 mm
19.81 in. 503 mm
(2)
25.62 in. 751 mm
25.62 in. 651 mm
38.01 in. 966 mm
Weld Voltage (NEMA)
27.4 V
23.6 V
15.2 V
14.1 V
Approx. 192 lbs.
87.1 kgs
Approx. 212lbs..
96.2 kgs.
Approx. 258lbs.
117.0 kgs.
PRECISION TIG 185
A-3
INSTALLATION
A-3

SAFETY PRECAUTIONS

Read entire installation section before starting installation.
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this installation.
• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.
• Do not touch electrically hot parts.
• Always connect the PRECISION TIG 185 to a power supply grounded per the National Electrical Code and any local codes.
---------------------------------------------------------------------------

SELECT SUITABLE LOCATION

Place the welder where clean cooling air can freely circulate in 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.

GRINDING

Do not direct grinding particles towards the welder. An abundance of conductive material can cause mainte­nance problems.

STACKING

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. can cause injury. • Never lift welder above per-
sonnel.
• Lift only with equipment of adequate lifting
capacity.
• 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.

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.
PRECISION TIG 185 cannot
be stacked.

LIFTING AND MOVING

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.
PRECISION TIG 185

ENVIRONMENTAL RATING

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.
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 FRE­QUENCY INTERFERENCE PROTECTION
This welder must be grounded! See your local and national electrical codes for proper grounding methods.
A-4
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:
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.
INSTALLATION
A-4
6. Keep cover and all screws securely in place.
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.
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. Input leads within 50 feet (15.2m) of the welder should be enclosed in rigid metallic conduit or equivalent shielding. 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.
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:
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.
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.
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 circuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush currents even if not welding at high currents.
1
Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.
1
circuit breakers. Using fuses or
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-5
FIGURE A.1 Reconnect Leads
INPUT LEADS INPUT LEADS
L1 & L2L1 & L2
LEAD H1LEAD H1
(DO NOT (DO NOT REMOVE)REMOVE)
FOR LOWEST RATED VOLTAGEFOR LOWEST RATED VOLTAGE : H2 CONNECTED: H2 CONNECTED FOR HIGHEST RATED VOLTAGEFOR HIGHEST RATED VOLTAGE : H3 CONNECTED: H3 CONNECTED
BACK VIEW OF LINE SWITCHBACK VIEW OF LINE SWITCH
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 machineʼs 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.
A-5
• Turn the input power OFF at the dis-

OUTPUT CONNECTIONS

connect 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.
FIGURE A.2 Location of Output Connections
ELECTRODE/GAS
OUTLET RECEPTACLE (TWIST-MATE)
WORK CABLE & CLAMP
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.

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-6
INSTALLATION
A-6
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.
WARNING
To avoid receiving a high frequency shock, keep the TIG torch and cables in good condition.
------------------------------------------------------------------------
WORK CABLE CONNECTION
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 models (See Accessories 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.
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.
REMOTE CONTROL 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 availiable separately for other models. Refer to the Optional Accessories sec­tion of this manual for other available remote controls.
CONNECTIONS FOR STICK (SMAW) WELDING
STICK ELECTRODE CABLE AND WORK CABLE CONNECTION
Refer to Field Installed Options in Accessories Section of this manual for STICK welding equipment which is availiable for use with the PRECISION TIG 185. An electrode holder with Twist-Mate cable and Twist­Mate connector are availiable separately for use with the PRECISION TIG 185. (See Accessories Section). Turn the Power Switch “OFF”. Connect the Twist­Mate 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 availiable 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
B-1
POSITIVE OUTPUT

OPERATION

B-1

SAFETY PRECAUTIONS

Read and understand this entire section before oper­ating the machine.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrode with skin or wet cloth­ing.
•
Insulate yourself from work and ground.
• Always wear dry insulating gloves.
•
Read and follow “Electric Shock Warnings” in the Safety section if welding must be performed under electrically hazardous conditions such as welding in wet areas or on or in the workpiece.
-------------------------------------------------------------------------------­FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
------------------------------------------------------------------------
• Use ventilation or exhaust 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.
GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL
INPUT POWER
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-2
OPERATION
PRODUCT DESCRIPTION
The PRECISION TIG 185 is a member of our field acclaimed Precision TIG family of industrial arc weld ­ing power sources. Premium features include:
1. Precise constant current output.
2. Full range square wave AC/DC TIG (GTAW) weld-­ing.
3. Enhanced version of the patented Micro­Start™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 Ready­Pak 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.
Four models are available for 60Hz. with Domestic and Canadian input voltages, as well as an International model with 50/60Hz voltages.
RECOMMENDED PROCESSES AND EQUIPMENT
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.
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.
PRECISION TIG 185
B-2
RECOMMENDED EQUIPMENT/INTERFACE
(See Installed Options in Accessories Section for more details)
The PRECISION TIG 185 will be available as a basic Machine (Only) and in two Factory-Configured Welding Packages:
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
Torch Starter Kit* Torch Starter Kit*
Water Cooler Not Applicable 115V 50/60Hz
Cool-Arc 40* Under-Storage K2348-(*) Cart (Optional ) Optional Remote Arc Start Switch* Trigger Device Foot Amptrol* (Select one) Start Pedal Foot Amptrol*
Hand Amptrol*
*For “Part Numbers” or “K Numbers” see Accessories Section.
EQUIPMENT LIMITATIONS
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.
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.
If a PRECISION Tig 185 is powered from an engine generator which doesnʼt have sufficient capacity, the AC Balance control and the Output control will not provide full range of control.
WELDING CAPABILITY(Duty Cycle)
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.
B-3
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
3
4
8
1
9
1. POWER SWITCH
5
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
6
7
B-3
2
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:
• Auto Balance position indicated by the Green panel light turning on.
11
12
This setting position feature automatically provides the proper amount of cleaning and penetration for normal AC TIG welding.
5. MAXIMUM OUTPUT CONTROL – Presets the out-
put 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-4
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.
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.
10. REMOTE RECEPTACLE – Provides for connec-
tion 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.
OPERATION
B-4
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”.
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.
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.
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 de­energized 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.
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 con-
nected 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.
PRECISION TIG 185
PULSE TIG CONTROL
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.
B-5
OPERATION
B-5

REMOTE CONTROL 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.
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.
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.
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-6
OPERATION
B-6
WELDING IN STICK MODE
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.
WARNING
• In Stick Mode the output terminal and electrode will be electrically hot whenever the power switch is turned on.
-----------------------------------------------------------------------
5. Turn the power switch to “ON”.
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.
RECOMMENDED ELECTRODE AMPERAGE RANGES - PRECISION TIG 185
The PRECISION TIG 185 is rated from 5-185 Amps.
SMAW Process
Welding Amp Range for Stick Electrode Size
ELECTRODE TYPE POLARITY 3/32" 1/8" 5/32" Fleetweld 5P, Fleetweld 5P+ E6010 DC+ 40 - 70 75 - 130 90 - 175 Fleetweld 180 E6011 DC+ 40 - 80 55 - 110 105 - 135 Fleetweld 37 E6013 DC+ 70 - 95 100 - 135 145 - 180 Fleetweld 47 E7014 DC- 75 - 95 100 - 145 135 - 200 Excalibur E7018 DC+ 85 - 110 110 - 160 130 - 200 Blue Max Stainless DC+ 40 - 80 75 - 110 95 - 150 Red Baron Stainless DC+ 40 - 70 60 - 100 90 - 140
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
GTAW Process
Electrode Polarity DC- AC Approximate Argon
Electrode Tip Preparation Sharpened Balled Gas Flow Rate
Electrode Type
EWTh-1, EWCe-2 EWTh-1, EWTh-2
EWTh-2, EWLa-1 EWP EWCe-2, EWLa-1 Stainless
Tungsten Size (in.) EWG EWG Aluminum Steel
.010 Up to 15 A. Up to 10 A. Up to 15 A. 3-8 (2-4) 3-8 (2-4) .020 Up to 15 A. Up to 15 A. Up to 20 A. 5-10 (3-5) 5-10 (3-5) .040 Up to 80 A. Up to 40 A. Up to 60 A. 5-10 (3-5) 5-10 (3-5) 1/16 Up to 150 A. Up to 100 A. Up to 130 A. 5-10 (3-5) 9-13 (4-6) 3/32 Up to MAX. A. Up to 160 A. Up to MAX. A. 13-17 (6-8) 11-15 (5-7)
1/8 X Up to MAX. A. X 15-23 (7-11) 11-15 (5-7)
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure ..................................EWP........green TRI-MIX OF ELEMENTS.............EWG.........gray
+1% Thoria .......................EWTh-1...yellow
+2% Thoria .......................EWTh-2...red
+2% Ceria.........................EWCe-2...orange
+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.
EWZr C.F.H. (l/min.)
PRECISION TIG 185
C-1

ACCESSORIES

C-1

FACTORY INSTALLED OPTIONS

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 user­configuration with optional accessories: (See Table C.1)
2. PRECISION TIG 185 Ready-Pak w/Cart (K2347-2)
• 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.
TABLE C.1
Select Machine
Optional Torch Starter Kit (Select one)
Water Cooler
Optional Under­Storage Cart
Optional Remote Trigger Device (Select one)
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
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)
K1813-1 115V 50/60Hz Cool-Arc 40
K2348-1
K814 Arc Start Switch K870 Foot Amptrol K870-1 Start Pedal Foot Amptrol K963-3 Hand Amptrol
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
Air Cooled System
PRECISION TIG 185
C-2
ACCESSORIES
C-2
FIELD INSTALLED OPTIONS
The following Options/Accessories are available for the PRECISION TIG 185:
• 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)
• 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:
• 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
• 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.
• 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
D-1
.020 Spark Gap

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should per­form this maintenance.
• Turn the input power OFF at the dis­connect switch or fuse box before working on this equipment.
• Do not touch electrically hot parts.
------------------------------------------------------------------------
WARNING
To avoid receiving a high frequency shock, keep the TIG torch and cables in good condition.
------------------------------------------------------------------------

ROUTINE AND PERIODIC MAINTENANCE

1. Disconnect power supply lines to machine before performing periodic maintenance.
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
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.
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 .020(.5mm) is set at the factory to a gap of 0.015 inches (0.4mm) 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).
PRECISION TIG 185
.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
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
E-1
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.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
PRECISION TIG 185
E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
Machine is Dead -No Output - No Fan
Fan runs normally at power up - No output from machine in either Stick or TIG modes.
TROUBLESHOOTING
POSSIBLE
CAUSE
OUTPUT PROBLEMS
1. Make certain that the input power switch is in the “ON” position and machine is plugged in.
2. Check the input voltage at the machine. Input voltage must match the rating plate and volt­age connection. Refer to Reconnect Procedure in the Installation section of this manual.
3. Blown or missing fuses in input line.
1. Check for proper input voltages per nameplate and voltage recon­nection.
E-2
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas of misadjustment have been checked and the problem persists,
Contact your local Lincoln Authorized Field Service Facility.
Fan runs - No output from machine in either Stick or TIG modes and the yellow light on the control panel is on.
Machine does not respond (no gas flow, no high frequency and no open circuit voltage) when arc start switch or Amptrol is activated - fan is work­ing.
2. Check to make sure polarity switch is not in between two posi­tions.
1. Welding application may have exceed the recommended duty cycle. Allow the unit to run until the fan cools the unit and the yel­low light goes out.
1. Machine MUST be in the TIG Mode.
2. The Amptrol may be defective. Check for continuity between pins “D” and “E” on cable connector when Amptrol is depressed.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
PRECISION TIG 185
E-3
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
Machine regularly over heats - the­mostat opens, Yellow light on front panel glows. The fan runs but machine has no output.
TROUBLESHOOTING
POSSIBLE
CAUSE
OUTPUT PROBLEMS
1. Welding application may exceed recommended duty cycle. Reduce the duty cycle.
2. Dirt and dust may have clogged the cooling channels inside the machine. Blow out unit with clean, dry low pressure air.
3. Air vents and exhaust louvers may be blocked due to inadequate clearance around machine.
E-3
RECOMMENDED
COURSE OF ACTION
Output current reduced significantly when AC Balance control knob is set near or at max. penetration or when Output control is set near or at full output.
1. Input power to machine doesnʼt have sufficient capacity. Try changing Input power to a suffi­cient supply, refer to Installation section.
2. Machine is powered from an engine generator or an engine welder. If welding at high currents are needed, try powering machine from electricity grid instead of engine generator.
3. Set AC Balance control at Auto Balance position.
If all recommended possible areas of misadjustment have been checked and the problem persists, Contact
your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
PRECISION TIG 185
E-4
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
Machine output is intermittently lost. Gas flow and high frequency are also interrupted.
TROUBLESHOOTING
POSSIBLE
CAUSE
TIG MODE PROBLEMS
1. 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.
2. Check Amptrol for proper opera­tion and loose connections.
E-4
RECOMMENDED
COURSE OF ACTION
Arc “Flutters” when TIG welding.
Arc “Pulsates” when AC TIG weld­ing.
3. Check for proper input voltage and proper voltage reconnection.
1. Tungsten electrode may be too large in diameter for the current setting.
2. Tungsten not “sharp” when weld­ing in DC - mode.
3. Gas shielding may be insufficient. Increase gas flow; reduce tung­sten stickout beyond gas cup.
4. Check for contaminated gas or leaks in the gas line, torch, or con­nections.
5. If a helium blend is used as a shielding gas, then reduce the percentage of helium.
1. Micro Switch mounted on Polarity Switch is not opening in “AC” mode.
If all recommended possible areas of misadjustment have been checked and the problem persists, Contact
your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
PRECISION TIG 185
E-5
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
Black areas along weld bead.
Weak high frequency - machine has normal welding output.
TROUBLESHOOTING
POSSIBLE
CAUSE
TIG MODE PROBLEMS
1. Clean any oily or organic contam­ination from the work piece.
2. Tungsten electrode may be cont­aminated. Replace or sharpen.
3. Check for contaminated gas or leaks in the gas line, torch, or connections.
4. Gas shielding may be insufficient. Increase gas flow; reduce tung­sten stickout beyond gas cup.
1. Check for poor connections in the welding circuit.
2. Gas shielding may be insufficient. Increase gas flow; reduce tung­sten stickout beyond gas cup.
E-5
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas of misadjustment have been checked and the problem persists, Contact
your local Lincoln Authorized Field Service Facility.
High frequency “spark” is present at tungsten electrode, but operator is unable to establish a welding arc. Machine has normal open circuit voltage (refer to Technical Specifications in the Installation Chapter).
3. Check for work and electrode cables in poor condition allowing high frequency to “Leak Off”.
4. Keep cables as short as possible.
5. Check Spark Gap operation and setting (0.020”).
1. The tungsten electrode may be contaminated. Replace or sharp­en.
2. The current control may be set too low.
3. The tungsten electrode may be too large for the process.
4. If a helium blend is used as a shielding gas, then reduce the percentage of helium.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
PRECISION TIG 185
E-6
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
No high frequency. Machine is in the TIG Mode and has normal output.
TROUBLESHOOTING
POSSIBLE
CAUSE
TIG WELDING PROBLEMS
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.
E-6
RECOMMENDED
COURSE OF ACTION
No gas flow when Amptrol is activat­ed in the TIG Mode. Machine has output - fan runs. A “Click” can be heard indicating that the gas sole­noid valve is operating.
When AC TIG welding, the arc is erratic and there is a loss of “clean­ing” of the work piece.
The end of the tungsten electrode melts away.
1. Gas supply is empty or not turned on.
2. Flow regulator may be set too low.
3. Gas hose may be pinched.
4. Gas flow may be blocked with dirt. Check filter screen inside gas inlet fitting to solenoid valve. Use filters to prevent reoccurrence.
5. Consult your local welder/gas dis­tributor.
1. Tungsten electrode may be too small for process. Use a larger diameter tungsten or a pure tung­sten.
2. If a helium blend is used as a shielding gas, then reduce the percentage of helium.
1. The welding current is too high for the electrode type and/or size. See Electrode Amperage Ranges in the Operation Section of this manual.
If all recommended possible areas of misadjustment have been checked and the problem persists, Contact
your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
PRECISION TIG 185
E-7
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
Stick electrode “Blasts Off” when arc is struck.
TROUBLESHOOTING
POSSIBLE
CAUSE
STICK WELDING PROBLEMS
1. Weld current may be set too high for electrode size. Reduce current control setting, or use a larger diameter electrode.
E-7
RECOMMENDED
COURSE OF ACTION
Stick electrode “sticks” in the weld puddle.
1. The weld current may be set too low. Increase the current control setting or use a smaller diameter electrode.
If all recommended possible areas of misadjustment have been checked and the problem persists, Contact
your local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
PRECISION TIG 185
F-1
WIRING DIAGRAM - PRECISION TIG 185
G4549
B
SCR4
SCR2
SCR1
D
C
B
A
REAR GANG
L1
ELECTRODE
T3
NC
NO
MICRO-SWITCH
T2
L2
L3
C3
SCR3
H1
H
G
311A
312A
OPEN
CLOSED
CLOSED
G4
216
G3
2
1
8
G2
G1
217
220
AC
E
F
PC BOARD
CONTROL PC BOARD
D1
S2
SV1
GAS VALVE
S2A
BYPASS/
STABILIZER
H1
X1
X2
R 222
W 221
WORK
R2
ARC
STARTER
AS'BLY
237
C4
R3
231
235
J3
236A
SPARK
GAP
284A
285A
AC
DC+
DC-
A-C, D-E, B-F
B-D, C-E, A-F, G-H
B-D, A-E, C-F, G-H
POLARITY SWITCH MICRO SWITCH
(REAR VIEW,
SHOWN IN AC POSITION)
115VAC
18VAC
18VAC
78VAC
T1
POLARITY
SWITCH
H3
H2
H3 (HIGH)
H2 (LOW)
L4
POS
X4
X5
X3
X6
X7
X8
C2
C1
201
204
209
210
231
232
AUTO
BALANCE
LED
PULSE
FREQ
LED
AC
BALANCE
CONTROL
PULSE
CONTROL
POSTFLOW
CONTROL
STICK LED
TIG LED
DIGITAL
DISPLAY
THERMAL
LED
OUTPUT
CONTROL
MODE
SWITCH
B
(L1)W(L2)
POWER
SWITCH
S1
G
FAN
115VAC
+
( )
( )
_
DC
115VAC
238
239
210
209
2
01
3
13
314
1 2 34
6
5
7
11 12
R 222
W 2211
2
8 9
10
RECEPTACLE
C
ABB
10K A-B
F
E
D
C
AT MINIMUM
D
REMOTE
TM
AMPTROL
OPTIONAL
A
E
REMOTE
J2
J1
A
1
J5
2
3
4
5
6
C
BDE
216A
2
4
0
L5
204
236
231A
260
R4
220A
245
R5
218A
244
TRIGGER
POWER
R1
284B
285B
285
2
8
4
AC
X2
FRONT
GANG
RG
G
G
Y
220A
218A
231A
J4
311
3
1
2
245
244
216
A
240
314
S4
CHOKE
313
SEE RATING PLATE FOR SPECIFIC VOLTAGES
230
or 400-415 or 575 VOLT CONNECTION
H1 and H3 (HIGH) TO POWER SWITCH.
208
or 380 or 460 VOLT CONNECTION
H1 and H2 (LOW) TO POWER SWITCH.
H3 NOT CONNECTED; INSULATE.
H2 NOT CONNECTED; INSULATE.
C1 AND C2 MUST ALWAYS BE CONNECTED
ACROSS TRANSFORMER PRIMARIES
VOLTAGE RECONNECTION
(AS SHOWN & AS SHIPPED FROM FACTORY)
B-BLACK
R-RED
G-GREEN W-WHITE
LEAD COLORING CODE:
CONNECTOR PIN NUMBERS:
VIEW OF CONNECTOR ON PC BOARD
123 7
8
14
LATCH
EXAMPLE: THIS IS PIN 7
OF CONNECTOR J4
COMPONENT VALUE
UNITS:
RESISTORS:
CAPACITORS:
OHMS/WATTS
MFD/VOLTS
J4
ELECTRICAL SYMBOLS PER E1537.
C1,C2 BY-PASS CAPACITORS, .0047/250VAC
C3 HIGH VOLTAGE CAPA CITOR, .0 025/10k V
C4 PHASE SHIFT CAPACITOR, 15/250VAC
C5,C6 BY -PAS S CAP ACITORS, .22/400 VDC
CB1 CIRCUIT BRE AKE R, 10 A
D1 FREE W HEELING DIODE
L1 OUTPUT INDUCTOR (CHOKE)
L2,L3 HIGH FRE QUENCY INDUCTORS
L4,L5 RF TOROID CHOKES
R1,R2 HOLDING RESISTORS, 100/100W
R3 PHASE SHIFT RES ISTOR, 200/100W
R4,R5 MICRO START RESISTORS, 12/100W
S1 INPUT POWER SWITCH
S2 POLARITY SWITCH
S2A MICROS WITCH O N PO LARITY S WITCH
S4 MA IN CHOKE THERMOSTAT
SCR1,2 ,3,4 MAIN POW ER SCR'S
SV1 GAS S OLENOID VALVE , 115VAC
T1 MAIN TRANSFORMER
T2 HIGH VOLTAGE TRANSFORMER
T3 HIGH FREQUENCY TRANS FORMER
43
2
1
235
260
G
4
220
G
2
G
1
2
1
6
G
3
218
2
1
7
1 2 3 45
6 7 8
DC
POS
SHUNT
X
1
236
2
3
2
INPUT PLUG (208V/230V ONLY)
TO GROUND PER
NATIONAL ELECTRIC CODE
285
284
G
4
G
2
1 2 3 4
G
3
G
1
P7
J7
1
2
3
J6
4
CONNECT GREEN LEAD TO GROUND PER
NATIONAL AND LOCAL ELECTRICAL CODE
CONNECT BLACK AND WHITE LEADS
TO SUPPLY CIRCUIT
B
(L1)
W
(L2)
G
380V AND ABOVE
208V/230V ONLY
311
312
ENHANCED

WIRING DIAGRAM

DIAGRAMS

F-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
PRECISION TIG 185
F-2
1
.46DOOR
CLOSED
2.44
DIMENSION PRINT
F-2
12.99
1.62
A
L12201
2.44
CL
.46
4.83
TOOL TRAY DOOR
20.25
24.00
22.00**
.24
1.00**
1.66TORCH HOLSTER
MACHINE ONLY AND READY-PAK FOR CODES 11105, 11108
7.00
.24
PRECISION TIG 185
12.38**.81**
O .284 BASE MOUNTING HOL E S.
** LOCATION OF (4)
14.00
F-3
6.00
2.44
.46DOOR
CLOSED
DIMENSION PRINT
6.00
F-3
A
L12202
13.27
37.24
12.99
4.83
TOOL TRAY DOOR
2.44
CL
.46
20.25
24.00
.75
10.53
30.78
READY-PAK WITH CART FOR CODE 11109
1.66TORCH HOLSTER
7.00
PRECISION TIG 185
14.00
19.81
NOTES
PRECISION TIG 185
WARNING
Spanish
AVISO DE
PRECAUCION
● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa moja­da.
● Aislese del trabajo y de la tierra.
● Keep flammable materials away.
● Mantenga el material combustible
fuera del área de trabajo.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha­da.
● Isole-se da peça e terra.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-
dos.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones de travail.
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Desconectar el cable de ali-
mentación de poder de la máquina antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
tien.
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Não toque as partes elétricas nuas.
● No operar con panel abierto o
guardas quitadas.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de protection enlevés.
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in Betrieb setzen!
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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