Lincoln Electric SVM169-A User Manual

PRECISION TIG 185

SVM169-A

July, 2006

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.

SERVICE MANUAL

For use with machines having Code Number : 11105 thru 11109

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i

SAFETY

i

PRECISION TIG 185

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.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.

___________________________________________________

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.

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. AFree 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.

WARNING

Mar ‘95

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

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 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 Diesel Engines

The Above For Gasoline Engines

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ii

SAFETY

ii

PRECISION TIG 185

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.

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.

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

PRECISION TIG 185

SAFETY

iii iii

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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.

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.

Mar ‘95

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.

PRECISION TIG 185

SAFETY

iv iv

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PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.

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

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

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

b. Porter des vêtements convenables afin de protéger la peau

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

c. Protéger l’autre personnel travaillant à proximité au

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

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

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

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

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

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

PRECISION TIG 185

vv

MASTER TABLE OF CONTENTS FOR ALL

SECTIONS

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P499 Series

RETURN TO MAIN MENU

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PRECISION TIG 185

Section A-1 Section A-1

TABLE OF CONTENTS

- INSTALLATION SECTION -

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

Technical Specifications.....................................................................................A-2/A-3

Safety Precautions ....................................................................................................A-4

Location.....................................................................................................................A-4

Grinding ..............................................................................................................A-4

Stacking ..............................................................................................................A-4

Lifting and Moving ..............................................................................................A-4

Tilting ..................................................................................................................A-4

Environmental Rating..........................................................................................A-4

Machine Grounding and High Frequency Interference Protection ...........................A-4

Input Connections.....................................................................................................A-5

Input Reconnect Procedure ......................................................................................A-6

Output Connections..................................................................................................A-6

Connections for TIG Welding .............................................................................A-6

TIG Torch Connection .................................................................................A-6

Work Cable Connection ..............................................................................A-7

Shielding Gas Connection...........................................................................A-7

Remote Control Connection........................................................................A-7

Connections for Stick Welding..................................................................................A-7

Stick Electrode Cable and Work Cable Connection ..........................................A-7

PRECISION TIG 185

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A-2

INSTALLATION

A-2

TECHNICAL SPECIFICATIONS - PRECISION TIG 185 (K2345-1AND K2347-1,-2)

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

Type of Output

CC (Constant Current)

AC/DC

Amps

185AAC/DC

90AAC/DC (BAL)

70AAC (AUTO-BAL)

185AAC/DC125

90AAC/DC

Maximum Open

Circuit Voltage

(STICK AND TIG)

AC OCV: 75
DC OCV: 59

Input Current at Rated Output

35A / 32A Effective

and 70A / 64A Maximum

Duty Cycle

GTAW 15% Duty Cycle

100% Duty Cycle

SMAW 15% Duty Cycle

100% Duty Cycle

Output Current

Range

7-185 Amps (AC)
5-185 Amps (DC)

Standard Voltage

208/230/1/60

INPUT - SINGLE PHASE ONLY

OUTPUT RANGE

RATED OUTPUT

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 sta ndard #8-3 input cable for protected

(1)

input supply

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

50 70 90 110 130 150 170 190

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

OUTPUT AMPS

OUTPUT % DUTY CYCLE

(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

INSTALLATION

A-3 A-3

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TECHNICAL SPECIFICATIONS - CANADIAN (K2345-2), INTERNATIONAL K2346-1)

MODEL HEIGHT WIDTH DEPTH WEIGHT

PHYSICAL DIMENSIONS

(2)

W

eld Voltage (NEMA)

27.4 V

23.6 V

15.2 V

14.1 V

Output T

ype

CC (Constant Current)

AC or DC

Weld Current

185 A AC/DC

90 A AC/DC

185 A AC/DC

90 A AC/DC (Auto-Bal.)

Weld Current

7-185 A (AC)

5-185 A (DC).

Process Duty Cycle*.

SMAW

15%

100%

GTAW

15%

100%

Max. OCV.

74 V (AC)

59 V (DC)

OUTPUT RANGE

RATED OUTPUT

Machine Only

(K2345-1,-2)

(K2346-1)

Ready-Pak

(K2347-1)

Ready-PakW/Cart

(K2347-2)

20.71 in.
526 mm

20.71 in.
526 mm

31.24 in.
794 mm

14.48 in.
368 mm

14.48 in.
368 mm

19.81 in.
503 mm

25.62 in.
751 mm

25.62 in.
651 mm

38.01 in.
966 mm

Approx. 192 lbs.

87.1 kgs

Approx. 212lbs..

96.2 kgs.

Approx. 258lbs.

117.0 kgs.

(2)

Dimensions are without Lift Eyebolt and Torch Holder

Power Factor

0.62 Min.

Idle Current

1.3 A/1.0 A Max.

Current

16 A/13 A Effective

32 A/26 A Max.

Voltage/Phase/Freq.

460/575/1/60

K2345-2 INPUT (at Rated Output)

K2346-1 INPUT (at Rated Output)

Power Factor

0.62 Min.

Idle Current

1.3 A/1.0 A Max.

Current

19 A/18 A Effective

39 A/37 A Max.

Voltage/Phase/Freq.

380/400-415/1/50/60

* Based on a 10 minute cycle.

N80

PRECISION TIG 185

INSTALLATION

A-4 A-4

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SAFETY PRECAUTIONS

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

Square Wave 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.

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.

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.

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.

---------------------------------------------------------------------------

WARNING

Read entire installation section before starting
installation.

• 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 per-

sonnel.

• Lift only with equipment of adequate lifting

• Be sure machine is stable when lifting.

------------------------------------------------------------------------

WARNING

PRECISION TIG 185

INSTALLATION

A-5 A-5

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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.

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.

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.

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.

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

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

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.

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.

PRECISION TIG 185

INSTALLATION

A-6 A-6

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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.

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.

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.

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.

CAUTION

WARNING

FIGURE A.1 Reconnect Leads

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

OUTPUT CONNECTIONS

FIGURE A.2 Location of Output Connections

ELECTRODE/GAS

OUTLET
RECEPTACLE
(TWIST-MATE)

WORK CABLE & CLAMP

PRECISION TIG 185

INSTALLATION

A-7 A-7

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APTA-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.

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.

The available Under-Storage Cart features a low plat­form that simplifies loading and unloading of gas cylin­ders.

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.

------------------------------------------------------------------------

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 available 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
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.

WARNING

WARNING

PRECISION TIG 185

NOTES

A-8 A-8

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PRECISION TIG 185

Section B-1 Section B-1

TABLE OF CONTENTS

- OPERATION SECTION -

Operation ................................................................................................................Section B

Safety Precautions .......................................................................................................B-2

Graphic Symbols..........................................................................................................B-2

Product Description......................................................................................................B-3

Recommended Processes and Equipment..................................................................B-3

Welding Capability (duty cycle) ....................................................................................B-3

Controls and Settings...................................................................................................B-4

Control Functionality .............................................................................................B-4/B-5

Operating Steps ...........................................................................................................B-5

Welding in TIG Mode....................................................................................................B-5

Pulse TIG Control .........................................................................................................B-5

Remote Control Operation ...........................................................................................B-6

Benefits of the Precision TIG 185 Design ....................................................................B-6

Welding in Stick Mode .................................................................................................B-7

Recommended Electrode Amperage Ranges..............................................................B-7

PRECISION TIG 185

OPERATION

B-2 B-2

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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.

-----------------------------------------------------------------------­ARC RAYS can burn.

•Wear eye, ear and body

protection.

------------------------------------------------------------------------

SAFETY PRECAUTIONS

Read and understand this entire section before operat­ing the machine.

Observe additional Safety Guidelines detailed in
the beginning of this manual.

------------------------------------------------------------------------

WARNING

INPUT POWER

POSITIVE OUTPUT

NEGATIVE OUTPUT

DIRECT CURRENT

PROTECTIVE
GROUND

WARNING OR
CAUTION

DO NOT SWITCH
WHILE WELDING

GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

PRECISION TIG 185

OPERATION

B-3 B-3

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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 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 start-

ing and continuous AC TIG welding.

5. AC/DC Stick (SMAW capability.) A new undercar-

riage (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 shield-

ing 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.

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 doesn’t 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.

PRECISION TIG 185

OPERATION

B-4 B-4

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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.

• 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.

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.

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

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

5

13

2

6

3

4

1

7

9

10

11

12

8

CAUTION

PRECISION TIG 185

OPERATION

B-5 B-5

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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.

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.

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 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

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

OPERATION

B-6 B-6

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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.

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.

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.

PRECISION TIG 185

OPERATION

B-7 B-7

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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.

• 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

EWZr C.F.H. (l/min.)

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.

WARNING

PRECISION TIG 185

NOTES

B-8 B-8

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PRECISION TIG 185

Section C-1 Section C-1

TABLE OF CONTENTS

- ACCESSORIES SECTION -

Accessories ............................................................................................................Section C

Options / Accessories ...........................................................................................C-2/C-3

PRECISION TIG 185

ACCESSORIES

C-2 C-2

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FACTORY INSTALLED OPTIONS

The Precision TIG 185 will be available in two Factory­Configured 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)

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.

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)

Not Applicable

Select Machine

Optional
Torch Starter Kit
(Select one)

Water Cooler
Optional Under-

Storage 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)

Air Cooled System

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)

K1813-1 115V 50/60Hz Cool-Arc 40

TABLE C.1

K2348-1
K814 Arc Start Switch

K870 Foot Amptrol
K870-1 Start Pedal Foot Amptrol
K963-3 Hand Amptrol

PRECISION TIG 185

ACCESSORIES

C-3 C-3

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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:

• 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)

• 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.

PRECISION TIG 185

NOTES

C-4 C-4

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PRECISION TIG 185

Section D-1 Section D-1

TABLE OF CONTENTS

- MAINTENANCE SECTION -

Maintenance ...........................................................................................................Section D

Safety Precautions ........................................................................................................D-2

Routine Maintenance.....................................................................................................D-2

Periodic Maintenance....................................................................................................D-2

Spark Gap Adjustment ..................................................................................................D-2

Fan Motor and Blade Replacement ..............................................................................D-2

Major Component Locations.........................................................................................D-3

PRECISION TIG 185

MAINTENANCE

D-2 D-2

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SAFETY PRECAUTIONS

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.

------------------------------------------------------------------------

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

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).

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

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.

WARNING

WARNING

WARNING

.020 Spark Gap

FIGURE D.2

.30

PRECISION TIG 185

MAINTENANCE

D-3 D-3

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FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.

1

9

5

8

8

3

6

2

4

7

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)

X

NOTES

D-4 D-4

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