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IM10059
March, 2010
SQUARE WAVE™TIG 175
For use with machines having Code Numbers:
11691
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.
OPERATOR’S MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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SAFETY
ARC RAYS can burn.
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.
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.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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 within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical ven-
tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
cautions are also required when welding on galvanized
steel.
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.
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 expo-
sure level should be checked upon installation and periodi-
cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
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.
5.c. 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 prod-
ucts.
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.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 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.f. Also see item 1.b.
Jan ‘09
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
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.
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.
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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
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.
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.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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).
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.
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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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.
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.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Jan ‘09
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SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
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 suiv-
antes:
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.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
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.
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 met-
allique 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 defonc-
tionnement.
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.
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 soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
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.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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 ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
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.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
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, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
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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!
Thank You
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric
for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that
time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or
advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect
to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any
such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with
respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in apply-
ing these types of fabrication methods and service requirements.
for any updated information.
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___________________________________________________________________________
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 WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“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:
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.
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TABLE OF CONTENTS
Page
_______________________________________________________________________________________
Installation ......................................................................................................Section A
Technical Specifications...............................................................................................A-1
Safety Precautions.. ............................................................................................................................................... .A-2
Select Suitable Location........................................................................................A-2
Grinding .................................................................................................................A-2
Stacking.................................................................................................................A-2
Lifting .....................................................................................................................A-2
Tilting .....................................................................................................................A-2
Environmental Rating ............................................................................................A-2
Machine Grounding and High FREQUENCY INTERFERENCE PROTECTION ...................A-2,A-3
Input Connections ........................................................................................................A-3
Input Reconnect Procedure .........................................................................................A-3
Output Connections .....................................................................................................A-4
Connections For Tig (GTAW) Welding............................................................A-4
Tig Torch Connections ....................................................................................A-4
Work Cable Connections ................................................................................A-4
Shielding Gas Connection ..............................................................................A-4
Remote Control Connection............................................................................A-5
Connections For Stick (SMAW) Welding .......................................................A-5
Stick Electrode Cable and Work Cable Connection .......................................A-5
______________________________________________________________________________
OPERATION .........................................................................................................................................................Section B-1
Safety Precautions.......................................................................................................B-1
Product Description......................................................................................................B-1
Included Equipment...............................................................................................B-1
GTAW (Tig Welding): ......................................................................................B-1
SMAW (Stick Welding):...................................................................................B-1
Installation and Startup: ..................................................................................B-1
Welding Capability.................................................................................................B-1
Controls and Settings ..........................................................................B-2 THRU B-3
Operating Steps.....................................................................................................B-3
Welding in Tig Mode .......................................................................................B-3
Remote Control Operation ..............................................................................B-3
Benefits of the SQUARE WAVE™ Operation.................................................B-3
Welding in Stick Mode ..........................................................................................B-4
______________________________________________________________________________
Accessories ............................................................................................................................................... .......Section C
Optional Equipment .....................................................................................................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 to E-7
______________________________________________________________________________
Diagrams..............................................................................................................................................................Section F
Wiring Diagram 208/230 V Model...................................................................................................................F-1
______________________________________________________________________________
Parts List......................................................................................................................................................................P-650
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - SQUARE WAVE™ TIG 175 (K1478-5)
INPUT - SINGLE PHASE ONLY
Standard
Voltage
208/230/1/60
Input Current at
Rated Output
58/52 AC/DC Stick & DC TIG - 64/57 AC TIG
Code
Number
11691
RATED OUTPUT
Duty Cycle
GTAW 25% Duty Cycle
40% Duty Cycle
Amps
150
125
110
Volts at Rated Amperes
15.0 V AC/DC
14.7 V AC/DC
14.3 V AC/DC
60% Duty Cycle
100% Duty Cycle
90
14.1V AC/DC
SMAW 25% Duty Cycle
40% Duty Cycle
150
125
110
90
26.0 V AC/DC
25.0 V AC/DC
25.0 V AC/DC
24.0 V AC/DC
60% Duty Cycle
100% Duty Cycle
OUTPUT
Maximum Open
Circuit Voltage
(STICK AND TIG)
AC OCV: 74
Output Current
Range
10-175 Amps
AC and DC
Type of Output
CC (Constant Current)
AC/DC
DC OCV: 59
RECOMMENDED FUSE SIZES
Wiring and Protection based on the 2008 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.
PHYSICAL DIMENSIONS
Height
Width
Depth
Weight
Power
Source
19.53 in.
496 mm
13.72 in.
349 mm
24.94 in.
633 mm
Approx. 200 lbs.
90.9 kgs.
SQUARE WAVE™ TIG 175
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A-2
A-2
INSTALLATION
SAFETY PRECAUTIONS
Read entire installation section before starting
installation.
MACHINE GROUNDING AND HIGH FRE-
QUENCY INTERFERENCE PROTECTION
The welder must be grounded. See your local and national
electrical codes for proper grounding methods.
WARNING
ELECTRIC SHOCK can kill.
Only qualified personnel should
perform this installation.
The high frequency generator, being similar to a radio
transmitter, can be blamed for 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.
•
•
Turn the input power OFF at the
disconnect switch or fuse box
before working on this
equipment.
•
•
Do not touch electrically hot
parts.
Radiated interference can develop in the following four
ways:
Always connect the SQUARE WAVE™ TIG 175 to a
power supply grounded per the National Electrical
Code and any local codes.
SELECT SUITABLE LOCATION
1. Direct interference radiated from the welder.
Place the welder where clean cooling air can freely cir-
culate in through the rear louvers and out through the
front and side louvers. Dirt, dust or any foreign mater-
ial 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 nui-
sance shut-downs.
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.
GRINDING
Do not direct grinding particles towards the welder. An
abundance of conductive material can cause mainte-
nance problems.
Keeping these contributing factors in mind, installing
equipment per the following instructions should mini-
mize problems.
STACKING
1. Keep the welder power supply lines as short as pos-
sible 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.
SQUARE WAVE™ TIG 175’s cannot be stacked.
LIFTING AND MOVING
The SQUARE WAVE™ TIG 175 should be lifted by two
or more people or with a hoist. (It weighs approximate-
ly 200 lbs./90.9 kg.) Its lifting handles are designed to
make lifting more convenient. An optional undercarriage
is available to easily move the unit. Refer to the
Accessories section of this manual.
2. Keep the work and electrode leads as short as pos-
sible and as close together as possible. Lengths
should not exceed 25 ft (7.6m). Tape the leads
together when practical.
TILTING
Each machine must be placed on a secure, level sur-
face, either directly or on a recommended undercar-
riage. The machine may topple over if this procedure
is not followed.
3. Be sure the torch and work cable rubber coverings
are free of cuts and cracks that allow high frequen-
cy leakage.
ENVIRONMENTAL RATING
The SQUARE WAVE™ TIG 175 power source carries an
IP21 environmental rating. It may be used in normal indoor
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 work-
piece.
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:
SQUARE WAVE™ TIG 175
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A-3
A-3
INSTALLATION
INPUT RECONNECT PROCEDURE
a) A metal underground water pipe in direct contact
with the earth for ten feet or more.
On multiple input voltage welders, be sure the machine
is connected per the following instructions for the volt-
age being supplied to the welder.
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.
CAUTION
The ground should be securely made and the ground-
ing cable should be as short as possible using cable of
the same size as the work cable, or larger. Grounding
to the building frame electrical conduit or a long pipe
system can result in re-radiation, effectively making
these members radiating antennas.
Failure to follow these instructions can cause immedi-
ate failure of components within the welder.
___________________________________________
Multiple voltage models are shipped connected for the
highest voltage. To change this connection refer to the
following instructions.
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 metal-
lic conduit or equivalent shielding, wherever possi-
ble. Flexible metallic conduit is generally not suit-
able.
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.
WARNING
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this
equipment.
Failure to observe these recommended installation
procedures can cause radio or TV and electronic
equipment interference problems and result in unsatis-
factory welding performance resulting from lost high
frequency power.
For the lowest rated voltage connection (Refer to figure A.1):
1. Remove the sheet metal cover.
2. Disconnect lead H3 from the power switch and insu-
late with the insulation from the H2 lead.
INPUT CONNECTIONS
3. Connect lead H2 to the power switch where H3 was
connected.
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.
4. Tighten connections.
208/230 volt models have a NEMA 6-50P plug
attached to the input power cord.
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:
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
1. Remove the sheet metal cover.
2. Disconnect lead H2 from the power switch and insu-
late with the insulation from the H3 lead.
1
type circuit breakers. Using fuses or circuit breakers
3. Connect lead H3 to the line switch where H2 was
connected.
smaller than recommended may result in “nuisance”
shut-offs from welder inrush currents even if not weld-
ing at high currents.
4. Tighten connections.
5. Replace sheet metal cover and all screws.
1
Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit
breakers which have a delay in tripping action that decreases as the magni-
tude of the current increases.
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A-4
A-4
INSTALLATION
A TIG welding torch with cable and connector is sup-
plied with the welder. Turn the Power Switch “OFF”.
Connect the torch cable 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
quick connect terminal and also provides the gas con-
nection for the shielding gas to the torch.
FOR LOWEST RATED VOLTAGE
: H2 CONNECTED
FOR HIGHEST RATED VOLTAGE
: H3 CONNECTED
LEAD H1
(DO NOT
REMOVE)
WARNING
To avoid receiving a high frequency shock, keep
the TIG torch and cables in good condition.
__________________________________________
WORK CABLE CONNECTION
INPUT LEADS
L1 & L2
A work cable with attached work clamp is factory con-
nected to the SQUARE WAVE™ TIG 175. To minimize
high frequency interference, refer to Machine
Grounding and High Frequency Interference
Protection section of this manual for the proper pro-
cedure on grounding the work clamp and work piece.
BACK VIEW OF LINE SWITCH
FIGURE A.1 Reconnect Leads
OUTPUT CONNECTIONS
SHIELDING GAS CONNECTION
An adjustable gas pressure regulator and flow gage is
supplied with the SQUARE WAVE™ TIG 175. 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 regu-
lator and gas inlet (located on the rear of the welder).
The gas inlet has a 5/16-18 right hand female thread;
CGA #032.
ELECTRODE/GAS OUTLET
RECEPTACLE
The optional undercarriage features a pivoting platform
that simplifies loading and unloading of gas cylinders.
WORK CABLE & CLAMP
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 cir-
cuits.
FIGURE A.2 Location of Output Connections
CONNECTIONS FOR TIG (GTAW) WELDING
TIG TORCH CONNECTION
• Maximum inlet pressure 150 psi.
___________________________________________
A cylinder is loaded by leaning it slightly sideways and
rolling it toward the platform. The cylinder’s weight will
push the platform downward against the floor, forming
a ramp. At this point, the cylinder may be rolled up the
platform into its final position. Secure the cylinder in
place with the provided chain. Unload by following
these steps in reverse.
Refer to Included Equipment in the Operation Section
of this manual for TIG welding equipment which is
included with the SQUARE WAVE™ TIG 175.
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A-5
A-5
INSTALLATION
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 Amptroltm, foot activated remote
control, is included with the SQUARE WAVE™ TIG
175. 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 Included Equipment in the Operation Section
of this manual for STICK welding equipment which is
included with the SQUARE WAVE™ TIG 175.
An electrode holder with cable is supplied with the
SQUARE WAVE™ TIG 175. Turn the Power Switch
“OFF”. Connect the cable quick connect plug into the
Electrode/Gas Output Receptacle and turn it clockwise
until it is tight. The work cable and work clamp are fac-
tory connected.
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B-1
B-1
OPERATION
SAFETY PRECAUTIONS
PRODUCT DESCRIPTION
Read and understand this entire section before operat-
ing the machine.
The SQUARE WAVE™ TIG 175 is a constant current,
single range AC/DC TIG (GTAW) arc welding power
source with built-in arc starter / stabilizer. It also has
stick welding (SMAW) capability.
WARNING
The SQUARE WAVE™ TIG 175 is recommended for
the TIG (GTAW) and stick (SMAW) welding processes
within its output capacity of 10 to 175 amps, on both
AC and DC polarity.
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts
or electrode with skin or wet cloth-
ing.
•
Insulate yourself from work and
ground.
INCLUDED EQUIPMENT
• Always wear dry insulating gloves.
•
Read and follow “Electric Shock
Warnings” in the Safety section if weld-
ing must be performed under electrical-
ly hazardous conditions such as weld-
ing in wet areas or on or in the work-
piece.
• Work Cable and Clamp.
• Input Cord with NEMA 6-50P Input Plug.
For GTAW (TIG Welding):
• TIG torch, (17 Series) with:
• 12.5 ft (3.8m) one-piece cable.
• 3/32” Collet body.
• 3/32” Collet.
• 3/32” x 7” 2% ceriated Tungsten Electrode.
• Long backcap.
• 7/16” Diameter Alumina gas Nozzle.
FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
• Adjustable argon gas pressure regulator and flow
gage.
• Gas hose.
• Foot Amptroltm remote current control with 15ft
(4.6m) cable.
For SMAW (Stick Welding):
• Electrode holder with cable and quick connect plug.
WELDING SPARKS
can cause fire or
explosion
WELDING CAPABILITY
• Keep flammable material away.
• Do not weld on containers that
have held combustibles.
The SQUARE WAVE™ TIG 175 is rated at 150 amps,
15 volts, at 25% duty cycle on a ten minute basis. It is
capable of higher duty cycles at lower output currents.
It is capable of 175 amps, 27 volts at a lower duty
cycle. If the duty cycle is exceeded, a thermal protec-
tor will shut off the output until the machine cools.
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
Observe additional Safety Guidelines detailed in
the beginning of this manual.
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B-2
B-2
OPERATION
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the front of the SQUARE WAVE™ TIG 175. Refer to Figure
B.1 and corresponding explanations.
FIGURE B.1 - CONTROL PANEL
1. POWER SWITCH
2. TIG/STICK SWITCH
3. POLARITY SWITCH
1
4
4. CURRENT CONTROL
5. OVER TEMPERATURE LIGHT
6. REMOTE CONTROL CONNECTOR
7. ELECTRODE/ GAS OUTPUT RECEPTACLE
8. WORK CABLE & CLAMP
2
3
5
7
6
8
1. POWER SWITCH - Turns power on
or off
to
CAUTION
Do not switch the polarity switch while
welding or damage may result to the
machine.
the welder. When switched “ON”, the cooling fan
runs.
2. TIG/STICK SWITCH - Selects the mode of output,
either TIG (GTAW) or Stick (SMAW). Refer to
Welding in TIG Mode and Welding in Stick Mode
later in this chapter for information on how the
machine functions in each of these modes.
--------------------------------------------------------
----------------
4. CURRENT CONTROL - This control is active in
both TIG and Stick modes. In Stick mode the cur-
rent control sets the welding current. In TIG mode
this control sets the maximum current. The Amptroltm
will adjust the welding current from the machine min-
imum to this maximum setting.
3. POLARITY SWITCH - Allows you to select between
welding in AC
, DC -
, or DC+
polar-
ity. In DC + polarity the electrode is positive and the
work clamp is negative. Use DC + for most stick
welding. In DC - the electrode is negative and the
work clamp is positive. Use DC - for TIG welding
stainless steel and mild steel. AC polarity is recom-
mended for TIG welding aluminum.
5. 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.
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B-3
B-3
OPERATION
6. REMOTE CONTROL CONNECTOR - This connector
provides connection for a remote control. See Remote
Control Operation in this section of the manual.
REMOTE CONTROL OPERATION
A Foot Amptrol™ is included with the SQUARE WAVE™
TIG 175 for remote current control while TIG welding.
An optional Hand Amptrol may also be used. An option-
al 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.
7. ELECTRODE/GAS OUTPUT RECEPTACLE - This
quick connect receptacle provides electrical connec-
tion to the electrode holder and cable for Stick weld-
ing and a combined electrical and gas connection
for the TIG torch when TIG welding.
Both the Hand and Foot Amptrol work in a similar man-
ner. 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.
8. 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 ground-
ing the work clamp and work piece to minimize high
frequency interference.
When the welder is in TIG mode activating the Amptrol
energizes the electrode terminal and varies the output
welding current from its minimum value of 10 amps, to
the maximum value set by the Current Control on the
control panel. This helps eliminate accidental high cur-
rent damage to the work piece and/or tungsten, and
gives a fine control of the current. When the welder is in
the stick mode a remote control has no effect and is not
used.
OPERATING STEPS
WELDING IN TIG MODE
1. Connect the TIG torch and cable quick connect plug
to the Electrode/Gas output receptacle. This recep-
tacle also contains an integral gas connection for the
torch. Connect the work clamp to the work piece.
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 reli-
ably, 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 the full range. To start the weld, 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 DC-, the SQUARE WAVE™ TIG 175 will start
a 3/32, 2% thoriated tungsten electrode at 15 amperes
provided the electrode tip is properly grounded and not
contaminated.
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. Set the Current Control on the control panel to the
maximum desired amps.
8. Depress the Foot Amptrol to energize the torch and
establish an an arc with the work piece.
BENEFITS OF THE SQUARE WAVE™ DESIGN
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 a 15 second post flow. 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.
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 such as aluminum. 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.
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B-4
B-4
OPERATION
The AC waveform of the SQUARE WAVE™ TIG 175
optimizes cleaning and heating of the work. The result
is the capability to weld through the complete range of
10 to 175 amperes in AC TIG or DC- TIG requiring only
one electrode, a 3/32” 2% ceriated tungsten
.
WARNING
In Stick Mode the output terminal and
electrode will be electrically hot
whenever the power switch is turned
on.
WELDING IN STICK MODE
1. Put the electrode holder and cable quick connect
plug into the electrode output receptacle. Turn clock-
wise until tight. Connect the work clamp to the work
piece.
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 dis-
abled.
2. Set the TIG/STICK switch to “STICK”.
3. Set the Polarity Switch for the type of electrode
being used (most commonly DC+).
4. Place the electrode in the electrode holder.
5. Turn the power switch to “ON”.
RECOMMENDED ELECTRODE AMPERAGE RANGES - SQUARE WAVE™ TIG 175
The SQUARE WAVE™ TIG 175 is rated from 10-175 Amps.
SMAW Process
ELECTRODE
Fleetweld 5P, Fleetweld 5P+
Fleetweld 180
Fleetweld 37
Fleetweld 47
Jet-LH MR
Blue Max Stainless
Red Baron Stainless
POLARITY
DC+
3/32"
40 - 70
40 - 80
70 - 95
75 - 95
85 - 110
40 - 80
40 - 70
1/8"
5/32"
75 - 130
55 - 110
100 - 135
100 - 145
110 - 160
75 - 110
60 - 100
90 - 175
105 - 135
145 - Max
135 - Max
130 - Max
95 - 110
DC+
DC+
DC-
DC+
DC+
DC+
90 - 140
Mild steel procedures are based on recommended procedures listed in C2.10 8/94 and the maximum rating of the SQUARE WAVE™ TIG 175
Jet-LH MR procedures are based on Jet-LH 78 MR
Blue Max procedures are based on C6.1 6/95
Red Baron Procedure are based on ES-503 10/93
GTAW Process
Electrode Polarity
Electrode Tip Prepration
DC-
Sharpened
AC
Balled
Approximate Argon
Gas Flow Rate
C.F.H. (l/min.)
EWZr
Electrode Type
EWTh-1, EWCe-2
EWTh-2, EWLa-1
EWG
Up to 15 A.
Up to 15 A.
Up to 80 A.
Up to 150 A.
Up to MAX. A.
X
EWTh-1, EWTh-2
EWCe-2, EWLa-1
EWG
EWP
Stainless
Steel
(2-4) 3-8 (2-4)
Electrode Size (in.)
Aluminum
3-8
.010
.020
.040
1/16
3/32
1/8
Up to 10 A.
Up to 15 A.
Up to 40 A.
Up to 15 A.
Up to 20 A.
Up to 60 A.
Up to 130 A.
Up to MAX. A.
X
5-10
5-10
5-10
(3-5) 5-10 (3-5)
(3-5) 5-10 (3-5)
(3-5) 9-13 (4-6)
Up to 100 A.
Up to 160 A.
Up to MAX. A.
13-17 (6-8) 11-15 (5-7)
15-23 (7-11) 11-15 (5-7)
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure..................................EWP........green
+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.
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C-1
C-1
ACCESSORIES
OPTIONAL EQUIPMENT
K964-1 Undercarriage with Pivoting Single Gas
Cylinder Platform - This undercarriage features a piv-
oting platform to easily load and unload the gas cylin-
der without lifting. It was designed specifically for the
SQUARE WAVE™ TIG 175 power source, and accom-
modates 7” to 9 1/4” diameter gas cylinders. The
undercarriage comes completely assembled and
mounts directly to the power source.
TIG Torch Parts Kits - Parts kits are available for the
PTA-9 and PTA-17 TIG torches. These kits include
back cap, collets, collet bodies, nozzles and tungstens.
Order KP507 for PTA-9 torches
Order KP508 for PTA-17 torches
See publication E12.150 for parts kits breakdown.
Cut Length Consumables - TIG welding filler metals
are available for welding stainless steel, mild steel, alu-
minum and copper alloys. See publication C9.10.
K963-3 Hand Amptrol™ - A Lincoln Foot Amptrol is
included with the SQUARE WAVE™ TIG 175 for
remote current control while TIG welding. The K963-3
Hand Amptrol may be used in place of the Foot Amptrol
if a thumb operated remote control is desired.
• K2374-1 Stick Electrode Holder and Cable
(Included with the machine) - 200 amp Electrode
Holder with 10 ft.(3.1m) cable and Twist-Mate con-
nector.
K814 Arc Start Switch - The Arc Start Switch may be
used instead of the Foot Amptrol included with the
SQUARE WAVE™ TIG 175. It allows on/off TIG weld-
ing at the current set by the Current Control on the con-
trol panel. The Arc Start Switch does not provide
remote current control.
Magnum® PTA-9 and PTA-17 TIG Torches - The fol-
lowing standard Magnum® TIG torches with one-piece
cable may be used with the SQUARE WAVE™ TIG
175.
• K1781-1 PTA-9 12.5 ft medium back cap.
• K1781-3 PTA-9 25 ft medium back cap.
• K1781-9 PTA-9F 12.5 ft Flex Head Torch Package
(1)
with Ultra-Flex™ cable .
• K1782-1 PTA-17 12.5 ft long back cap.
• K1782-3 PTA-17 25 ft long back cap.
• K1782-12 PTA-17 12.5 ft long with Ultra-Flex™
cable.
(1) K1781-9 includes Twist-Mate adapter, 1/16” gas lens collet Body,
Collet and Gas lens.
NOTE: Each torch requires a Twite-Mate adapter (one
is included with the torch that comes with the
machine). Collets, collet bodies, and nozzles are not
included and must be ordered separately.
See Lincoln Publication E12.150 for a full listing of TIG
Torches and Torch Expendable parts.
Twist-Mate Torch Adapter K1622-1 - One is shipped
with the welder torch. If you do not care to interchange
this part between torches (one is required to connect
Magnum PTA-9 or PTA-17 TIG torches with one-piece
cable to the SQUARE WAVE™ TIG 175 you may order
)
an additional adapters. The quick connect plug pro-
vides connection for both gas and welding current.
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D-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
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 volt-
age transformer (T3) because the output voltage is
dangerously high.
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.
Refer to figure C.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.
• Do not touch electrically hot
parts.
To check the spark gap:
- Turn off input power as specified above.
- Remove the wraparound from the machine, the spark gap is
located on the lower right side.
WARNING
- Check the spark gap with a feeler gauge.
If adjustment is needed:
To avoid receiving a high frequency shock, keep the
TIG torch and cables in good condition.
- Adjust the gap by loosening the allen head screw in one of the
aluminum blocks, and tighten the screw in the new position.
If the gap is correct:
ROUTINE AND PERIODIC MAINTENANCE
- Replace the wraparound.
1. Disconnect power supply lines to machine before
performing periodic maintenance.
8. Inspect gas hose and inlet fitting for cracks or leaks.
9. Replace any unreadable labels or decals.
2. Periodically clean the inside of the machine with a
low pressure air system. Be sure to clean the
following components thoroughly.
10. Verify that the machine and welding circuit is properly
grounded.
• Main Transformer
• Electrode/Gas Output Receptacle
• Polarity Switch
FIGURE C.1 SPARK GAP
• Rectifier Assembly
• Arc Starter/Spark Gap Assembly
• PC Boards
.015 Spark Gap
• 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.
RIGHT SIDE OF MACHINE
FAN MOTOR OR FAN BLADE REPLACEMENT
When installing a new fan blade or fan motor be sure
to maintain proper shaft spacing per Figure C.2 below.
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
0.015 inches (0.4mm) See Figure C.1. This setting
is adequate for most applications. Where less high
frequency is desired, the setting can be reduced to
0.008 inches (0.2mm).
.30
Figure C.2
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E-1
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Look under the column labeled “PROBLEM (SYMP-
TOMS)”. 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
CAUTION
DO NOT use a volt-ohm meter to measure output voltages in TIG mode. The
High Frequency Arc Starter voltage can damage the meter.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine is Dead -
No Output - No Fan
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 sec-
tion of this manual.
3. Blown or missing fuses in
input line.
Fan runs - No output from machine 1. Check for proper input voltages
in either Stick or TIG modes.
per nameplate and voltage
reconnection.
Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
2. Check to make sure polarity
switch is not in between two
positions.
Fan runs - No output from machine 1. Welding application may have
in either Stick or TIG modes and the
yellow light on the control panel is
on.
exceed the recommended duty
cycle. Allow the unit to run until
the fan cools the unit and the
yellow light goes out.
Machine does not respond (no gas 1. Machine MUST be in
flow, no high frequency and no open
circuit voltage) when arc start switch
the TIG Mode.
or Amptrol is activated - fan is work- 2. The Amptrol may be defective.
ing.
Check for continuity between
pins “D” and “E” on cable con-
nector 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 Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SQUARE WAVE™ TIG 175
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Machine regularly over heats - ther- 1. Welding application may
mostat opens, Yellow light on front
panel glows. The fan runs but
machine has no output.
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
Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
low pressure air.
3. Air intake and exhaust louvers
may be blocked due to
inadequate clearance around
machine.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
TIG MODE PROBLEMS
Machine output is intermittently lost. 1. Problem may be caused by high
Gas flow and high frequency are
also interrupted.
frequency interference. Make
sure that the machine is ground-
ed properly according to the
installation instructions. If there
are other high frequency
sources in the area, make cer-
tain that they are grounded
properly.
2. Check Amptrol for proper opera-
tion and loose connections.
3. Check for proper input voltage
and proper voltage reconnec-
tion.
Arc “Flutters” when TIG welding.
1. Tungsten electrode may be too
large in diameter for the current
setting.
2. Tungsten not “sharp” when
welding in DC - mode.
Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
3. Gas shielding may be insuffi-
cient. 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.
Arc “Pulsates” when AC TIG
welding.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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APR96
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E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
TIG WELDING PROBLEMS
Black areas along weld bead.
1. Clean any oily or organic conta-
mination from the work piece.
2. Tungsten electrode may be cont-
aminated. Replace or sharpen.
3. Check for contaminated gas or
leaks in the gas line, torch, or
connections
4. Gas shielding may be insuffi-
cient. Increase gas flow; reduce
tungsten stickout beyond gas
cup.
1. Check for poor connections in
the welding circuit.
Weak high frequency - machine has
normal welding output.
2. Gas shielding may be insuffi-
cient. Increase gas flow; reduce
tungsten stickout beyond gas
cup.
3. Check for work and electrode
cables in poor condition allowing
high frequency to “Leak Off”.
Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
4. Keep cables as short as possible
.
5. Check Spark Gap operation and
setting (0.015”)
1. The tungsten electrode may be
contaminated. Replace or sharp-
en.
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).
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 Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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E-6
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
TIG WELDING PROBLEMS
No high frequency. Machine is in
the TIG Mode and has normal out-
put.
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.
No gas flow when Amptrol is activat- 1. Gas supply is empty or not
ed in the TIG Mode. Machine has
output - fan runs. A “Click” can be
heard indicating that the gas sole-
noid valve is operating.
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 reoccur-
rence.
Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
5. Consult your local welder/gas
distributor.
When AC TIG welding, the arc is
erratic and there is a loss of “clean-
ing” of the work piece.
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.
The end of the tungsten electrode
melts away.
1. The welding current is too high
for the electrode type and/or
size. See the Table B.1 in the
Operation Section of this manu-
al.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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E-7
E-7
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
STICK WELDING PROBLEMS
Stick electrode “Blasts Off” when arc 1. Weld current may be set too
is struck.
high for electrode size. Reduce
current control setting, or use a
larger diameter electrode.
Stick electrode “sticks” in the weld
puddle.
1. The weld current may be set too Contact your Local Lincoln Authorized
low. Increase the current control Field Service Facility for technical
setting or use a smaller diame- troubleshooting assistance.
ter electrode.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
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F-1
F-1
Enhanced Diagram
WIRING DIAGRAM
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NOTES
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G Do not touch electrically live parts or G Keep flammable materials away.
G Wear eye, ear and body protection.
electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
WARNING
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible
G Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
G Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
G Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
G Gardez à l’écart de tout matériel
inflammable.
G Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
G Isolez-vous du travail et de la terre.
German
G Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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G Keep your head out of fumes.
G Use ventilation or exhaust to
remove fumes from breathing zone.
G Turn power off before servicing.
G Do not operate with panel open or
guards off.
WARNING
Spanish
G Los humos fuera de la zona de res-
piración.
G Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
G Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
G No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
tien.
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
G Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
G Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
G Vermeiden Sie das Einatmen von
Schweibrauch!
G Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
G Não opere com as tampas removidas.
G Desligue a corrente antes de fazer
serviço.
G Mantenha-se afastado das partes
moventes.
G Não opere com os paineis abertos
ou guardas removidas.
G Mantenha seu rosto da fumaça.
G Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
G Não toque as partes elétricas nuas.
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.
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• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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