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IM607
May, 2000
Square Wave TIG 175
For use with machines having Code Numbers:
10457
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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
• 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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ii
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 below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.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. 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.
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. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
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.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
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SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
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.
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.
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.
• 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
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).
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.
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.
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.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.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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SAFETY
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 suiv-
antes:
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.
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.
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.
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.
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.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
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 debranch-
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.
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
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
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.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.
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
SAFETY .........................................................................................................................i-iv
INSTALLATION SECTION .................................................................................................1
TECHNICAL SPECIFICATIONS......................................................................................1
SELECT SUITABLE LOCATION......................................................................................2
STACKING ................................................................................................................2
LIFTING & MOVING .................................................................................................2
TILTING.....................................................................................................................2
ENVIRONMENTAL RATING............................................................................................2
MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION.2
INPUT CONNECTIONS ..................................................................................................3
INPUT RECONNECT PROCEDURE..............................................................................3
OUTPUT CONNECTIONS ..............................................................................................4
CONNECTIONS FOR TIG (GTAW) WELDING.........................................................4
TIG TORCH CONNECTION...............................................................................4
WORK CABLE CONNECTION...........................................................................4
SHIELDING GAS CONNECTION ......................................................................4
REMOTE CONTROL CONNECTION.................................................................5
CONNECTIONS FOR STICK (SMAW) WELDING ..................................................5
STICK ELECTRODE CABLE AND WORK CABLE CONNECTION ..................5
OPERATION SECTION......................................................................................................6
SAFETY PRECAUTIONS................................................................................................6
GENERAL DESCRIPTION..............................................................................................6
INCLUDED EQUIPMENT .........................................................................................6
FOR GTAW (TIG WELDING):.............................................................................6
FOR SMAW (STICK WELDING): .......................................................................6
FOR INSTALLATION AND STARTUP: ...............................................................6
WELDING CAPABILITY............................................................................................6
CONTROLS AND SETTINGS.........................................................................................7
OPERATING STEPS .......................................................................................................8
WELDING IN TIG MODE (2-STEP)..........................................................................8
WELDING IN TIG MODE (4-STEP)..........................................................................8
REMOTE CONTROL OPERATION...........................................................................9
BENEFITS OF THE SQUARE WAVE DESIGN ........................................................9
WELDING IN STICK MODE ..................................................................................10
ACCESSORIES SECTION...............................................................................................11
MAINTENANCE SECTION ..............................................................................................12
TROUBLESHOOTING SECTION.....................................................................................13
DIAGRAM SECTION........................................................................................................20
WIRING DIAGRAM........................................................................................................20
DIMENSION PRINT.......................................................................................................21
PARTS LISTS .......................................................................P281 SERIES, P210-F, P66-J
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1
1
INSTALLATION
TECHNICAL SPECIFICATIONS - Square Wave TIG 175 (K1583-1 only)
INPUT - SINGLE PHASE ONLY
Standard
Voltage
240/380/415/1/50/60
Additional Lincoln Rating 220-240/400-415/1/50/60
Input Current at
Rated Output
54/33/30 AC/DC Stick & DC TIG, 71/41/37 AC TIG
54/30 AC/DC Stick & DC TIG, 71/37 AC TIG
Code
Number
10457
RATED OUTPUT
Duty Cycle
GTAW 25% Duty Cycle
40% Duty Cycle
Volts at Rated Amperes
16.0 V AC/DC
Amps
150
125
110
85
15.0 V AC/DC
14.4 V AC/DC
13.4 V AC/DC
60% Duty Cycle
100% Duty Cycle
SMAW 25% Duty Cycle
40% Duty Cycle
26.0 V AC/DC
25.0 V AC/DC
24.4 V AC/DC
23.4 V AC/DC
150
125
110
85
60% Duty Cycle
100% Duty Cycle
OUTPUT
Maximum Open
Circuit Voltage
(STICK AND TIG)
AC OCV: 78
Output Current
Range
10-175 Amps
AC and DC
Type of Output
CC (Constant Current)
AC/DC
DC OCV: 64
RECOMMENDED INPUT WIRE AND FUSE SIZES(1)
For AC/DC Stick and DC TIG Welding at 150A/25%
For AC TIG Welding at 150 A/25% Duty
Duty Cycle and for AC TIG Welding up to
110A/25% Duty Cycle. Based on the 1996 U.S.
National Electrical Code
Cycle, Based on the 1996 U.S. National
Electrical Code
Type 75°C
Type 75°C
Input
Fuse
Input
Type 75°C
Copper Wire in
Copper Ground
Fuse
Input
Type 75°C
Copper Wire in
Conduit AWG
(IEC) Sizes
Copper Ground
Voltage / (Super Lag) Ampere
Wire in
(Super Lag)
Ampere
Wire in
phase/
or Breaker Rating on Conduit AWG Conduit AWG or Breaker Rating on
Conduit AWG
(IEC) Sizes
Frequency
Size
100
60
Nameplate
(IEC) Sizes
(IEC) Sizes
Size
125
80
Nameplate
2
2
2
2
240/1/50
380/1/50
415/1/50
220/1/50
400/1/50
54
33
30
54
30
10 (5.2 mm )
10 (5.2 mm )
71
41
37
67
37
8 (8.2 mm )
8 (8.2 mm )
2
2
2
2
14 (2.1 mm )
14 (2.1 mm )
12 (3.3 mm )
12 (3.3 mm )
2
2
2
2
60
14 (2.1 mm )
14 (2.1 mm )
70
12 (3.3 mm )
12 (3.3 mm )
2
2
2
2
100
60
10 (5.2 mm )
10 (5.2 mm )
125
70
8 (8.2 mm )
8 (8.2 mm )
2
2
2
2
14 (2.1 mm )
14 (2.1 mm )
12 (3.3 mm )
12 (3.3 mm )
(1)
The National Electrical Code permits operation at rated output and duty cycle from a 50 amp receptacle when supply lines and fuses are sized per this table.
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.
Power Source
on
27.93 in.
709 mm
19.22 in.
488 mm
36.74 in.
933 mm
Approx. 230 lbs.
105 kgs.
Undercarriage
SQUARE WAVE TIG 175
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2
2
INSTALLATION
Read entire installation section before starting
installation.
MACHINE GROUNDING AND HIGH FRE-
QUENCY INTERFERENCE PROTECTION
Safety Precautions
The welder must be grounded. See your local and national
electrical codes for proper grounding methods.
WARNING
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.
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.
Radiated interference can develop in the following four
ways:
• Do not touch electrically hot
parts.
• Always connect the Square Wave TIG 175 to
a power supply grounded per the National
Electrical Code and any local codes.
1. Direct interference radiated from the welder.
2. Direct interference radiated from the welding leads.
SELECT SUITABLE LOCATION
3. Direct interference radiated from feedback into the
power lines.
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 materi-
al 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.
4. Interference from re-radiation of “pickup” by
ungrounded metallic objects.
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 approximately
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
surface, either directly or on a recommended
undercarriage. 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
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.
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 fol-
lowing methods:
a) A metal underground water pipe in direct contact
with the earth for ten feet or more.
SQUARE WAVE TIG 175
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3
3
INSTALLATION
1
super lag fuses or delay type 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.
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 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.
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.
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.
6. Keep cover and all screws securely in place.
CAUTION
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.
Failure to follow these instructions can cause immediate fail-
ure of components within the welder.
--------------------------------------------------------------------------------
Multiple voltage models are shipped connected for the high-
est voltage. To change this connection refer to the following
instructions.
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 220-240V connection (Refer to figure A.1 and INPUT SUPPLY
CONNECTIONS. A different cord connector must be obtained when
connecting to this voltage):
INPUT SUPPLY 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.
1. Remove the sheet metal cover.
2. Disconnect the copper link between the switch stud and H4.
3. Connect the copper link from the switch stud to H2 and
tighten nuts securely.
1. Connect terminal marked
to earth ground per National
Electric Code or any local codes.
2. Connect the supply lines to the line switch terminals as
shown in figure A.1.
3. Install in accordance with all local and national electrical
codes.
4. Replace sheet metal cover and all screws.
For 380V connection (Refer to figure A.1):
1. Remove the sheet metal cover.
The Square Wave TIG is supplied with one cord connector.
The cord connector provides a strain relief for the input power
cord as it passes through the rear access hole. The cord
connector is designed for a cord diameter of 11.4 to 18.0mm
(.450 to .704 in.). Remove the plastic compression nut from
the cord connector and place it on the cord. (Note: If you are
connecting the machine for 220-240V operation you will have
to obtain a different cord connector. The new connector
should fit the existing knock out which is 33mm (1.3 in.) in
diameter. Strip away outer jacket of cord, trim fillers and
insert conductors through cord connector. The jacketed por-
tion of the cord must go through the cord connector. Slide the
plastic compression nut up the cord to the connector and turn
it until it tightens on the input cord.
2. Disconnect the copper link between the switch stud and H4.
3. Connect the copper link from the switch stud to H3 and
tighten nuts securely.
4. Replace sheet metal cover and all screws.
For 400-415V connection (Refer to figure A.1):
1. Remove the sheet metal cover.
2. Disconnect the copper link between the switch stud and H2 or H3.
3. Connect the copper link from the switch stud to H4 and
tighten nuts securely.
Refer to the Technical Specifications page at the beginning
of this section. Fuse the input circuit with the recommended
4. Replace sheet metal cover and all screws.
SQUARE WAVE TIG 175
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4
INSTALLATION
INPUT LEADS L1 & L2
strain relief boot onto the torch and connect the fitting
to the adapter. The rubber strain relief boot slips over
the connection and adapter block to provide shock pro-
tection.
INPUT SUPPLY
CONNECTION
WARNING
To avoid receiving a high frequency shock, keep the
TIG torch and cables in good condition.
__________________________________________
WORK CABLE CONNECTION
A work cable with attached work clamp is factory 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 procedure on grounding
the work clamp and work piece.
H4
H2
H3
FOR 220-240V: CONNECT COPPER LINK TO H2 -
(SEE INPUT SUPPLYCONNECTION SECTION)
FOR 380V: CONNECT COPPER LINK TO H3
FOR 400-415V: CONNECT COPPER LINK TO H4 (AS SHOWN)
FIGURE A.1 Reconnect Leads
SHIELDING GAS CONNECTION
Obtain the necessary inert shielding gas (usually
argon). Connect a cylinder of gas with a pressure reg-
ulator and flow gage. Install a gas hose between the
regulator and gas inlet (located on the rear of the
welder). The gas inlet has a 5/8-18 right hand female
thread; CGA #032.
OUTPUT CONNECTIONS
WARNING
ELECTRODE/GAS OUTLET
RECEPTACLE
CYLINDER could explode
if damaged.
•Keep cylinder upright and chained
to a support.
WORK CABLE & CLAMP
•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.
___________________________________________
FIGURE A.2 Location of Output Connections
The optional undercarriage features a pivoting platform
that simplifies loading and unloading of gas cylinders.
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.
CONNECTIONS FOR TIG (GTAW) WELDING
TIG TORCH CONNECTION
The Square Wave TIG 175 is supplied with a Twistmate
receptacle which combines the Electrode and Gas
connections. Use a LA-9, LA-17 (See OPTIONAL
ACCESSORIES section), or any equivalent TIG torch
with a right hand male 3/8-24UNF-2B fitting. An
adapter and protective boot are included to connect
torches with the specified fittings. Slide the rubber
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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. 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 Twistmate plug into the Electrode/Gas
Output Receptacle and turn it clockwise until it is tight.
The work cable and work clamp are factory connected.
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6
6
OPERATION
SAFETY PRECAUTIONS
GENERAL 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 weld-
ing (SMAW) capability.
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.
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
INCLUDED EQUIPMENT
•
Insulate yourself from work and ground.
For GTAW (TIG Welding):
• TIG connector (Twistmate adaptor)
• Strain relief boot
• Always wear dry insulating gloves.
•
Read and follow “Electric Shock Warnings”
in the Safety section if welding must be per-
formed under electrically hazardous condi-
tions such as welding in wet areas or on or
in the workpiece.
For SMAW (Stick Welding):
• Electrode holder with cable and Twistmate plug
For Installation and startup:
• Work Cable and Clamp
FUMES AND GASES
can be dangerous.
WELDING CAPABILITY
The Square Wave TIG 175 is rated at 150 amps, 16
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.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
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.
Observe additional Safety Guidelines detailed in
the beginning of this manual.
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7
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
9
1. POWER SWITCH & LIGHT
10
2. ELECTRODE/ GAS OUTPUT RECEPTACLE
3. WORK CABLE & CLAMP
4. REMOTE CONTROL CONNECTOR
5. OVER TEMPERATURE LIGHT
6. POLARITY SWITCH
8
1
7. MODE SWITCH
8. CURRENT CONTROL
9. DOWNSLOPE TIME
10. START/CRATER CURRENT
7
6
5
2
4
3
1. POWER SWITCH & LIGHT - Turns power on
or
5. OVER TEMPERATURE LIGHT -
If the welder
off o the welder. When switched “ON”, the cool-
ing fan runs and the white light will illuminate indi-
cating that the power is on.
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.
2. ELECTRODE/GAS OUTPUT RECEPTACLE - This
Twistmate receptacle provides the 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.
6. POLARITY SWITCH - Allows you to select between
welding in AC
, DC -
, or DC+
polar-
3. 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.
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.
CAUTION
4. REMOTE CONTROL CONNECTOR - This connector
provides connection for a remote control. See Remote
Control Operation in this section of the manual.
Do not switch the polarity switch while
welding or damage may result to the
machine.
------------------------------------------------------------------------
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OPERATION
7. MODE SWITCH - A three position toggle switch
used to select the welding mode. Refer to WELD-
ING IN THE STICK MODE, and WELDING IN THE
TIG MODE(2-STEP AND 4-STEP) later in this sec-
tion for information on how the machine functions in
each of these modes.
3. Set the Polarity Switch to DC- for weld-
ing steel or stainless steel; or to AC for welding alu-
minum.
4. Connect an Arc Start Switch or Amptrol to the
Remote Control Connector.
STICK: This mode is used for the stick electrode
(SMAW) welding process. In this position the only
active control is the output current control.The out-
put terminals are continuously energized.
5. Turn on the cylinder gas valve and adjust the flow
regulator to obtain desired flow.
2-STEP TIG: This mode is used for the TIG
(GTAW) welding process. An Arc Start switch or
Amptrol must be used to weld. The Down slope
Time and Start/Crater Current controls have no
effect in this mode.
6. Turn the power switch to “ON - I”. 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.
4-STEP TIG: This mode is used for the TIG
(GTAW) welding process. An Arc Start switch or
Amptrol must be used. All controls are active in
this mode.
8. Depress the Arc Start Switch or amptrol to energize
the torch and establish an an arc with the work
piece.
8. CURRENT CONTROL - This control is active in both
TIG and Stick modes. In Stick mode the current con-
trol sets the welding current. In TIG mode this con-
trol sets the maximum current. The Amptroltm will
adjust the welding current from the machine mini-
mum to this maximum setting.
NOTE: When the MODE switch is set to “2 STEP 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.
9. DOWN SLOPETIME - This control is active in the 4-
STEP TIG mode only. It is used to set the amount
of time the output takes to go from the preset level to
the Crater current level. The adjustable range is
approximately 0.5 to 10 seconds.
WELDING IN TIG MODE (4-STEP)
10. START/CRATER CURRENT - This control is active
in the 4-STEP TIG mode only. It sets the Start and
Crater currents of the weld as a percentage of the
peak current set with the Current control knob. If
the Start current set is not above the minimum
starting current of the machine or electrode the
weld will not start. If this occurs increase the per-
centage and try again.
In 4-STEP mode an Arc Start switch or Amptrol must
be used. The switch or Amptrol is pressed and then
released to start the weld cycle. Pressing and releas-
ing the switch or Amptrol a second time ends the weld
cycle. This eliminates the need to continuously hold
down the switch or Amptrol during the weld. The
process works as follows:
A
(STEP 1) First Press: Initiates a 0.5 second preflow
of shielding gas and starts the weld at the Start cur-
rent level set with the Start/Crater Current control.
(Note: The Start current is determined by setting a
peak current with the output control knob and then
setting a percentage of that current with the
Start/Crater Current control. IMPORTANT! THE
WELD WILL NOT START IF THE START CURRENT
IS SET BELOW THE MACHINES MINIMUM WELD-
ING CURRENT. (Approx 10 Amps))
OPERATING STEPS
WELDING IN TIG MODE (2 STEP)
In 2-STEP mode an Arc Start switch or Amptrol must be
used. The switch or Amptrol is pressed to start the weld.
(Step 1) Output continues at the level set with the Current
control until the switch or Amptrol is released. (Step 2)
1. If connecting a Lincoln LA-9 or LA-17 TIG torch simply
connect the Twistmate plug to the receptacle located
on the front of the machine. See INPUT SUPPLY
CONNECTIONS if another TIG torch is used.
(STEP 2) First Release: The output ramps up to the
preset level in 0.5 seconds.
2. Set the MODE switch to “2 STEP TIG”.
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OPERATION
(STEP 3) Second Press: The output ramps down to
the level set with the Start/Crater Current control.
The time it takes to ramp down is set with the Down
slope Time control. (Approx. 0.5 to 10 seconds)
on with the output and remain on continuously until the
remote control is released.
REMOTE CONTROL OPERATION
(STEP 4) Second Release: Output is turned off stop-
ping the weld and a 15 second Postflow of shielding
gas is applied.
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 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.
1. If connecting a Lincoln LA-9 or LA-17 TIG torch con-
nect the Twistmate plug to the receptacle located on
the front of the machine. See INPUT SUPPLY CON-
NECTIONS if another TIG torch is used.
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 mod-
els. 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.
2. Set the MODE switch to “4-STEP TIG”
3. Set the Polarity Switch to DC- for welding steel or
stainless steel; or to AC for welding aluminum.
4. Connect an Arc Start switch or Amptrol to the
Remote Control Connector.
When the welder is in 2 Step 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 acci-
dental high current damage to the work piece and/or
tungsten, and gives a fine control of the current. When
the welder is in 4 Step TIG mode the Amptrol acts as
an Arc Start Switch. When the welder is in the stick
mode a remote control has no effect and is not used.
5. Turn on the cylinder gas valve and adjust the flow
regulator to obtain the desired flow.
6. Turn the power switch to “ON - I”. 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.
A
8. Set the Start/Crater Current control
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” tung-
sten may be used on DC- to weld the full range. To
start the weld, the operator may have to turn the cur-
rent control up and depress the Amptrol approximately
1/4 of the way down. Depressing the Amptrol to its min-
imum position may not start the arc. Also if the Current
Control or Start/Crater current 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 175 will start a 3/32,
2% thoriated tungsten electrode at 15 amperes provid-
ed the electrode tip is properly grounded and not con-
taminated.
on the control panel to obtain the desired level as a
percentage of the maximum current. Note: The level
set must be above the machines minimum starting
level. (12 Amps)
9. Set the Down slope Time control
on the control panel to the desired level.
10. Depress the Arc Start switch or Amptrol to energize
the torch and establish an arc at the Start current
level with the work piece.
11. Release the Arc Start switch or Amptrol to ramp up
to the maximum current setting.
12. Depress the Arc Start switch or Amptrol again to
start the Down slope time.
13. Release the Arc Start switch or Amptrol to stop
welding.
BENEFITS OF THE SQUARE WAVE 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 such as aluminum. However
NOTE: 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
SQUARE WAVE TIG 175
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10
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OPERATION
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 Square Wave TIG 175 optimizes
cleaning and heating of the work. The result is the
capability to weld through the complete range of 12 to
175 amperes in AC TIG or DC- TIG requiring only one
electrode, a 3/32” 2% thoriated tungsten.
WARNING
In Stick Mode the output terminal and
electrode will be electrically hot
whenever the power switch is turned
on.
4. Place the electrode in the electrode holder.
5. Turn the power switch to “ON”.
WELDING IN STICK MODE
6. Adjust the Current Control to the desired amps.
7. Strike an arc and weld.
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.
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+).
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
90 - 140
DC+
DC+
DC-
DC+
DC+
DC+
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 100 A.
Up to 160 A.
Up to MAX. 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)
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.
SQUARE WAVE TIG 175
MAY96
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11
ACCESSORIES
OPTIONAL ACCESSORIES
TIG Torch Parts Kits - Parts kits are available for the
LA-9 and LA-17 TIG torches. These kits include back
cap, collets, collet bodies, nozzles and tungstens.
Order KP507 for LA-9 torches
Order KP508 for LA-17 torches
See publication E12.150 for parts kits breakdown.
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 accommo-
dates 7” to 9 1/4” diameter gas cylinders. The under-
carriage comes completely assembled and mounts
directly to the power source.
Cut Length Consumables - TIG welding filler metals
are available for welding stainless steel, mild steel, alu-
minum and copper alloys. See publication C9.10.
K870 Foot Amptrol™ - A foot operated remote current
control to be used while welding in 2 Step TIG mode.
In 4 Step TIG mode the Foot Amptrol acts as an Arc
Start Switch.
K812 Hand Amptrol™ - A thumb operated remote
current control to be used while welding in 2 Step TIG
mode. In 4 Step TIG mode the Hand Amptrol acts as
an Arc Start Switch.
K814 Arc Start Switch - The Arc Start Switch does not
provide remote current control. In 2 Step TIG mode the
Arc Start Switch allows on/off welding at the current set
with the Current Control on the control panel. The
Start/Crater Current and Downslope Time controls are
only active in 4 Step mode.
Magnum® LA-9 and LA-17 TIG Torches - The follow-
ing standard Magnum® TIG torches with one-piece
cable may be used with the Square Wave TIG 175.
• K859-1
• K859-5
• K860-1
• K860-5
LA-9 12.5 ft medium back cap
LA-9 25 ft medium back cap
LA-17 12.5 ft long back cap
LA-17 25 ft long back cap
NOTE: Each torch requires a Twistmate plug (S22529-
1) and strain relief boot (M17255) be installed onto the
cable. Collets, collet bodies, and nozzles are not
included and must be ordered separately.
Twistmate® Plug (S22529-1) and Strain Relief Boot
(M17255) - One of each is shipped with the welder to
connect any TIG torch with a right hand male 3/8-
24UNF-2B fitting. The Magnum LA-9 and LA-17
Torches are recommended. If you do not care to inter-
change these parts when using more than one torch
you may order additional sets. The Twistmate plug pro-
vides connection for both gas and welding current.
Tungstens, Collets, Collet Holders, Gas Cups,
Backcaps and Other Torch Parts - Standard
Magnum® parts and accessories for this torch may be
used when using a Magnum LA-9 or LA-17.
SQUARE WAVE TIG 175
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12
MAINTENANCE
ommended. If the contacts are replaced reset the
gap spacing to 0.015. Refer to figure C.1. Note in
highly dirty environments where there is an abun-
dance of conductive contaminants, use a low pres-
sure air stream to clean the spark gap. Do not dis-
turb the factory setting.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
8. Inspect gas hose and inlet fitting for cracks or
leaks.
• Only qualified personnel should
perform this maintenance.
9. Replace any unreadable labels or decals.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this
equipment.
10. Verify that the machine and welding circuit is prop-
erly grounded.
FIGURE C.1 SPARK GAP
• Do not touch electrically hot
parts.
WARNING
To avoid receiving a high frequency shock, keep the
TIG torch and cables in good condition.
.015 Spark Gap
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.
LEFT SIDE OF MACHINE
• Main Transformer
• Electrode/Gas Output Receptacle
• Polarity Switch
• Rectifier Assembly
• Arc Starter/Spark Gap Assembly
• PC Boards
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.
• 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. The arc starter spark gap spacing is factory set at
0.015 inch. It typically will not require periodic
maintenance. Refinishing the contacts is not rec-
.30
Figure C.2
SQUARE WAVE TIG 175
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13
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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.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos-
sible symptoms that the machine may exhib-
Step 3. RECOMMENDED COURSE OF
ACTION
it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob-
lems, TIG mode problems, TIG welding prob-
lems and Stick welding Problems.
If you have exhausted all of the items in step
2. Contact your Local Lincoln Authorized
Field Service Facility.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
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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14
14
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
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.
Output is present
No Fan, High Frequency,
Lights, or Gas Solenoid
1. Check 5A fuse F1 located next
to the control PC board on the
left side of the machine.
Fan runs - No output from machine 1. Check for proper input voltages
in either Stick or TIG (2/4 Step)
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 (2/4 Step)
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.
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15
15
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
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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16
16
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
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
Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
welding in DC - mode.
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.
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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17
17
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
TIG WELDING PROBLEMS
Black areas along weld bead.
1. Clean any oily or organic conta-
mination from the work piece.
When welding aluminum, clean
oxide layer with a stainless steel
brush.
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.
Weak high frequency - machine has 1. Check for poor connections in
normal welding output.
the welding circuit.
2. Gas shielding may be insuffi-
cient. Increase gas flow; reduce
tungsten stickout beyond gas
cup.
Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
3. Check for work and electrode
cables in poor condition allowing
high frequency to “Leak Off”.
4. Keep cables as short as possible
.
5. Check Spark Gap operation and
setting (0.015”)
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).
1. The tungsten electrode may be
contaminated. Replace or sharp-
en.
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.
5. If in 4 Step TIG mode the
Start/Crater current control may
be set to low.
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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18
18
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
TIG WELDING PROBLEMS
No high frequency. Machine is in
either 2 or 4 Step TIG Mode and has
normal output. Fan is running and
power light is on.
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 2/4 Step TIG Modes.
turned on.
Machine has output - fan runs. A
“Click” can be heard indicating that 2. Flow regulator may be set too
the gas solenoid valve is operating.
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.
5. Consult your local welder/gas
distributor.
Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
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.
3. Gas shielding may be insuffi-
cient. Increase gas flow; reduce
tungsten stickout beyond gas
cup. Minimize crossdrafts in
welding area.
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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19
19
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
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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20
20
WIRING DIAGRAM
B
B
2 0 9 R
2 1 0 U
2 3 0 B
W
R
2 2 1 ( + )
2 2 2 ( - )
B
2 3 2 B
2 3 8
2 3 4
2 3 5
2 0 4 W
2 0 1 W
2 3 6
2 1 7
G 1
2 1 8
G 2
G 3
2 2 0
2 1 6
G 4
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21
21
DIMENSION PRINT
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NOTES
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NOTES
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Now Available...12th Edition
New Lessons in Arc Welding
The Procedure Handbook of Arc Welding
Lessons, simply written, cover manipulatory techniques;
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The book contains the latest information and application
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Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability
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● Do not touch electrically live parts or ● Keep flammable materials away.
● Wear eye, ear and body protection.
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
WARNING
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● 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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● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
Spanish
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux
tien.
● Gardez la tête à l’écart des fumées.
● 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
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
● 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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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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