RETURN TO MAIN MENU
IM565-B
Square Wave TIG 175 April, 2000
10265
For use with machines having Code Numbers:
10387
10456
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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
For Gasoline Engines: The engine exhaust from
For Diesel Engines: Diesel engine exhaust and
this product contains chemicals known to the
some of its constituents are known to the State
State of California to cause cancer, birth defects,
of California to cause cancer, birth defects, and
or other reproductive harm.
other reproductive harm.
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-
chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler 2.d.3. Do not place your body between the electrode and
by pushing on the throttle control rods while work cables. If the electrode cable is on your right
the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot� when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot� parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
3.b. Insulate yourself from work and ground using dry insulation.
material to protect your skin and that of your helpers from
Make certain the insulation is large enough to cover your full
the arc rays.
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if welding
screening and/or warn them not to watch the arc nor expose
must be performed under electrically hazardous
themselves to the arc rays or to hot spatter or metal.
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,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
can be dangerous.
the following equipment:
5.a. Welding may produce fumes and gases
� Semiautomatic DC Constant Voltage (Wire) Welder.
hazardous to health. Avoid breathing these
� DC Manual (Stick) Welder.
fumes and gases.When welding, keep
� AC Welder with Reduced Voltage Control.
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,
fumes and gases away from the breathing zone. When
electrode reel, welding head, nozzle or semiautomatic
welding with electrodes which require special
welding gun are also electrically “hot�.
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
3.d. Always be sure the work cable makes a good electrical
cadmium plated steel and other metals or coatings
connection with the metal being welded. The connection
which produce highly toxic fumes, keep exposure as
should be as close as possible to the area being welded.
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
3.e. Ground the work or metal to be welded to a good electrical
confined spaces or in some circumstances, outdoors, a
(earth) ground.
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating
products.
3.h. Never simultaneously touch electrically “hot� parts of
electrode holders connected to two welders because voltage
5.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
5.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.j. Also see Items 6.c. and 8.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact can
any other source of heat, sparks, or flame.
cause overheating and create a fire hazard.
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
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
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
iv iv
SAFETY
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
7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés possible de
1. Protegez-vous contre la secousse électrique:
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
a. Les circuits à l’électrode et à la piéce sont sous tension
éloignés de la zone de travail, on augmente le risque de voir
quand la machine à souder est en marche. Eviter toujours
passer le courant de soudage par les chaines de levage,
tout contact entre les parties sous tension et la peau nue
câbles de grue, ou autres circuits. Cela peut provoquer des
ou les vétements mouillés. Porter des gants secs et sans
risques d’incendie ou d’echauffement des chaines et des
trous pour isoler les mains.
câbles jusqu’� ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans
Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande
galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse.
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
10. Ne pas souder en présence de vapeurs de chlore provenant
tionnement.
d’opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l’eau pour le
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
refroidir.
du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension
ou autres produits irritants.
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
total de la tension à vide des deux machines.
le code “Code for safety in welding and cutting� CSA Standard
f. Si on utilise la machine à souder comme une source de
W 117.2-1974.
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
PRÉCAUTIONS DE SÛRETÉ POUR
contre les chutes dans le cas ou on recoit un choc. Ne jamais
LES MACHINES À SOUDER À
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
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 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. 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
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
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 er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. 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
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product •â?¢â??
as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
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.
vi vi
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 ..........................................................................................8
AMPTROLTM ACCESSORY OPERATION...........................................................8
BENEFITS OF THE SQUARE WAVE DESIGN ..................................................8
WELDING IN STICK MODE ....................................................................................9
ACCESSORIES SECTION ...............................................................................................10
MAINTENANCE SECTION ..............................................................................................11
TROUBLESHOOTING SECTION.....................................................................................12
DIAGRAM SECTION ........................................................................................................19
WIRING DIAGRAM 208/230 V MODEL ........................................................................19
WIRING DIAGRAM 460/575 V MODEL ........................................................................20
PARTS LISTS.......................................................................................................Appendix
1 1
INSTALLATION
TECHNICAL SPECIFICATIONS - Square Wave TIG 175 (K1478-1 & -2 only)
INPUT - SINGLE PHASE ONLY
Code
Standard Input Current at
Number
Voltage Rated Output
10265
208/230/1/60 59/53 AC/DC Stick & DC TIG - 72/65 AC TIG
10387
460/575/1/60 27/22 AC/DC Stick & DC TIG - 33/27 AC TIG
RATED OUTPUT
Volts at Rated Amperes
Duty Cycle Amps
14.8 V AC/DC
GTAW 25% Duty Cycle 150
14.5 V AC/DC
40% Duty Cycle 125
14.3 V AC/DC
60% Duty Cycle 110
14.1V AC/DC
100% Duty Cycle 90
26.0 V AC/DC
SMAW 25% Duty Cycle 150
25.0 V AC/DC
40% Duty Cycle 125
24.4 V AC/DC
60% Duty Cycle 110
23.6 V AC/DC
100% Duty Cycle 90
OUTPUT
Maximum Open
Type of Output
Output Current Circuit Voltage
Range (STICK AND TIG) CC (Constant Current)
AC OCV: 74
10-175 Amps AC/DC
DC OCV: 59
AC and DC
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 Cycle, Based on the 1996 U.S. National
110A/25% Duty Cycle. Based on the 1996 U.S. Electrical Code
National Electrical Code
Type 75°C
Type 75°C
Input Copper Ground
Fuse
Input Copper Ground
Type 75°C Type 75°C
Fuse Input
Ampere Wire in
(Super Lag)
Voltage / (Super Lag) Ampere Wire in
Copper Wire in Copper Wire in
or Breaker Rating on Conduit AWG Conduit AWG or Breaker Rating on Conduit AWG
phase/ Conduit AWG
Nameplate (IEC) Sizes
Size
Frequency (IEC) Sizes
(IEC) Sizes (IEC) Sizes
Size Nameplate
8 (8.2 mm2)
10 (5.2 mm2)
10 (5.2 mm2) 8 (8.2 mm2)
72
125
208/1/60 100 59
8 (8.2 mm2)
10 (5.2 mm2)
10 (5.2 mm2) 8 (8.2 mm2)
65
125
230/1/60 100 53
14 (2.1 mm2)
14 (2.1 mm2)
14 (2.1 mm2) 14 (2.1 mm2)
33
60
460/1/60 50 27
14 (2.1 mm2)
14 (2.1 mm2)
14 (2.1 mm2) 14 (2.1 mm2)
27
50
575/1/60 40 22
(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 19.53 in. 13.72 in. 24.94 in. Approx. 200 lbs.
496 mm 349 mm 633 mm 90.9 kgs.
Source
Power Source 27.93 in. 19.22 in. 36.74 in. Approx. 230 lbs.
709 mm 488 mm 933 mm 105 kgs.
on
Undercarriage
SQUARE WAVE TIG 175
2 2
INSTALLATION
Read entire installation section before starting MACHINE GROUNDING AND HIGH FRE-
installation.
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
ELECTRIC SHOCK can kill. transmitter, can be blamed for radio, TV and electronic
� Only qualified personnel should
equipment interference problems. These problems may
perform this installation.
be the result of radiated interference. Proper grounding
� Turn the input power OFF at the
methods can reduce or eliminate radiated interference.
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.
1. Direct interference radiated from the welder.
� Always connect the Square Wave TIG 175 to
a power supply grounded per the National
Electrical Code and any local codes.
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
4. Interference from re-radiation of “pickup� by
front and side louvers. Dirt, dust or any foreign materi-
ungrounded metallic objects.
al that can be drawn into the welder should be kept at
a minimum. Failure to observe these precautions can
Keeping these contributing factors in mind, installing
result in excessive operating temperatures and nui-
equipment per the following instructions should mini-
sance shut-downs.
mize problems.
STACKING
1. Keep the welder power supply lines as short as pos-
Square Wave TIG 175’s cannot be stacked. sible and enclose as much of them as possible in
rigid metallic conduit or equivalent shielding for a
LIFTING AND MOVING distance of 50 feet (15.2m). There should be good
electrical contact between this conduit and the
The Square Wave TIG 175 should be lifted by two or
welder case ground. Both ends of the conduit
more people or with a hoist. (It weighs approximately
should be connected to a driven ground and the
200 lbs./90.9 kg.) Its lifting handles are designed to
entire length should be continuous.
make lifting more convenient. An optional undercarriage
is available to easily move the unit. Refer to the
2. Keep the work and electrode leads as short as pos-
Accessories section of this manual.
sible and as close together as possible. Lengths
TILTING
should not exceed 25 ft (7.6m). Tape the leads
together when practical.
Each machine must be placed on a secure, level
surface, either directly or on a recommended
undercarriage. The machine may topple over if this 3. Be sure the torch and work cable rubber coverings
procedure is not followed. are free of cuts and cracks that allow high frequen-
cy leakage.
ENVIRONMENTAL RATING
The Square Wave TIG 175 power source carries an 4. Keep the torch in good repair and all connections
IP21 environmental rating. It may be used in normal tight to reduce high frequency leakage.
industrial and commercial environments. Avoid using
it in environments which have falling water such as
5. The work piece must be connected to an earth
rain. Read and follow “Electric Shock Warnings� in the
ground close to the work clamp, using one of the fol-
Safety section if welding must be performed under
lowing methods:
electrically hazardous conditions such as welding in
wet areas or on or in the workpiece.
a) A metal underground water pipe in direct contact
SQUARE WAVE TIG 175
3 3
INSTALLATION
with the earth for ten feet or more. ing at high currents.
b) A 3/4� (19mm) galvanized pipe or a 5/8� (16mm)
INPUT RECONNECT PROCEDURE
solid galvanized iron, steel or copper rod driven
at least eight feet into the ground.
On multiple input voltage welders, be sure the machine
The ground should be securely made and the ground- is connected per the following instructions for the volt-
ing cable should be as short as possible using cable of age being supplied to the welder.
the same size as the work cable, or larger. Grounding
to the building frame electrical conduit or a long pipe
CAUTION
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.
6. Keep cover and all screws securely in place. ___________________________________________
7. Electrical conductors within 50 ft (15.2m) of the Multiple voltage models are shipped connected for the
welder should be enclosed in grounded rigid metal- highest voltage. To change this connection refer to the
lic conduit or equivalent shielding, wherever possi- following instructions.
ble. Flexible metallic conduit is generally not suit-
able.
WARNING
8. When the welder is enclosed in a metal building, the ELECTRIC SHOCK can kill.
metal building should be connected to several good
earth driven electrical grounds (as in 5 (b) above) � Turn the input power OFF at the
around the periphery of the building. disconnect switch or fuse box
before working on this
Failure to observe these recommended installation equipment.
procedures can cause radio or TV and electronic
equipment interference problems and result in unsatis- For the lowest rated voltage connection (Refer to figure A.1):
factory welding performance resulting from lost high
frequency power. 1. Remove the sheet metal cover.
INPUT CONNECTIONS 2. Disconnect lead H3 from the power switch and insu-
late with the insulation from the H2 lead.
Be sure the voltage, phase, and frequency of the input
power is as specified on the rating plate, located on the 3. Connect lead H2 to the power switch where H3 was
rear of the machine. connected.
208/230 volt models have a NEMA 6-50P plug 4. Tighten connections.
attached to the input power cord and a NEMA 6-50R
receptacle is included. Other voltage models have an 5. Replace sheet metal cover and all screws
input power cord but no plug or receptacle.
For the highest rated voltage connection (Refer to figure A.1):
Have a qualified electrician provide input power supply The machine is normally shipped connected for the
to the receptacle or cord in accordance with all local highest rated voltage, however verify the following:
and national electrical codes. Use a single phase line
or one phase of a two or three phase line. Choose an 1. Remove the sheet metal cover.
input and grounding wire size according to local or
national codes. Refer to the Technical Specifications 2. Disconnect lead H2 from the power switch and insu-
page at the beginning of this section. Fuse the input late with the insulation from the H3 lead.
circuit with the recommended super lag fuses or delay
type1 circuit breakers. Using fuses or circuit breakers 3. Connect lead H3 to the line switch where H2 was
smaller than recommended may result in “nuisance� connected.
shut-offs from welder inrush currents even if not weld-
4. Tighten connections.
1Also called “inverse time� or “thermal/magnetic� circuit breakers; circuit break-
ers which have a delay in tripping action that decreases as the magnitude of 5. Replace sheet metal cover and all screws.
the current increases.
SQUARE WAVE TIG 175
4 4
INSTALLATION
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-
FOR LOWEST RATED VOLTAGE
nection for the shielding gas to the torch.
: H2 CONNECTED
FOR HIGHEST RATED VOLTAGE
: H3 CONNECTED
WARNING
LEAD H1
(DO NOT
To avoid receiving a high frequency shock, keep the
REMOVE)
TIG torch and cables in good condition.
__________________________________________
WORK CABLE CONNECTION
A work cable with attached work clamp is factory con-
INPUT LEADS
L1 & L2
nected to the Square Wave TIG 175. To minimize high
frequency interference, refer to Machine Grounding
and High Frequency Interference Protection section
BACK VIEW OF LINE SWITCH
of this manual for the proper procedure on grounding
the work clamp and work piece.
FIGURE A.1 Reconnect Leads SHIELDING GAS CONNECTION
OUTPUT CONNECTIONS 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
WARNING
CYLINDER could explode
if damaged.
•Keep cylinder upright and chained
WORK CABLE & CLAMP
to a support.
•Keep cylinder away from areas where it could be
damaged.
•Never allow the torch to touch the cylinder.
•Keep cylinder away from live electrical circuits.
FIGURE A.2 Location of Output Connections
•Maximum inlet pressure 150 psi.
CONNECTIONS FOR TIG (GTAW) WELDING ___________________________________________
The optional undercarriage features a pivoting platform
TIG TORCH CONNECTION
that simplifies loading and unloading of gas cylinders.
A cylinder is loaded by leaning it slightly sideways and
Refer to Included Equipment in the Operation Section
rolling it toward the platform. The cylinder’s weight will
of this manual for TIG welding equipment which is
push the platform downward against the floor, forming
included with the Square Wave TIG 175.
a ramp. At this point, the cylinder may be rolled up the
platform into its final position. Secure the cylinder in
A TIG welding torch with cable and connector is sup-
place with the provided chain. Unload by following
plied with the welder. Turn the Power Switch “OFF�.
these steps in reverse.
Connect the torch cable quick connect plug into the
SQUARE WAVE TIG 175
5 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 man-
ual 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.
SQUARE WAVE TIG 175
6 6
OPERATION
SAFETY PRECAUTIONS GENERAL DESCRIPTION
Read and understand this entire section before operat- The Square Wave TIG 175 is a constant current, single
ing the machine. 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
WARNING
(GTAW) and stick (SMAW) welding processes within its
output capacity of 10 to 175 amps, on both AC and DC
ELECTRIC SHOCK
polarity.
can kill.
� Do not touch electrically live parts or
INCLUDED EQUIPMENT
electrode with skin or wet clothing.
� Insulate yourself from work and ground. For GTAW (TIG Welding):
� TIG torch, factory assembled with:
� Always wear dry insulating gloves. � 12.5 ft (3.8m) one-piece cable
� 3/32� Collet body
� Read and follow “Electric Shock Warnings� � 3/32� Collet
in the Safety section if welding must be per- � Short backcap
formed under electrically hazardous condi- Not assembled:
tions such as welding in wet areas or on or � 3/32� x 7� 2% Thoriated Tungsten Electrode
in the workpiece. � Long backcap
� 1/2� Diameter Alumina gas cup
FUMES AND GASES � Adjustable argon gas pressure regulator and flow
can be dangerous. gage
� Gas hose
� Keep your head out of fumes. � Foot Amptroltm remote current control with 15ft
(4.6m) cable
� Use ventilation or exhaust to
remove fumes from breathing For SMAW (Stick Welding):
zone. � Electrode holder with cable and quick connect plug
� Electrode sample pack.
WELDING SPARKS For Installation and startup:
can cause fire or � “How To� VHS Videotape
explosion � Work Cable and Clamp
� Input Cord
� Keep flammable material away. � Input plug and receptacle (208/230 volt models only)
� Do not weld on containers that WELDING CAPABILITY
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
ARC RAYS capable of higher duty cycles at lower output currents.
can burn. It is capable of 175 amps, 27 volts at a lower duty
cycle. If the duty cycle is exceeded, a thermal protec-
� Wear eye, ear and body tor will shut off the output until the machine cools.
protection.
Observe additional Safety Guidelines detailed in
the beginning of this manual.
SQUARE WAVE TIG 175
7 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
1 1. POWER SWITCH & LIGHT
2. TIG/STICK SWITCH
3. POLARITY SWITCH
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 & LIGHT - Turns power on or
CAUTION
off to the welder. When switched “ON�, the cool-
ing fan runs and the light will illuminate indicating
Do not switch the polarity switch while
that the power is on.
welding or damage may result to the
machine.
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
4. CURRENT CONTROL - This control is active in
later in this chapter for information on how the
both TIG and Stick modes. In Stick mode the current
machine functions in each of these modes.
control sets the welding current. In TIG mode this
control sets the maximum current. The Amptroltm will
3. POLARITY SWITCH - Allows you to select between
adjust the welding current from the machine mini-
welding in AC , DC - , or DC+ polar-
mum to this maximum setting.
ity. In DC + polarity the electrode is positive and the
work clamp is negative. Use DC + for most stick
5. OVER TEMPERATURE LIGHT - If the welder
welding. In DC - the electrode is negative and the
overheats due to blocked air flow, high ambient air
work clamp is positive. Use DC - for TIG welding
temperature, or exceeded duty cycle, an internal
stainless steel and mild steel. AC polarity is recom-
thermostat will open disabling the welding output
mended for TIG welding aluminum.
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.
SQUARE WAVE TIG 175
8 8
OPERATION
6. REMOTE CONTROL CONNECTOR - This connector REMOTE CONTROL OPERATION
provides connection for a remote control. See Remote
Control Operation in this section of the manual. A Foot Amptrolâ„? is included with the Square Wave TIG
175 for remote current control while TIG welding. An
7. ELECTRODE/GAS OUTPUT RECEPTACLE - This optional Hand Amptrol may also be used. An optional
quick connect receptacle provides electrical connec- Arc Start Switch may be used to start and stop the
tion to the electrode holder and cable for Stick weld- welding if no remote control of the current is desired.
ing and a combined electrical and gas connection for Refer to the Accessories section of this manual.
the TIG torch when TIG welding.
Both the Hand and Foot Amptrol work in a similar man-
8. WORK CABLE - This work cable is factory con- ner. For simplicity, the following explanation will refer
nected to the welder and is connected to the work only to “Amptrols�, meaning both Foot and Hand mod-
piece to complete the welding circuit. Refer to els. The term “minimum� refers to a foot pedal in the
Machine Grounding and High Frequency “up� position, as it would be with no foot pressure, or a
Interference Protection in the Installation section Hand Amptrol in the relaxed position, with no thumb
of this manual for the proper procedure on ground- pressure. “Maximum� refers to a fully depressed Foot
ing the work clamp and work piece to minimize high Amptrol, or a fully extended Hand Amptrol.
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
OPERATING STEPS the maximum value set by the Current Control on the
control panel. This helps eliminate accidental high cur-
WELDING IN TIG MODE rent damage to the work piece and/or tungsten, and
gives a fine control of the current. When the welder is
1. Connect the TIG torch and cable quick connect plug in the stick mode a remote control has no effect and is
to the Electrode/Gas output receptacle. This recep- not used.
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
2. Set the TIG/STICK switch to “TIG�. the tungsten may be too large or cold. To start an arc
reliably, it is important to depress the Amptrol far
3. Set the Polarity Switch to DC- for welding steel or enough so that the machine output current is near the
stainless steel; or to AC for welding aluminum. tungsten operating range. For example, a 3/32� tung-
sten may be used on DC- to weld the full range. To
4. Connect the Foot Amptrol to the Remote Control Connector. start the weld, the operator may have to turn the cur-
rent control up and depress the Amptrol approximately
5. Turn on the cylinder gas valve and adjust the flow 1/4 of the way down. Depressing the Amptrol to its min-
regulator to obtain desired flow. imum position may not start the arc. Also if the current
control is set too low, the arc may not start. In most
6. Turn the power switch to “ON�. NOTE: There will be cases, a large or cold tungsten will not readily establish
a 15 second gas flow when the power is turned on. an arc at low currents. This is normal. In DC-, the
Square Wave 175 will start a 3/32, 2% thoriated tung-
7. Set the Current Control on the control panel to the sten electrode at 15 amperes provided the electrode
maximum desired amps. tip is properly grounded and not contaminated.
8. Depress the Foot Amptrol to energize the torch and BENEFITS OF THE SQUARE WAVE DESIGN
establish an an arc with the work piece.
In AC TIG welding of aluminum, the positive portion of the AC
NOTE: When the TIG/STICK switch is set to “TIG�, wave provides cleaning (removal of aluminum oxide) of the
depressing the remote control will start a 0.5 second gas work piece. This is desirable on materials with a heavy oxide
pre-flow before energizing the TIG torch. When the remote coating such as aluminum. However the positive portion may
control is released the TIG torch is de-energized and gas also cause the electrode to overheat at high currents causing
flow will continue for a 15 second post flow. When the “tungsten spitting�. The negative portion of the AC wave offers
polarity switch is set to DC, the TIG Arc Starter will turn on no cleaning action but concentrates more heat on the work.
and off automatically to start and stabilize the arc. In AC The AC waveform of the Square Wave TIG 175 optimizes
the TIG Arc Starter will turn on with the output and remain cleaning and heating of the work. The result is the capability
on continuously until the remote control is released.
SQUARE WAVE TIG 175
9 9
OPERATION
to weld through the complete range of 10 to 175 amperes in
WARNING
AC TIG or DC- TIG requiring only one electrode, a 3/32� 2%
thoriated tungsten.
In Stick Mode the output terminal and
WELDING IN STICK MODE electrode will be electrically hot
whenever the power switch is turned
1. Put the electrode holder and cable quick connect
on.
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.
2. Set the TIG/STICK switch to “STICK�. 7. Strike an arc and weld.
3. Set the Polarity Switch for the type of electrode NOTE: When the TIG/STICK switch is set to “STICK�
being used (most commonly DC+). the output is always on when the power switch is on. A
remote control has no effect on the welding current and
4. Place the electrode in the electrode holder. the gas flow and high frequency TIG arc starter are dis-
abled.
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 POLARITY 3/32" 1/8" 5/32"
Fleetweld 5P, Fleetweld 5P+ DC+ 40 - 70 75 - 130 90 - 175
Fleetweld 180 DC+ 40 - 80 55 - 110 105 - 135
Fleetweld 37 DC+ 70 - 95 100 - 135 145 - Max
Fleetweld 47 DC- 75 - 95 100 - 145 135 - Max
Jet-LH MR DC+ 85 - 110 110 - 160 130 - Max
Blue Max Stainless DC+ 40 - 80 75 - 110 95 - 110
Red Baron Stainless DC+ 40 - 70 60 - 100 90 - 140
Mild steel procedures are based on recommended procedures listed in C2.10 8/94 and the maximum rating of the 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 DC- AC Approximate Argon
Electrode Tip Prepration Sharpened Balled Gas Flow Rate
EWZr C.F.H. (l/min.)
Electrode Type
EWTh-1, EWCe-2 EWTh-1, EWTh-2
EWTh-2, EWLa-1 EWP EWCe-2, EWLa-1 Stainless
Electrode Size (in.) EWG EWG Aluminum Steel
.010 Up to 15 A. Up to 10 A. Up to 15 A. 3-8 (2-4) 3-8 (2-4)
.020 Up to 15 A. Up to 15 A. Up to 20 A. 5-10 (3-5) 5-10 (3-5)
.040 Up to 80 A. Up to 40 A. Up to 60 A. 5-10 (3-5) 5-10 (3-5)
1/16 Up to 150 A. Up to 100 A. Up to 130 A. 5-10 (3-5) 9-13 (4-6)
3/32 Up to MAX. A. Up to 160 A. Up to MAX. A. 13-17 (6-8) 11-15 (5-7)
1/8 X Up to MAX. A. X 15-23 (7-11) 11-15 (5-7)
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure ..................................EWP ........green
+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
10 10
ACCESSORIES
OPTIONAL ACCESSORIES
TIG Torch Parts Kits - Parts kits are available for the
K964-1 Undercarriage with Pivoting Single Gas
LA-9 and LA-17 TIG torches. These kits include back
Cylinder Platform - This undercarriage features a piv-
cap, collets, collet bodies, nozzles and tungstens.
oting platform to easily load and unload the gas cylin-
Order KP507 for LA-9 torches
der without lifting. It was designed specifically for the
Order KP508 for LA-17 torches
Square Wave TIG 175 power source, and accommo-
See publication E12.150 for parts kits breakdown.
dates 7� to 9 1/4� diameter gas cylinders. The under-
Cut Length Consumables - TIG welding filler metals
carriage comes completely assembled and mounts
are available for welding stainless steel, mild steel, alu-
directly to the power source.
minum and copper alloys. See publication C9.10.
tm
K812 Hand Amptrol - A Lincoln Foot Amptrol is
included with the Square Wave TIG 175 for remote cur-
rent control while TIG welding. The K812 Hand
Amptrol may be used in place of the Foot Amptrol if a
thumb operated remote control is desired.
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 welding at
the current set by the Current Control on the control
panel. The Arc Start Switch does not provide remote
current control.
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 LA-9 12.5 ft medium back cap
� K859-5 LA-9 25 ft medium back cap
� K860-1 LA-17 12.5 ft long back cap
� K860-5 LA-17 25 ft long back cap
NOTE: Each torch requires a quick connector 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.
Quick Connect Plug (S22529-1) and Strain Relief
Boot (M17255) - One of each is shipped with the
welder to connect the Magnum LA-9 torch. If you do
not care to interchange these parts between torches
(one of each is required to connect Magnum LA-9 or
LA-17 TIG torches with one-piece cable to the Square
Wave TIG 175) you may order additional sets. The
quick connect plug provides connection for both gas
and welding current.
Tungstens, Collets, Collet Holders, Gas Cups,
Backcaps and Other Torch Parts - A Lincoln Magnum
LA-9 with 12.5 ft. one-piece cable is included with the
Square Wave TIG 175. Standard Magnum® parts and
accessories for this torch may be used.
SQUARE WAVE TIG 175
11 11
MAINTENANCE
SAFETY PRECAUTIONS 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-
WARNING turb the factory setting.
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
10. Verify that the machine and welding circuit is prop-
disconnect switch or fuse box
erly grounded.
before working on this
equipment.
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
FAN MOTOR OR FAN BLADE REPLACEMENT
� Rectifier Assembly
� Arc Starter/Spark Gap Assembly
When installing a new fan blade or fan motor be sure
� PC Boards
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
.30
0.015 inch. It typically will not require periodic
maintenance. Refinishing the contacts is not rec- Figure C.2
SQUARE WAVE TIG 175
12 12
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 Step 3. RECOMMENDED COURSE OF
(SYMPTOMS)�. This column describes pos- ACTION
sible symptoms that the machine may exhib-
it. Find the listing that best describes the If you have exhausted all of the items in step
symptom that the machine is exhibiting. 2. Contact your Local Lincoln Authorized
Symptoms are grouped into the following Field Service Facility.
categories: output problems, function prob-
lems, TIG mode problems, TIG welding prob-
lems and Stick welding Problems.
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.
SQUARE WAVE TIG 175
13 13
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
OUTPUT PROBLEMS
Machine is Dead - 1. Make certain that the input
No Output - No Fan 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
2. Check to make sure polarity
troubleshooting assistance.
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 exceed the recommended duty
yellow light on the control panel is cycle. Allow the unit to run until
on. 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 the TIG Mode.
circuit voltage) when arc start switch
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
14 14
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
OUTPUT PROBLEMS
Machine regularly over heats - ther- 1. Welding application may
mostat opens, Yellow light on front exceed recommended duty
panel glows. The fan runs but cycle. Reduce the duty cycle.
machine has no output.
2. Dirt and dust may have
clogged the cooling channels
Contact your Local Lincoln Authorized
inside the machine. Blow out
Field Service Facility for technical
unit with clean, dry
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.
SQUARE WAVE TIG 175
15 15
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
TIG MODE PROBLEMS
Machine output is intermittently lost. 1. Problem may be caused by high
Gas flow and high frequency are frequency interference. Make
also interrupted. 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
welding in DC - mode.
Field Service Facility for technical
3. Gas shielding may be insuffi- troubleshooting assistance.
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
Arc “Pulsates� when AC TIG
Switch is not opening in “AC� mode.
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.
SQUARE WAVE TIG 175
APR96
16 16
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) 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.
Weak high frequency - machine has 1. Check for poor connections in
the welding circuit.
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 Contact your Local Lincoln Authorized
cables in poor condition allowing
Field Service Facility for technical
high frequency to “Leak Off�.
troubleshooting assistance.
4. Keep cables as short as possible.
5. Check Spark Gap operation and
setting (0.015�)
High frequency “spark� is present at 1. The tungsten electrode may be
contaminated. Replace or sharp-
tungsten electrode, but operator is
en.
unable to establish a welding arc.
Machine has normal open circuit 2. The current control may be set
too low.
voltage (refer to Technical
Specifications in the Installation
3. The tungsten electrode may be
Chapter). 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.
SQUARE WAVE TIG 175
17 17
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
TIG WELDING PROBLEMS
No high frequency. Machine is in 1. If the machine location is in a
the TIG Mode and has normal out- highly dirty environment with
put. 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 turned on.
output - fan runs. A “Click� can be
heard indicating that the gas sole- 2. Flow regulator may be set too
noid 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.
Contact your Local Lincoln Authorized
Field Service Facility for technical
5. Consult your local welder/gas
troubleshooting assistance.
distributor.
When AC TIG welding, the arc is 1. Tungsten electrode may be too
erratic and there is a loss of “clean- small for process. Use a larger
ing� of the work piece. 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 1. The welding current is too high
melts away. 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.
SQUARE WAVE TIG 175
18 18
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) 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 1. The weld current may be set too Contact your Local Lincoln Authorized
puddle. 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.
SQUARE WAVE TIG 175
19
WIRING DIAGRAM - SQUARE WAVE TIG 175 (208/ 230/ 1/ 60)
H3 (230V)
VOLTAGE RECONNECTION
H2 (208V)
230 VOLT CONNECTION (AS SHOWN)
H2
H1
H1 and H3 TO POWER SWITCH. H1
H3
R 209 W X3
H2 NOT CONNECTED; INSULATE. T1
S
18VAC
208 VOLT CONNECTION
F
U 210 B X4
H1 and H2 TO POWER SWITCH.
W 221 X1
W 201 W X5 S
H3 NOT CONNECTED: INSULATE. C1 C2 R 222
18VAC 78VAC
C1 AND C2 MUST ALWAYS BE
F
W 204 W X6 X2
CONNECTED ACROSS POWER SWITCH. (-)
B 230 B X7
220
115VAC
115VAC
FAN
B X8
L1 B 232
SCR1
L2
G1 B
INPUT PLUG
217
SCR2
L1
G2
POLARITY SWITCH MICRO SWITCH
TO GROUND PER
218 AC A-C, D-E, B-F OPEN
NATIONAL ELECTRICAL CODE DC+ B-D, C-E, A-F, G-H CLOSED
DC- B-D, A-E, C-F, G-H CLOSED
(+)
FRONT GANG
D
S2A NO
G3
H
L2 E NC
A
SCR3
TOROID
G
F
216 C
G4 POS
POWER "ON" LIGHT B X1
314 SCR4
G4
216
220
G3
G2
218
G1
217
R 222 (-)
W 221 (+)
313
231 W
(-)
S2
PL1
233
POLARITY
(REAR VIEW,
D1 SWITCH
CURRENT CONTROL
SHOWN IN AC POSITION)
J1 J2
J3 R1
R2
277
312
B
B
276
244
311 275
242
J4 STICK BYPASS/
SQUARE WAVE TIG 175
241 STABILIZER
S3
233 PC BOARD
243
MODE SWITCH
275
WIRING DIAGRAM
( STICK - CLOSED
231
TIG - OPEN )
276
244
243
277
TIG
THERMAL LIGHT
S L3
R 241 C3
Y
SPARK
115VAC T3 T4
GAP
TL1
B 242
F
J6 E L4
A A
D
B B 237
J5 ARC STARTER AS’BLY
C C C
A D D
R3 C4
B
10K A-B
E E
AT MINIMUM
F
236B
236
235
234
238
232
230
210
209
W 201
W 204
B
B
U
R
REMOTE REMOTE
236A
TM
RECEPTACLE AMPTROL
238
236 236A
SV1
J4
234
235
ELECTRICAL SYMBOLS PER E1537. 7-12-96
L10060
19
20
WIRING DIAGRAM - SQUARE WAVE TIG 175 (460/575/1/60)
H3 (575V)
VOLTAGE RECONNECTION
H2 (460V)
575 VOLT CONNECTION (AS SHOWN)
H2
H1
H1 and H3 TO POWER SWITCH. H1
H3
R 209 W X3
H2 NOT CONNECTED; INSULATE. T1
S
18VAC
460 VOLT CONNECTION
F
U 210 B X4
H1 and H2 TO POWER SWITCH.
W 221 X1
W 201 W X5 S
H3 NOT CONNECTED: INSULATE. C1 C2 R 222
18VAC 78VAC
C1 AND C2 MUST ALWAYS BE
F
W 204 W X6 X2
CONNECTED ACROSS POWER SWITCH. (-)
B 230 B X7
220
115VAC
115VAC
FAN
B X8
L1 B 232
SCR1
L2
G1 B
217
{
SCR2
L1
G2
POLARITY SWITCH MICRO SWITCH
218 AC A-C, D-E, B-F OPEN
DC+ B-D, C-E, A-F, G-H CLOSED
DC- B-D, A-E, C-F, G-H CLOSED
(+)
FRONT GANG
D
S2A NO
G3
H
L2 E NC
A
SCR3
TOROID
G
F
216 C
G4 POS
POWER "ON" LIGHT B X1
314 SCR4
G4
216
220
G3
G2
218
G1
217
R 222 (-)
W 221 (+)
313
231 W
(-)
S2
PL1
233
POLARITY
(REAR VIEW,
D1 SWITCH
CURRENT CONTROL
SHOWN IN AC POSITION)
J1 J2
J3 R1
R2
277
312
B
B
276
244
311 275
242
J4 STICK
SQUARE WAVE TIG 175
BYPASS/
241 STABILIZER
S3
233 PC BOARD
243
MODE SWITCH
275
WIRING DIAGRAM
( STICK - CLOSED
231
TIG - OPEN )
276
244
243
277
TIG
THERMAL LIGHT
S L3
R 241 C3
Y
SPARK
115VAC T3 T4
GAP
TL1
B 242
F
J6 E L4
A A
D
B B 237
J5 ARC STARTER AS’BLY
C C C
A D D
R3 C4
B
10K A-B
E E
AT MINIMUM
F
236B
236
235
234
238
232
230
210
209
W 201
W 204
B
B
U
R
REMOTE REMOTE
236A
TM
RECEPTACLE AMPTROL
238
236 236A
SV1
J4
234
235
ELECTRICAL SYMBOLS PER E1537. B
20
L10569
NOTES
SQUARE WAVE TIG 175
Now Available...12th Edition New Lessons in Arc Welding
The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects, such
since 1933, the Procedure Handbook is considered by many to as distortion; and supplemental information on arc welding
be the “Bible� of the arc welding industry. applications, speeds and costs. Practice materials, exercises,
questions and answers are suggested for each
This printing will go fast so don’t delay. Place your
lesson.
order now using the coupon below.
528 pages, well illustrated, 6� x 9� size, bound in simulated,
The hardbound book contains over 750 pages of welding infor-
gold embossed leather.
mation, techniques and procedures. Much of this material
$5.00 postage paid U.S.A. Mainland
has never been included in any other book.
A must for all welders, supervisors, engineers and
designers. Many welding instructors will want to use the book as
a reference for all students by taking advantage of the low quan-
tity discount prices which include shipping by
4th class parcel post.
$15.00 postage paid U.S.A. Mainland
Need Welding Training?
The Lincoln Electric Company operates the oldest and
most respected Arc Welding School in the United States at its
How To Read Shop Drawings
corporate headquarters in Cleveland, Ohio. Over 100,000 students
have graduated. Tuition is low and the training is
The book contains the latest information and application
“hands on�
data on the American Welding Society Standard Welding
For details write: Lincoln Welding School
Symbols. Detailed discussion tells how engineers and drafts-
22801 St. Clair Ave.
men use the “short-cut� language of symbols to pass on
assembly and welding information to shop personnel. Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability and ask for bulletin ED-80 or call 216-383-2259 and ask for the
to visualize mechanically drawn objects as they will appear in Welding School Registrar.
their assembled form.
187 pages with more than 100 illustrations. Size 8-1/2� x 11� Lincoln Welding School
Durable, cloth-covered board binding. BASIC COURSE $700.00
$4.50 postage paid U.S.A. Mainland 5 weeks of fundamentals
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
$5.00 For order value up to $49.99
$10.00 For order value between $50.00 & $99.99
$15.00 For order value between $100.00 & $149.00
For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders) Name: _______________________________________________
CHECK ONE:
Address: _______________________________________________
Please Invoice (only if order is over $50.00)
_______________________________________________
Check or Money Order Enclosed, U.S. Funds only
Credit Card - Telephone: _______________________________________________
VISA MasterCard
®
®
Signature as it appears on Charge Card:
|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| |_|_| |_|_|
Account No. Exp Date
______________________
AMERICAN EXPRESS
MasterCard
Month Year
AMERICAN EXPRESS
USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
BOOKS OR FREE INFORMATIVE CATALOGS
Lincoln Welding School Titles: Price Code Quantity Cost
(ED-80) New Lessons in Arc Welding $5.00 L
Seminar Information Procedure Handbook “Twelfth Edition� $15.00 PH
(ED-45) How to Read Shop Drawings $4.50 H
Educational Video Information Incentive Management $5.00 IM
(ED-93) A New Approach to Industrial Economics $5.00 NA
James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Foundation Book Information Welding Preheat Calculator $3.00 WC-8
(JFLF-515) Pipe Welding Charts $4.50 ED-89
SUB TOTAL
Additional Shipping Costs if any
TOTAL COST
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
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 UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� 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
|