Lincoln Electric IM607 User's Manual
Contents
1. 1 SELEGT SUITABLE LOCATION 2 STACKING 2 LIFTING MOVING 2 niece 2 ENVIRONMENTAL RATING x tos eas 2 MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION 2 INPUT CONNECTIONS ct ctt ncs us deerat evo ege mne 3 INPUT RECONNECT PROCEDURE is 3 OUTPUT CONNEC MONS ethics dedos p 4 CONNECTIONS FOR TIG GTAW 4 TIG TORGH CONNECTION Popes tete nee erbe ren essent en 4 WORK CABLE CONNECTION nnne nr nnn 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 onec cu 6 SAFETY PRECAUTIONS cett nee be esse nie serein tante 6 GENERAL DESGRIPTION 6 INCLUDED EQUIPMENT ctt rper ns 6 FOR TIG 6 FOR SMAW STICK WELDING iii 6 F2. pep HA HAA BPs BEC ET alal gl illai aul Gud al oig Gail guet Gras LINCOLN B 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
3. SMAW 25 Duty Cycle 26 0 V AC DC 40 Duty Cycle 25 0 V AC DC 60 Duty Cycle 24 4 V AC DC 100 Duty Cycle 23 4 V AC DC OUTPUT Maximum Open Output Current Circuit Voltage Type of Output Range STICK AND CC Constant Current 10 175 Amps AC OCV 78 AC DC AC and DC DC OCV 64 RECOMMENDED INPUT WIRE AND FUSE SIZES 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 Fuse Input 75 C Copper Ground Fuse Input Type 75 C Copper Ground Voltage Super Lag Ampere Copper Wire Wire in Super Lag Ampere Copper Wire in Wire in phase or Breaker Rating on Conduit AWG Conduit AWG or Breaker Rating Conduit AWG Conduit AWG Frequency Size Nameplate Sizes i i oe Sizes Sizes zono we s 10 s LEE UNE UNT LS RN Lans PHYSICAL DIMENSIONS Height Width Depth Weight 19 53 in 13 72 in 24 94 in Approx 200 Ibs 496 mm 349 mm 633 mm 90 9 kgs Power Source 27 93 in 19 22 in 36 74 in Approx 230 lbs on 709 mm 488 mm 933 mm 105 kgs Undercarriage SQUARE WAVE TIG 175 LINCOLN 2 INSTALLATION Read entire installation se
4. SQUARE WAVE TIG 175 LINCOLN 10 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 WELDING IN STICK MODE 1 Put the electrode holder and cable quick connect plug into the electrode output receptacle Turn clock wise until tight Connect the work clamp to the work piece 2 Set the TIG STICK switch to STICK 3 Set the Polarity Switch for the type of electrode being used most commonly DC OPERATION 10 A 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 6 Adjust the Current Control to the desired amps 7 Strike an arc and weld NOTE When the TIG STICK switch is set to STICK the output is always on when the power switch is on A remote control has no effect on the welding current and the gas flow and high frequency TIG arc starter are dis abled RECOMMENDED ELECTRODE AMPERAGE RANGES SQUARE WAVE TIG 175 The Square Wav
5. 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 8 Inspect gas hose and inlet fitting for cracks or leaks 9 Replace any unreadable labels or decals 10 Verify that the machine and welding circuit is prop erly grounded FIGURE C 1 SPARK GAP lx 015 Spark Gap LEFT SIDE OF MACHINE FAN MOTOR OR FAN BLADE REPLACEMENT When installing a new fan blade or fan motor be sure to maintain proper shaft spacing per Figure C 2 below 30 Figure C 2 SQUARE WAVE TIG 175 LINCOLN TROUBLESHOOTING 15 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 ex
6. A h bo Y 21 H 13 76 11 50 CENTERED 19 22 19 53 25 19 23 28 SQUARE WAVE TIG 175 LINCOLN 27 93 10 00 NOTES SQUARE WAVE TIG 175 LINCOLN NOTES SQUARE WAVE TIG 175 LINCOLN Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding infor mation techniques and procedures Much of this material 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 How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symb
7. American Welding Society AWS ul M green 1 Thoria yellow 2 Thoria red 2 2 0range 41 596 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 LINCOLN 11 ACCESSORIES 11 OPTIONAL ACCESSORIES 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 K870 Foot Amptrol 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 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 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
8. Avenue Cleveland Ohio 44117 1199 looks OR FREE INFORMATIVE CATALOGS Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Welding School Titles 1 Price Code Quantity Cost 559 New Lessons in Arc Welding 5500 Seminar Information Procedure Handbook Twelfth Edition 15 00 PH 1 ED 45 How to Read Shop Drawings Educational Video Information Incentive Management 5 00 EH ED 93 A New Approach to Industrial Economics ames Lincoln Arc Welding e American Century of John Lincoln 55 00 __ Foundation Book Information Welding Preheat Calculator 3 00 1 JFLF 515 Pipe Welding Charts SUB Additional Shipping Costs ifany TOTAL 5 el WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teil
9. 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 amp Number Code amp 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 A 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 TABLE CONTENTS Page SAFETY c i iv INSTALLATION SECTION scesceecenseensennenncenceeeeesseneeensnnnnancenseessessesesensnnenanaeneees 1 TECHNICAL SPECIFICATIONS
10. 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 AC the TIG Arc Starter will turn on With the output and remain on continuously until the remote control is released WELDING IN TIG MODE 4 STEP In 4 STEP mode an Arc Start switch 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 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 STEP 2 First Release The output ramps up to the preset level in 0 5 seconds SQUARE WAVE TIG 175 LINCOLN 9 OPERATION 9 STEP 3 Second Press The output ramps down to the level set with the Start Crater Curre
11. 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 Refer to the Technical Specifications page at the beginning of this section Fuse the input circuit with the recommended super lag fuses or delay type circuit breakers 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 1Also 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 CAUTION 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 A WARNING ELECTRIC SHOCK can kill e Turn the input power OFF at the disconnect switch or fuse box before working on this equipment For 220 240V connection Refer to figure A 1 and INPUT SUPPLY CONNECTIONS different cord connector must be o
12. possi ble Flexible metallic conduit is generally not suit able 8 When the welder is enclosed in a metal building the metal building should be connected to several good earth driven electrical grounds as in 5 b above around the periphery of the building 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 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 Connect terminal marked to earth ground per National Electric Code or any local codes 2 Connect the supply lines the line switch terminals as shown in figure A 1 3 Install in accordance with all local and national electrical codes 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
13. 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 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 on with the output and remain on continuously until the remote control is released REMOTE CONTROL OPERATION A Foot Amptrol is included with the Square Wave TIG 175 for remote current control while TIG welding An optional Hand Amptrol may also be used An optional Arc Start Switch may be used to start and stop the welding if no remote control of the current is desired Refer to the Accessories section of this manual Both the Hand and Foot Amptrol work in a similar 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 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 ac
14. 7 OIL 43150 INdLNO viv aid 8 2 6 2 AL E leZ 1N3Uuno 40801 H3LVHO LHVLS Sec vec LAS 5 9 Q4VO8 8x4 OVAS LL oza XM 0c M OVA8L SX M 102 M YX8 e 0 20 OVASE 0408 04 SSVdA8 Ova 77 093 HILIMS u3MOd i cH LV LSOWYSHL YANISLVSH 825 HOLIMS H3MOd SSOH9Y Q3103NNOO 38 SAVMTV 15 Od SSVdAg SLOAN N3LHOIL OL GALS HOLIMS H3MOd 339909 193NNOO NOLLO3NNOO LIOA 070 SLAN N3LHOIL OL GALS HOLIMS U3MOd 084 YANIT H3ddO9 LOANNOD NOILOANNOO LIOA 086 SLNN NALHOLL PH OL 0015 HOLIMS HAMOd NIT 334409 LOINNOOD NMOHS SY NOLLOANNOO 170A 917 NOLLO3NNOO3U NMOHS SV HOLIMS 30 401 3Hl 01 S3HIM OML 1 123 02 53002 1v2IlH12313 W301 TIYNOILVN H3d 3NIHOVW 09 0S 1 G1t 08 0 2 921 DIL 3AVM 34VNOS ONIHIM SQUARE WAVE TIG 175 21 DIMENSION PRINT 0 8 aA a s Sa 7 E i Vesa e e E M o T WJ D f A d
15. ES 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 UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Turn power off before servicing Do not operate with panel open or Use ventilation or exhaust to guards off remove fumes from breathing zone WA R N G Los humos fuera de la zona de res e Desconectar el cable de ali No operar con panel abierto Spanish Hs a calea urie ie mentaci n de poder de la m quina guardas quitadas AVISO D E humos Utilice ventilaci n 0 antes de iniciar cualquier servicio PRECAUCION aspiraci n para gases Gardez la t te l cart des fum es D branchez le courant avant l entre N op rez pas avec les panneaux French Utilisez un ventilateur ou un aspira tien ouverts ou avec les dispositifs de teur pour ter les fum es des zones protection enlev s ATT de travail Vermeiden Sie das Einatmen von Strom vor Wartungsarbeiten Anlage nie ohne Schutzgeh use German Schweibrauch abschalten N
16. LD 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 amp Cutting ANSI Standard 749 1 from the American Welding Society 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running cm 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 6 Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 a MAGNETIC FIELDS 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 ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric c
17. NTS S COURSE OF ACTION TIG WELDING PROBLEMS Black areas along weld bead Weak high frequency machine has normal welding output 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 Clean any oily or organic conta mination from the work piece When welding aluminum clean oxide layer with a stainless steel brush Tungsten electrode may be cont aminated Replace or sharpen Check for contaminated gas or leaks in the gas line torch or connections Gas shielding may be insuffi cient Increase gas flow reduce tungsten stickout beyond gas cup Check for poor connections in the welding circuit Gas shielding may be insuffi cient Increase gas flow reduce tungsten stickout beyond gas Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance Check for work and electrode cables in poor condition allowing high frequency to Leak Off Keep cables as short as possible Check Spark Gap operation and setting 0 015 The tungsten electrode may be contaminated Replace or sharp en The current control may be set too low The tungsten electrode may be too large for the process If a helium blend is used as a shielding gas then reduce the percentage of helium If in 4 Step TIG
18. OR INSTALLATION AND STARTUP 6 WELDING CAPABILITY rn eei teo ico i anes 6 CONTROLS AND SETTINGS 7 OPERATING STEPS 8 WELDING IN TIG MODE 2 STEP 8 WELDING TIG MODE 4 5 cns 8 REMOTE CONTROL OPERATION 9 BENEFITS OF THE SQUARE WAVE DESIGN 9 WELDING IN STICK MODE 10 ACCESSORIES SEGCTIQN errori nn nn een energies 11 MAINTENANCE 12 TROUBLESHOOTING 13 DIAGRAM 5 H 20 WIRING DIAGRAM ei es ette e reote 20 DIMENSION PRINT 21 PARTS LISTS uec rennes 281 SERIES P210 F P66 J LINCOLN 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS Square Wave TIG 175 K1583 1 only INPUT SINGLE PHASE ONLY Standard Input Current at Voltage Rated Output 240 380 415 1 50 60 54 33 30 AC DC Stick amp DC TIG 71 41 37 AC TIG Additional Lincoln Rating 220 240 400 415 1 50 60 54 30 AC DC Stick amp DC TIG 71 37 AC TIG RATED OUTPUT Duty Cycle Volts at Rated Amperes GTAW 25 Duty Cycle 16 0 V AC DC 40 Duty Cycle 15 0 V AC DC 60 Duty Cycle 14 4 V AC DC 100 Duty Cycle 13 4 V AC DC
19. RETURN TO MAIN MENU IM607 Square Wave TIG 1 75 oe 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 LSS EEE SSE LINCOLN 5 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 216 486 1751 WEB SITE www lincolnelectric com SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS For Diesel Engines Diesel engine exhaust and For Gasoline Engines The engine exhaust from some of its constituents are known to the State this product contains chemicals known to the of California to cause cancer birth defects and State of California to cause cancer birth defects other reproductive harm or other reproductive harm ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOU
20. ainless steel mild steel alu minum and copper alloys See publication C9 10 SQUARE WAVE TIG 175 LINCOLN 12 MAINTENANCE 12 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this maintenance Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts WARNING To avoid receiving a high frequency shock keep the TIG torch and cables in good condition ROUTINE AND PERIODIC MAINTENANCE 1 Disconnect power supply lines to machine before performing periodic maintenance 2 Periodically clean the inside of the machine with a low pressure air system Be sure to clean the following components thoroughly Main Transformer Electrode Gas Output Receptacle Polarity Switch Rectifier Assembly Arc Starter Spark Gap Assembly PC Boards Fan Blades 3 Inspect welder output and control cables for fraying cuts and bare spots 4 Keep 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 ommended If the contacts are replaced reset the gap spacing to 0 015 Refer to figure C 1 Note in
21. ak 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 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 2 Set the MODE switch to 2 STEP TIG 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 5 Turn on the cylinder gas valve and adjust the flow regulator to obtain 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 8 Depress the Arc Start Switch or amptrol to energize the torch and establish an an arc with the work piece 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
22. ante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place LINCOLN V V for selecting a QUALITY product by Lincoln Electric We you ank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please
23. 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 LINCOLN WIRING DIAGRAM 20 20 808011 716913 339 STOSWAS 1991819373 03908 24 NO HOI23NNOO 30 0123 02 40 2 SI SIHI 3 1dAVX3 SH38WTIN 80123 02 5110 0 4 034 4 15401199495 MOTTIA A 39NYHO O SILVM SWHO 3LIHM M N3382 9 bbc rS 3n ig n 18 8 IN3NOdWO3 3002 9 0102 Qv31 31 14917 1vWH3HL YJNYOJSNYHL_ 03H4 IH u3NHOJSNVHI 39VLIOA YAWYOSSNVYL NIV QVASII 010 3105 Sv9 5535 NIV HOLIMS ALIHYT0d NO HOLIMSOUSIN 3401S NMOG IN3HHNI YSLVYD 14715 001 002 YOLSISSY LAHS dSVHd 001 0G YOLSISSY 9NIQIOH HAL ANOIINALOd 1081403 1 38 DVAGII LHII NO YAMOd 54012 0 0383 IH 10301 340HJ N0ILJJLOYd 0383 3YX0H9 YOLINGNI LAdLNO LSV4 VS ISNA 30010 9NIT33HM 3383 2 062 315 1465 3SvHd AMZI SIOO 0127472 39V170A HIH 3004123130 Od rivis SSVdAd AT8 SV HALYVLS 3719143939 SLOWSY 310N3H WAWININ 1v 7 Ov NI NMOHS 0385010 49 035019 rv NadO 44 HOLIMS OHOIN HOLIMS MAIA 434 HOLIMS ALIHVIOd OLS OIL 4315
24. atic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 6 Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch t
25. btained when connecting to this voltage 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 4 Replace sheet metal cover and all screws For 380V connection Refer to figure A 1 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 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 4 Replace sheet metal cover and all screws SQUARE WAVE TIG 175 LINCOLN INPUT LEADS L1 amp L2 SIL connection 47 7 REP a N u 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 OUTPUT CONNECTIONS 29 H4 ELECTRODE GAS OUTLET RECEPTACLE 0 WORK CABLE amp CLAMP FIGURE A2 Location of Output Connections CONNECTIONS FOR TIG WELDING TIG TORCH CONNECTION The Square Wave TIG 175 is supplied
26. ci 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 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 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
27. ct entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des proj
28. cted to the welder and is connected to the work piece to complete the welding circuit Refer to Machine Grounding and High Frequency Interference Protection the Installation section of this manual for the proper procedure on ground ing the work clamp and work piece to minimize high frequency interference REMOTE CONTROL CONNECTOR This connector provides connection for a remote control See Remote Control Operation in this section of the manual 5 OVER TEMPERATURE LIGHT E If the welder overheats due to blocked air flow high ambient air temperature or exceeded duty cycle an internal thermostat will open disabling the welding output and this yellow light will illuminate The cooling fans will continue to run to cool the unit during this time The light will go out when the unit cools and the thermostat resets 6 POLARITY SWITCH Allows you to select between welding in AC DC orDC polar ity In DC polarity the electrode is positive and the work clamp is negative Use DC for most stick welding In DC the electrode is negative and the work clamp is positive Use DC for TIG welding stainless steel and mild steel AC polarity is recom mended for TIG welding aluminum CAUTION Do not switch the polarity switch while Q welding or damage may result to the machine SQUARE WAVE TIG 175 LINCOLN 8 OPERATION 8 7 MODE SWITCH A three position toggle switch used to select th
29. ction before starting installation Safety Precautions WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse box before working on this equipment 0 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 SELECT SUITABLE LOCATION 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 STACKING 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 TILTING Each machine must be placed on a secure level surface either directly or on a recommended undercarriage The machine may topple over if this procedure is not followed ENVIRONMENTAL RATING The Square Wave TIG 175 power source carries an IP21 environmenta
30. cylinder eKeep cylinder away from live electrical circuits Maximum inlet pressure 150 psi 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 cylinders 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 SQUARE WAVE TIG 175 LINCOLN 5 INSTALLATION REMOTE CONTROL CONNECTION 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 SQUARE WAVE TIG 175 LINCOLN 6 OPERATION 6 SAFETY PRECAUTIONS Read and understand th
31. de holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 iv SAFETY iv PR CAUTIONS SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout conta
32. e 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 Fectode PS ewin1 EWCe2 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
33. e 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 Check Amptrol for proper opera tion and loose connections Check for proper input voltage and proper voltage reconnec tion Arc Flutters when TIG welding Tungsten electrode may be too large in diameter for the current setting Tungsten not sharp when welding in DC mode Contact your Local Lincoln Authorized Field Service Facility for technical Gas shielding be insuffi troubleshooting assistance cient Increase gas flow reduce tungsten stickout beyond gas cup Check for contaminated gas or leaks in the gas line torch or connections 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 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 TROUBLESHOOTING 17 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTME
34. e oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra e REPOR 7 amp nf dchsn zucct MLMPT APSSAPREBS FSU e E UD TERRE RR E SPR 9e f KE C EUNT PETER eru SUSS Xe e AXE endi slay ay SN gh iL e deua Vile uao Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e naedoe6 0o08 CIE REA SEL IF eis A Jo ALD al pis Ac AI Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo HAUSHERMRELTTF HRSESOREME ez 119 59 s ESSAI dise ule vues al ad ne 4 aun y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTIC
35. e 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 T 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 0 2 STEP TIG This mode is used for the TIG I 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 4 STEP TIG This mode is used for the TIG welding process An Arc Start switch or Amptrol must be used All controls are active in this mode 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 Amptrol will adjust the welding current from the machine mini mum to this maximum setting 9 DOWN SLOPE TIME This control is active in the 4 It is used to set the amount Ju TIG mode only of time the output takes to go from the preset level to A the Crater current level The adjustable range is approximately 0 5 to 10 seconds 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 pe
36. ections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffis
37. een this conduit and the welder case ground Both ends of the conduit should be connected to a driven ground and the entire length should be continuous 2 Keep the work and electrode leads as short as pos sible and as close together as possible Lengths should not exceed 25 ft 7 6m Tape the leads together when practical 3 Be sure the torch and work cable rubber coverings are free of cuts and cracks that allow high frequen cy leakage 4 Keep the torch in good repair and all connections tight to reduce high frequency leakage 5 The work piece must be connected to an earth ground close to the work clamp using one of the fol lowing methods a metal underground water pipe in direct contact with the earth for ten feet or more SQUARE WAVE TIG 175 LINCOLN 3 INSTALLATION 3 b 3 4 19mm galvanized pipe 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 6 Keep cover and all screws securely in place 7 Electrical conductors within 50 ft 15 2m of the welder should be enclosed in grounded rigid metal lic conduit or equivalent shielding wherever
38. etzstrom v llig ff oder Innenschutzverkleidung in Sorgen Sie fiir gute Be und nen Maschine anhalten Betrieb setzen WAR N U N G Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaga ma ang com as tampas removidas Mantenha se afastado das partes Portuguese _ Use ventila o exhaust o para Desligue a corrente antes de fazer moventes remover fumo da zona respirat ria servi o N o opere com os paineis abertos ATE toque as partes el tricas nuas ou guardas removidas e FHR 4 UAUNUD enivehnn tEusurzx Panes FERA FE L e EE UR 24752 AAS ero 921 Asal 5 87 8 21 AH 794714 7 ABHA alaa oe daly su Giles Juill ail AREY hil lu Qin y e of aal Ale Cut gl Ait oe LEIA COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO AS PARTES DE USO SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR SRM OBHOX HD OHRBEE lt K MRA CL TRHORERMEI HS ET AIL BE Rr de OE D S
39. gistrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals Ex MEE RARE 700 00 lorders 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 l IP rices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS 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 amp 99 99 15 00 For order value between 100 00 amp 149 00 North America invoiced orders over 550 00 amp 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 IMETHOD OF PAYMENT Sorry No C O D Orders eee I CHECK ONE Address I Please Invoice only if order is over 550 00 Check or Money Order Enclosed U S Funds only 1 Credit Card LE Telephone _____________________________ _ Signature as it appears on Charge Card Baccount No LLL LL LI LII l DR e ne nn lyse THIS FORM TO ORDER Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair
40. he arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 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 Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS a
41. hib 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 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 Step 3 RECOMMENDED COURSE OF ACTION If you have exhausted all of the items in step 2 Contact your Local Lincoln Authorized Field Service Facility CAUTION DO NOT use a volt ohm meter to measure output voltages in 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 LINCOLN 5 14 TROUBLESHOOTING 14 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 mac
42. hine is plugged in 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 Check 5A fuse F1 located next No Fan High Frequency to the control PC board on the Lights or Gas Solenoid 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 per nameplate and voltage modes reconnection Contact your Local Lincoln Authorized Field Service Facility for technical 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 2 4 Step exceed the recommended duty modes and the yellow light on the cycle Allow the unit to run until control panel is on the fan cools the unit and the yellow light goes out Machine does not respond no gas 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 y
43. hollow castings or containers before heating cutting or welding They may explode 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 Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electro
44. 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 LA 9 12 5 ft medium back cap K859 5 LA 9 25ft medium back K860 1 LA 17 12 5ft long back cap K860 5 LA 17 25ft 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 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 Cut Length Consumables TIG welding filler metals are available for welding st
45. is entire section before operat ing the machine WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground e 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 FUMES AND GASES can be dangerous Keep your head out of fumes 3 TN 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 4 can burn Wear eye ear and body protection NM Observe additional Safety Guidelines detailed in the beginning of this manual GENERAL DESCRIPTION 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 INCLUDED EQUIPMENT For GTAW TIG Welding TIG connector Twistmate adaptor Strain relief boot For SMAW Stick Welding Electrode holder with cable and Twistma
46. l rating It may be used in normal industrial and commercial environments Avoid using it in environments which have falling water such as rain Read and follow Electric Shock Warnings in the Safety section if welding must be performed under electrically hazardous conditions such as welding in wet areas or on or in the workpiece MACHINE GROUNDING AND HIGH FRE QUENCY INTERFERENCE PROTECTION The welder must be grounded See your local and national electrical codes for proper grounding methods 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 Radiated interference can develop in the following four ways 1 Direct interference radiated from the welder 2 Direct interference radiated from the welding leads 3 Direct interference radiated from feedback into the power lines 4 Interference from re radiation of pickup by ungrounded metallic objects Keeping these contributing factors in mind installing equipment per the following instructions should mini mize problems 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 betw
47. mode the Start Crater current control may be set to low CAUTION 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 LINCOLN 18 TROUBLESHOOTING 18 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 either 2 or 4 Step TIG Mode and has normal output Fan is running and power light is on No gas flow when Amptrol is activat ed in the 2 4 Step TIG Modes Machine has output fan runs A Click can be heard indicating that the gas solenoid valve is operating When AC TIG welding the arc is erratic and there is a loss of clean ing of the work piece The end of the tungsten electrode melts away 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 Gas supply is empty or not turned on Flow regulator may be set too low Gas hose may be pinched Gas flow may be blocked with dirt Check filter screen inside gas inlet fitting to solenoid valve Use filters to prevent reoccur rence Consult your local welder gas distrib
48. nd follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Mar 95 SAFETY EU WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 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 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 Vent
49. nt control The time it takes to ramp down is set with the Down slope Time control Approx 0 5 to 10 seconds STEP 4 Second Release Output is turned off stop ping the weld and 15 second Postflow of shielding gas is applied 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 2 Set the MODE switch to 4 STEP TIG 1 3 Set the Polarity Switch to DC for welding steel stainless steel or to AC for welding aluminum 4 Connect an Arc Start switch Amptrol to the Remote Control Connector 5 Turn on the cylinder gas valve and adjust the flow regulator to obtain the desired flow 6 Turn the power switch to ON NOTE There will be a 15 second gas flow when the power is turned on 7 Set the Current Control on the control panel to the maximum desired amps 8 Set the Start Crater Current control AJ 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 t 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
50. ols Detailed discussion tells how engineers and drafts men use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland Ihere is 10 discount on all orders of 50 00 or more for shipment at one to one location _ New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 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 corporate headquarters in Cleveland Ohio Over 100 000 students have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Re
51. our Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SQUARE WAVE TIG 175 LINCOLN 15 TROUBLESHOOTING 15 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION OUTPUT PROBLEMS Welding application may exceed recommended duty cycle Reduce the duty cycle Machine regularly over heats ther 1 mostat opens Yellow light on front panel glows The fan runs but machine has no output 2 Dirt and dust may have clogged the cooling channels inside the machine Blow out unit with clean dry low pressure air Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance 3 Air intake and exhaust louvers may be blocked due to inadequate clearance around machine CAUTION 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 LINCOLN 16 TROUBLESHOOTING 16 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 ar
52. te plug For Installation and startup Work Cable and Clamp WELDING CAPABILITY The Square Wave TIG 175 is rated at 150 amps 16 volts at 2596 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 SQUARE WAVE TIG 175 LINCOLN 7 OPERATION 7 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 POWER SWITCH amp LIGHT ELECTRODE GAS OUTPUT RECEPTACLE o 9997 00 F WORK CABLE amp CLAMP REMOTE CONTROL CONNECTOR OVER TEMPERATURE LIGHT POLARITY SWITCH MODE SWITCH CURRENT CONTROL DOWNSLOPE TIME 0 START CRATER CURRENT POWER SWITCH amp LIGHT Turns power or off the welder When switched ON the cool ing fan runs and the white light will illuminate indi cating that the power is on 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 WORK CABLE This work cable is factory con ne
53. trode cable is on your right side the work cable should also be on your right side AY 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 2 d 5 Do not work next to welding power source Mar 95 LINCOLN B SAFETY ELECTRIC SHOCK can kill 8 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautom
54. urrent flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in posi tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 In some cases it may be necessary to remove safety did e minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running e 2 d 3 Do not place your body between the electrode and work cables If the elec
55. utor Contact your Local Lincoln Authorized Field Service Facility for technical Tungsten electrode may be too troubleshooting assistance small for process Use a larger diameter tungsten or a pure tungsten If a helium blend is used as a shielding gas then reduce the percentage of helium Gas shielding may be insuffi cient Increase gas flow reduce tungsten stickout beyond gas cup Minimize crossdrafts in welding area 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 SQUARE WAVE TIG 175 LINCOLN 19 TROUBLESHOOTING 19 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 high for electrode size Reduce current control setting or use a larger diameter electrode Stick electrode sticks in the weld 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
56. 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 INSTALLATION 4 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 A 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 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 A WARNING CYLINDER could explode if damaged 3 eKeep cylinder upright and chained to a support eKeep cylinder away from areas where it could be damaged Never allow the torch to touch the
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