Lincoln Electric SVM169-A service manual Product Description, Recommended Processes and Equipment

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B-3

OPERATION

B-3

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PRODUCT DESCRIPTION

The Precision TIG 185 is a member of our field acclaimed Precision TIG family of industrial arc weld - ing power sources. Premium features include:

1.Precise constant current output.

2.Full range square wave AC/DC TIG (GTAW) weld-- ing.

3.Enhanced version of the patented Micro- Start™Technology for its lower Minimum(5 amps) to higher Maximum (185 amps) output control range.

4.Built-in high frequency stabilization for DC TIG start- ing and continuous AC TIG welding.

5.AC/DC Stick (SMAW capability.) A new undercar- riage (with gas bottle rack) is available for field installation, or is included with an available Ready- Pak TIG Welding Package. The Precision TIG patented convenient built-in storage provisions for welding components and cable management.

The Precision TIG 185 also provides advanced fea- tures such as:

Digital Meter

Presettable control, adjustable Auto Balance™

Fan As Needed (F.A.N.)

Timers for fixed Preflow and variable Postflow shield- ing gas.

Built-in, easy to set single knob Pulse TIG control with a "blinking" light to indicate the pulse frequency set- ting.

Auto-Sense remote control selection.

Tool-less Twist-Mate electrode cable connection.

Built-in work clamp cable permanently attached.

Four models are available for 60Hz. with Domestic and Canadian input voltages, as well as an International model with 50/60Hz voltages.

RECOMMENDED PROCESSES AND EQUIPMENT

RECOMMENDED PROCESSES

The Precision TIG 185 is recommended for the TIG (GTAW) and Stick (SMAW) welding processes within its output capacity range of 5 amps DC,or 7 amps AC, to 185 amps AC/DC. It is compatible with most Magnum TIG accessories, as well as many industry standard items, such as TIG torches (adapted for Twist-Mate), hoses, and water coolers.

PROCESS LIMITATIONS

The Precision TIG machines are not recommended for arc gouging due to it's limited output capacity, and are also not recommended for pipe thawing.

RECOMMENDED EQUIPMENT/INTERFACE

(See Installed Options in Accessories Section for more details)

The Precision TIG 185 will be available as a basic Machine (Only) and in two Factory-Configured Welding Packages:

1.Machine(Only) (K2345-1)

2.Ready-Pak (K2347-1)

3.Ready-Pak w/Cart (K2347-2)

Basic module will also be available as with Domestic, Canadian and International input voltages for user con- figuration, with optional accessories.

Select Machine

208/230/1/60 Machine with 6 NEMA 6-50P

 

Plug Cable and Receptacle (K2345-1)

 

460/575/1/60 Machine only with cable (K2345-2)

 

380/400/415/1/50/60 Machine only

 

with cable (K2346-1)

 

Torch Starter Kit

Air Cooled System:

Water Cooled System:

(Select one)

TIG-Mate

TIG-Mate 20

 

Torch Starter Kit*

Torch Starter Kit*

Water Cooler

Not Applicable

115V 50/60Hz

 

 

Cool-Arc 40*

Under-Storage

K2348-(*)

Cart (Optional )

 

 

Optional Remote

Arc Start Switch*

Trigger Device

Foot Amptrol*

(Select one)

Start Pedal Foot Amptrol*

 

Hand Amptrol*

*For “Part Numbers” or “K Numbers” see Accessories Section.

EQUIPMENT LIMITATIONS

The Precision TIG machines are protected from over loads beyond the output ratings and duty cycles, per the Specifications in the Installation Section, with Thermostat protection of the output power coils and rectifiers.

The PRECISION TIG 185 machine uses Twist-Mate output terminals, therefore stud connection adapters (such as LECO. S19257-series) cannot be used for torch connection.

If a Precision Tig 185 is powered from an engine gen- erator which doesn’t have sufficient capacity, the AC Balance control and the Output control will not provide full range of control.

WELDING CAPABILITY(Duty Cycle)

The PRECISION TIG 185 is rated at 185 amps, 27 volts, at 15% duty cycle on a ten minute basis. It is capable of higher duty cycles at lower output currents. See rated output graph, on specification sheet located in the Installation Section. If the duty cycle is exceed- ed, a thermal protector will shut off the output until the machine cools.

PRECISION TIG 185

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Contents Precision TIG Safety Electric Shock can kill Welding Sparks can cause fire or explosion SafetySûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Section Table of ContentsInput Single Phase only InstallationK2345-2 Input at Rated Output Model Height Width Depth WeightSelect Suitable Location Safety PrecautionsInput Connections Output Connections Input Reconnect ProcedureConnections for TIG Gtaw Welding TIG Torch ConnectionShielding GAS Connection Remote Control ConnectionWork Cable Connection Precision TIG Section B Operation SectionOperation Recommended Processes and Equipment Product DescriptionControl Functionality Controls and SettingsPulse TIG Control Welding in TIG ModeOperating Steps Benefits of the Precision TIG 185 Design Remote Control OperationRecommended Electrode Amperage Ranges Precision TIG Welding in Stick ModePrecision TIG Accessories Section Table C.1 AccessoriesFactory Installed Options K2348-1 Under-Storage Cart Field Installed OptionsPrecision TIG Section D Maintenance SectionSpark GAP Adjustment MaintenanceRoutine and Periodic Maintenance Figure D.2 Location of Maintenance Components Return to Section TOC Section E Theory of Operation SectionGeneral Description Input Power CircuitTheory of Operation Figure E.3 Control Board and Output Feedback Control Output Rectification Feedback ControlFigure E.4 High Voltage/High Frequency Circuit High Voltage / High Frequency CircuitFigure E.5 DC Welding Current Generation DC Welding OutputFigure E.6 AC Square Wave Welding Current Generation AC Welding OutputFigure E.7 SCR Operation SCR OperationOverload Protection Protective CircuitsThermal Protection Section F Troubleshooting & Repair SectionHigh Voltage / High Frequency can damage test equipment Troubleshooting & RepairWorkstations PC Board Troubleshooting ProceduresCourse of Action Problems Possible Areas Recommended SymptomsPossible Areas Recommended Symptoms Problems Possible Areas Check the welding cables and or TIG Mode Problems Troubleshooting & Repair TIG Welding Problems Problems Possible Areas Electric Shock can Problems Possible Areas Recommended Symptoms Stick Welding Problems Test Description High Frequency Circuit Disable ProcedureFigure F.1 Spark GAP Assembly ProcedureT1 Transformer Test T1 Transformer Test Test ProcedurePrimary Windings Primary Voltages Return to Section Section TOCPrecision TIG Static SCR Test Static SCR Test Assembly Removal and Replacement Precision TIG Active SCR Test Active SCR Test Figure F.6 SCR Gate Locations Precision TIG Normal Open Circuit Voltage Waveform AC TIG ModeScope Settings DC TIG Mode AC Stick Mode DC Stick Mode Machine Loaded to 180 Amps AT 16VDC Typical Output Voltage Waveform Machine LoadedDC TIG Mode Machine Loaded to 180 Amps AT 26VDC DC Stick Mode 50 V/Div Precision TIG SCR Bridge Assembly Removal and Replacement Procedure Troubleshooting and RepairProcedure SCR Bridge AssemblyFront Panel Mounting Screws Figure F.9 Plug J2 on Control Board 42TROUBLESHOOTING & REPAIRF-42Replacement Procedure 43TROUBLESHOOTING & REPAIRF-43Precision TIG Polarity Switch Removal and Replacement Procedure Removal Procedure Polarity SwitchReplacement Procedure Precision TIG High Voltage Transformer Removal and Replacement Procedure Transformer Secondary Leads Precision TIG High Voltage TransformerFigure F.12 High Voltage Transformer Mounting Insulators Precision TIG Nutdriver Wrench Wire cutters Perform the SCR Bridge Assembly Removal Procedure Assembly Replacement Procedure Precision TIG Retest After Repair Troubleshooting and RepairInput Idle Amps Recommended Meters for Machine Output TestsPrecision TIG Electrical Diagrams Section Precision TIG Wiring Diagram Entire Machine G4549G4588 Schematic Entire Machine G4588Schematic Control PC Board G4550-1B4-1 Schematic Control P.C. Board G4550-1B4-2 Schematic Control P.C. Board G4550-1B4-3 G4551 PC Board Assembly Control G4551-1SVM Error Reporting Form