Lincoln Electric PRECISION TIG 185 SVM169-A Service Manual
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Lincoln Electric PRECISION TIG 185 SVM169-A Service Manual

Lincoln Electric PRECISION TIG 185 SVM169-A Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN MENU
SVM169-A
July, 2006
PRECISION TIG 185
For use with machines having Code Number : 11105 thru 11109
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.

SERVICE MANUAL

Copyright © 2006 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric PRECISION TIG 185 SVM169-A

  • Page 1: Service Manual

    RETURN TO MAIN MENU SVM169-A July, 2006 PRECISION TIG 185 For use with machines having Code Number : 11105 thru 11109 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 .

  • Page 2: Safety

    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.

  • Page 3: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6: Table Of Contents

    RETURN TO MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety ............i-iv Installation .

  • Page 7: Installation Section

    Section A-1 - INSTALLATION SECTION - Installation ...Section A Technical Specifications...A-2/A-3 Safety Precautions ...A-4 Location...A-4 Grinding ...A-4 Stacking ...A-4 Lifting and Moving ...A-4 Tilting ...A-4 Environmental Rating...A-4 Machine Grounding and High Frequency Interference Protection ...A-4 Input Connections...A-5 Input Reconnect Procedure ...A-6 Output Connections ...A-6 Connections for TIG Welding ...A-6 TIG Torch Connection ...A-6...

  • Page 8: Installation

    Use a Super Lag type fuse or circuit breaker with a delay in tripping action. Models with NEMA 6-50P plug may be used with a 50 amp protected 6-50R receptacle, or with a maximum 70 amp protected 6-50R receptacle if dedicated for the welder. INSTALLATION...
  • Page 9 TECHNICAL SPECIFICATIONS - CANADIAN (K2345-2), INTERNATIONAL K2346-1) Voltage/Phase/Freq. 460/575/1/60 Voltage/Phase/Freq. 380/400-415/1/50/60 Max. OCV. 74 V (AC) 59 V (DC) Process Duty Cycle*. SMAW 100% GTAW 100% Based on a 10 minute cycle. MODEL HEIGHT Machine Only 20.71 in. (K2345-1,-2) 526 mm (K2346-1) Ready-Pak 20.71 in.

  • Page 10: Safety Precautions

    Electrical Code and any local codes. --------------------------------------------------------------------------- SELECT SUITABLE LOCATION Place the welder where clean cooling air can freely cir- culate in and out through the rear louvers. Dirt, dust or any foreign material that can be drawn into the welder should be kept at a minimum.

  • Page 11: Input Connections

    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).

  • Page 12: Input Reconnect Procedure

    CAUTION Failure to follow these instructions can cause immedi- ate failure of components within the welder and void machine’s warranty. ----------------------------------------------------------------------- Multiple voltage models are shipped connected for the highest voltage.

  • Page 13: Work Cable Connection

    (usually argon). Connect the cylinder of gas with the pressure regulator and flow gage. Install the gas hose between the regulator and gas inlet (located on the rear of the welder). The gas inlet has a 5/16-18 right hand female thread; CGA#032.
  • Page 14 NOTES PRECISION TIG 185...
  • Page 15 Section B-1 TABLE OF CONTENTS Section B-1 - OPERATION SECTION - Operation ...Section B Safety Precautions ...B-2 Graphic Symbols...B-2 Product Description...B-3 Recommended Processes and Equipment...B-3 Welding Capability (duty cycle) ...B-3 Controls and Settings...B-4 Control Functionality ...B-4/B-5 Operating Steps ...B-5 Welding in TIG Mode...B-5 Pulse TIG Control ...B-5 Remote Control Operation ...B-6 Benefits of the Precision TIG 185 Design ...B-6...

  • Page 16: Operation

    SAFETY PRECAUTIONS Read and understand this entire section before operat- ing the machine. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet cloth- ing. • Insulate yourself from work and ground. •...

  • Page 17: Operation

    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.

  • Page 18: Controls And Settings

    CONTROLS AND SETTINGS All operator controls and adjustments are located on the front of the PRECISION TIG 185. Refer to Figure B.1 and corresponding explanations. CONTROL FUNCTIONALITY 1. POWER SWITCH – Input line switch turns input power ON or OFF, as indicated by the on or off sta- tus of the front panel digital display (See Item 6).

  • Page 19: Operating Steps

    TIG torch when TIG welding. 12. WORK CABLE - This work cable is factory con- nected to the welder and is connected to the work piece to complete the welding circuit. Refer to Machine Grounding and High Frequency...

  • Page 20: Remote Control Operation

    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.

  • Page 21: Welding In Stick Mode

    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 to the weld mode desired for the type of electrode being used (most commonly DC+).
  • Page 22 NOTES PRECISION TIG 185...
  • Page 23 Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES SECTION - Accessories ...Section C Options / Accessories ...C-2/C-3 PRECISION TIG 185...

  • Page 24: Accessories

    FACTORY INSTALLED OPTIONS The Precision TIG 185 will be available in two Factory- Configured Welding Packages: 1. Precision TIG 185 Ready-Pak (K2347-1) • 208/230/1/60 Machine (K2345-1) • 9 ft. (2.7m) Input Cable with NEMA 6-50P Plug* • NEMA 6-50R Receptacle •...
  • Page 25 FIELD INSTALLED OPTIONS The following Options/Accessories are available for the Precision TIG 185: • K2348-1 Under-Storage Cart Includes a front magnetic latch storage drawer and rear storage bin on a single bottle undercarriage. (L12225 Installation Instructions included) • K870 Foot Amptrol Single pedal foot activation of arc start switch and output control, with 25 ft.(7.6m) plug cable.
  • Page 26 NOTES PRECISION TIG 185...

  • Page 27: Maintenance Section

    Section D-1 Section D-1 TABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ...Section D Safety Precautions ...D-2 Routine Maintenance...D-2 Periodic Maintenance...D-2 Spark Gap Adjustment ...D-2 Fan Motor and Blade Replacement ...D-2 Major Component Locations...D-3 PRECISION TIG 185...

  • Page 28: Maintenance

    • Arc Starter/Spark Gap Assembly • PC Boards • 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 cool- ing.
  • Page 29 MAINTENANCE FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS. 1. Case Front Assembly 2. Case Back Assembly 3. Arc Starter & Bypass Assembly 4. Center Assembly 5. Cover Assembly 6. Cart Base Assembly 7. Upper Cylinder Support Assembly 8. TIG Torch & Cable Assembly 9.
  • Page 30 NOTES...
  • Page 31 Section E-1 - THEORY OF OPERATION SECTION - Theory of Operation ...Section E General Description ...E-2 Input Power Circuit ...E-2 Output Rectification and Feedback Control...E-3 High Voltage/High Frequency Circuit ...E-4 DC Welding Output...E-5 AC Welding Output ...E-6 SCR Operation...E-7 Protective Circuits...E-8 Thermal Protection ...E-8 Overload Protection ...E-8 FIGURE E.1 –...

  • Page 32: Theory Of Operation

    THEORY OF OPERATION GENERAL 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.

  • Page 33: Output Rectification And Feedback Control

    THEORY OF OPERATION FIGURE E.3 Control Board and Output Feedback Control. INPUT POWER SWITCH BYPASS ASBLY RECEPTACLE AUTO BALANCE OUTPUT RECTIFICATION FEEDBACK CONTROL The AC output from the main transformer secondary is rectified and controlled through the SCR bridge. Output current is sensed at the shunt as a low voltage signal and fed back to the control board.

  • Page 34: High Voltage/High Frequency Circuit

    THEORY OF OPERATION FIGURE E.4 High Voltage/High Frequency Circuit. INPUT POWER SWITCH BYPASS ASBLY RECEPTACLE HIGH VOLTAGE / HIGH FREQUENCY CIRCUIT The control board passes the 115VAC voltage to the primary of the high voltage transformer. ondary of the high voltage transformer is coupled to a spark gap generator and also to the high frequency transformer.

  • Page 35: Dc Welding Output

    THEORY OF OPERATION DC WELDING OUTPUT When the polarity switch is placed in either DC position, the AC voltage from the main transformer secondary is applied to the SCR bridge. The SCR bridge and choke circuits are connected in a conventional full wave bridge and filter configuration, resulting in a controlled DC output.

  • Page 36: Ac Welding Output

    THEORY OF OPERATION Rotating the polarity switch to the AC position changes the welding power circuit. One lead (X1) of the main transformer secondary is connected to the machine output work terminal. The other secondary lead (X2) is connected to one of the AC connections on the SCR bridge. The electrode terminal is connected to the other AC side of the bridge.

  • Page 37: Scr Operation

    THEORY OF OPERATION SCR OPERATION A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load. An SCR acts very much like a switch. When a gate signal is applied to the SCR it is turned ON and there is current flow from anode to cathode.

  • Page 38: Protective Circuits

    OVERLOAD PROTECTION The machine is electronically protected from producing excessively high output currents. The output is limited to 200 amps. If the welder PRECISION TIG 185...
  • Page 39 Section F-1 - TROUBLESHOOTING & REPAIR SECTION - Troubleshooting & Repair Section ...Section F How to Use Troubleshooting Guide...F-2 PC Board Troubleshooting Procedures and Replacement...F-3 Troubleshooting Guide ...F-4 Test Procedures High Frequency Circuit Disable Procedure ...F-15 T1 Transformer Test ...F-17 Static SCR Test ...F-21 Active SCR Test...F-25 Oscilloscope Waveforms...
  • Page 40 • Perform all voltage and waveform checks with high frequency circuit OFF. Perform High Frequency Disable Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION Step 3.

  • Page 41: Pc Board Troubleshooting Procedures

    - If the PC board uses protective shorting jumpers, don’t remove them until installation is complete. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- er failure analysis.

  • Page 42: Troubleshooting Guide

    TIG modes. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. detailed in the beginning of this manual.
  • Page 43 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. detailed in the beginning of this manual.
  • Page 44 TIG mode. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 45 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. detailed in the beginning of this manual.
  • Page 46 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. detailed in the beginning of this manual.
  • Page 47 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. detailed in the beginning of this manual.
  • Page 48 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. detailed in the beginning of this manual.
  • Page 49 Chapter. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. detailed in the beginning of this manual.
  • Page 50 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 51 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. detailed in the beginning of this manual.
  • Page 52 Stick mode. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 53: High Frequency Circuit Disable Procedure

    If for any reason you do not understand the test procedures or are unable to per- form the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 54 F-16 TROUBLESHOOTING & REPAIR HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE PROCEDURE 1. Remove input power to the TIG185 machine. 2. Using the 3/8” nutdriver remove the right side panel. 3. Locate the Spark Gap Assembly at the right side of the machine. See Figure F.1.

  • Page 55: T1 Transformer Test

    If for any reason you do not understand the test procedures or are unable to per- form the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 56 F-18 TROUBLESHOOTING & REPAIR T1 TRANSFORMER TEST (continued) TEST PROCEDURE 1. Remove main supply power to the machine. 2. Using the 3/8” nutdriver remove the case wrap-around cover. 3. Locate plugs J3 and J4 on the control board. See Figure F.2. FIGURE F.2 - Plugs J3 &...
  • Page 57 F-19 TROUBLESHOOTING & REPAIR T1 TRANSFORMER TEST (continued) 6. If all of the secondary voltages are correct the T1 transformer is func- tioning properly. A. If all of the secondary voltages are missing or incorrect make certain that the correct input volt- age is being applied to the correct primary leads.
  • Page 58 F-20 F-20 NOTES PRECISION TIG 185...

  • Page 59: Static Scr Test

    If for any reason you do not understand the test procedures or are unable to per- form the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 60 F-22 TROUBLESHOOTING & REPAIR STATIC SCR TEST (continued) TEST PROCEDURE 1. Remove main supply power to the TIG 185 and remove the case wrap- around cover. 2. Locate and remove plug J2 from the control board. See Figure F.3. Figure F.3 - Plug J2 Location on Control Board PRECISION TIG 185 CONTROL PRECISION TIG 185 F-22...
  • Page 61 F-23 TROUBLESHOOTING & REPAIR STATIC SCR TEST (continued) 3. Using an analog ohmmeter test the resistance from anode to cathode of SCR1. Reverse the meter leads and check from cathode to anode of SCR1. See Figure F.4. If a low resis- tance is indicated in either direction SCR1 is faulty.
  • Page 62 F-24 F-24 NOTES PRECISION TIG 185...

  • Page 63: Active Scr Test

    If for any reason you do not understand the test procedures or are unable to per- form the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 64 F-26 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST (continued) TEST PROCEDURE 1. Remove main supply power to the TIG 185 machine. 2. Locate and remove plug J2 from the control board. See Figure F.3. 3. Perform test procedure as outlined in Figure F.5.
  • Page 65 F-27 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST (continued) SCR1 ANODE SCR1 CATHODE/SCR2 ANODE 6. Connect SCR into the test circuit as shown (A) lead to anode (C) lead to cathode and (G) lead to the gate. 7. Close switch SW-1 (switch SW-2 should open), voltmeter should read zero.
  • Page 66 F-28 F-28 NOTES PRECISION TIG 185...

  • Page 67: Normal Open Circuit Voltage Waveform-Ac Tig Mode

    F-29 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. • Perform High Frequency Disable Procedure. ____________________________________________________________________ 50 V This is the typical AC output voltage wave- form generated from a properly operating machine.

  • Page 68: Normal Open Circuit Voltage Waveform-Dc Tig Mode

    F-30 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. • Perform High Frequency Disable Procedure. ____________________________________________________________________ 50 V This is the typical DC (+) output voltage waveform generated from a properly operat- ing machine.

  • Page 69: Normal Open Circuit Voltage Waveform-Ac Stick Mode

    F-31 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. • Perform High Frequency Disable Procedure. ____________________________________________________________________ 50 V This is the typical AC output voltage wave- form generated from a properly operating machine.

  • Page 70: Normal Open Circuit Voltage Waveform-Dc Stick Mode

    F-32 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. • Perform High Frequency Disable Procedure. ____________________________________________________________________ 50 V This is the typical DC (+) output voltage waveform generated from a properly operat- ing machine.

  • Page 71: Typical Output Voltage Waveform-Machine Loaded Ac Tig Mode

    F-33 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. • Perform High Frequency Disable Procedure. ____________________________________________________________________ 10 V MACHINE LOADED TO 180 AMPS AT 16VDC.

  • Page 72: Typical Output Voltage Waveform-Machine Loaded Dc Tig Mode

    F-34 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. • Perform High Frequency Disable Procedure. ____________________________________________________________________ 10 V MACHINE LOADED TO 180 AMPS AT 16VDC.

  • Page 73: Typical Output Voltage Waveform-Machine Loaded Ac Stick Mode

    F-35 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. • Perform High Frequency Disable Procedure. ____________________________________________________________________ 10 V MACHINE LOADED TO 180 AMPS AT 26VDC.

  • Page 74: Typical Output Voltage Waveform-Machine Loaded Dc Stick Mode

    F-36 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. • Perform High Frequency Disable Procedure. ____________________________________________________________________ 10 V MACHINE LOADED TO 180 AMPS AT 26VDC.
  • Page 75 F-37 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE - DC TIG MODE ONE OUTPUT SCR NOT FUNCTIONING HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment. • Perform all voltage and waveform checks with high frequency circuit OFF. • Perform High Frequency Disable Procedure. ____________________________________________________________________ 50 V This is NOT the typical DC (+) output voltage...
  • Page 76 F-38 F-38 NOTES PRECISION TIG 185...

  • Page 77: Troubleshooting And Repair

    If for any reason you do not understand the test procedures or are unable to per- form the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 78 F-40 TROUBLESHOOTING AND REPAIR REMOVAL AND REPLACEMENT PROCEDURE (Continued) PROCEDURE 1. Remove input power to the TIG 185 machine. 2. Using the 3/8” nutdriver remove the case wrap-around cover. 3. With the slot head screwdriver loosen the input cable strain relief to allow movement of case back.
  • Page 79 F-41 TROUBLESHOOTING AND REPAIR REMOVAL AND REPLACEMENT PROCEDURE (Continued) FIGURE F.8 FRONT PANEL MOUNTING SCREWS 9. Remove plug J2 from the control board. (See Figure F.9.) Also remove plug and lead harness from internal divider panel. 10. Carefully slide the internal divider panel away a few inches to allow access to the SCR bridge assem- bly.
  • Page 80 F-42 F-42 TROUBLESHOOTING & REPAIR SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (Continued) FIGURE F.9 PLUG J2 ON CONTROL BOARD PLUG J2 REMOVED PRECISION TIG 185 CONTROL DIODE PIGTAIL CONNECTION FIGURE F.10 DIODE PIGTAIL CONNECTION TO POLARITY SWITCH LEAD. PRECISION TIG 185...
  • Page 81 F-43 TROUBLESHOOTING & REPAIR REMOVAL AND REPLACEMENT PROCEDURE (Continued) 16. With the 3/8” wrench remove the four mounting screws holding the SCR bridge assembly to the main transformer frame. Note insulator placement. 17. Carefully remove the SCR bridge assembly from the TIG 185 cutting any necessary cable ties.
  • Page 82 F-44 F-44 NOTES PRECISION TIG 185...

  • Page 83: Polarity Switch Removal And Replacement

    If for any reason you do not understand the test procedures or are unable to per- form the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 84 F-46 TROUBLESHOOTING & REPAIR REMOVAL AND REPLACEMENT PROCEDURE (Continued) REMOVAL AND REPLACEMENT PROCEDURE (Continued) REMOVAL PROCEDURE 1. Remove the input power to the TIG 185 machine. 2. Using the 3/8” nutdriver remove the case wrap-around cover. 3. Using the 3/32” Allen type wrench remove the output control knob.

  • Page 85: Polarity Switch

    F-47 TROUBLESHOOTING & REPAIR REMOVAL AND REPLACEMENT PROCEDURE (Continued) REPLACEMENT PROCEDURE 1. Carefully position the new polarity switch in position on the front panel. Make certain the micro-switch is assembled to the polarity switch cor- rectly. 2. Solder leads #311 and #312 to the micro -switch.
  • Page 86 F-48 F-48 NOTES PRECISION TIG 185...

  • Page 87: High Voltage Transformer Removal And Replacement

    If for any reason you do not understand the test procedures or are unable to per- form the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 88 F-50 TROUBLESHOOTING & REPAIR HIGH VOLTAGE TRANSFORMER HIGH VOLTAGE TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (Continued) REMOVAL AND REPLACEMENT PROCEDURE (Continued) REMOVAL PROCEDURE 1. Remove input power to the TIG 185 machine. 2. Using the 3/8” nutdriver remove the case wrap-around cover. 3.
  • Page 89 F-51 TROUBLESHOOTING & REPAIR HIGH VOLTAGE TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (Continued) REPLACEMENT PROCEDURE 1. Carefully position the new high volt- age transformer in place in the two rear mounting insulators. See Figure F.12. 2. Install the front mounting insulators and mounting screw.
  • Page 90 F-52 F-52 NOTES PRECISION TIG 185...
  • Page 91 If for any reason you do not understand the test procedures or are unable to per- form the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 92 F-54 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (Continued) REMOVAL PROCEDURE 1. Remove input power to the TIG 185 machine. 2. Perform the SCR Bridge Assembly Removal Procedure. 3. Unsolder the two 115VAC leads and leads B231 and B232 from the main transformer leads.
  • Page 93 F-55 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (Continued) REPLACEMENT PROCEDURE 1. Position the new transformer/choke assembly onto the base and mount- ing bolts. 2. Assemble the four nuts and washers to the mounting bolts on the base of the machine.
  • Page 94 F-56 F-56 NOTES PRECISION TIG 185...

  • Page 95: Retest After Repair

    F-57 TROUBLESHOOTING AND REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested. Input Volts/Hertz 208/60 230/60...
  • Page 96 F-58 F-58 NOTES PRECISION TIG 185...
  • Page 97 Section G-1 Section G-1 TABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams ...Section G Wiring Diagram (G4549) ..........G-2 Entire Machine Schematic (G4588) .

  • Page 98: Electrical Diagrams

    WIRING DIAGRAM - ENTIRE MACHINE - (G4549) 10K A-B AT MINIMUM OPTIONAL REMOTE REMOTE AMPTROL RECEPTACLE WORK ELECTRODE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ELECTRICAL DIAGRAMS VOLTAGE RECONNECTION SEE RATING PLATE FOR SPECIFIC VOLTAGES...
  • Page 99 SCHEMATIC - ENTIRE MACHINE - (G4588) G4588 ENGINEERING CONTROLLED CHANGE DETAIL: RELEASED FROM X A.02 MANUFACTURER: DISPLAY PRESET AT IDLE ACTUAL AMP WHEN WELDING NO HOLD FUNCTION 3 DIGIT METER (DISP1) OUTPUT CONTROL & MODE SETTINGS ARE MEMORIZED AT POWER - DOWN AND RECALLED METER AT POWER - UP...
  • Page 100 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD - (G4550-1B4-1) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRECISION TIG 185...
  • Page 101 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL P.C. BOARD - (G4550-1B4-2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRECISION TIG 185...
  • Page 102 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL P.C. BOARD - (G4550-1B4-3) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRECISION TIG 185...
  • Page 103 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 104 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 04/06 Thank You, Technical Services Group Lincoln Electric Co. 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...

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