Lincoln Electric SVM186-A manual

For use with machine code numbers: SVM186-A October , 2008 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- IN[...]

Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilate[...]

SAFETY ii ii Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC 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 ga[...]

SAFETY iii iii Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Jan ‘07 FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and[...]

SAFETY iv iv Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Mar ‘93 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: [...]

SAFETY v v Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility ([...]

SAFETY vi vi Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Met[...]

- MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I PRECISION TIG® 225 RETURN TO MAIN INDEX Page S a f e t y ........................................................................... i - i v I n s t a l l a t i o n .................................................................. S e c t i o nA O p e r a t i o n .................................[...]

T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 I n s t a l l a t i o n ............................................................................. A - 1 T e c h n i c a l S p e c i f i c a t i o n s.....................................[...]

INST ALLA TION A-2 A-2 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC TECHNICAL SPECIFICA TIONS - PRECISION TIG® 225 (K2533-1AND K2535-1,-2) Weld V oltage (NEMA) 15.7 V AC/DC 15.2 V AC/DC 14.1 V A[...]

INST ALLA TION A-3 A-3 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC TECHNICAL SPECIFICA TIONS - CANADIAN (K2533-2), INTERNA TIONAL K2534-1) MODEL HEIGHT WIDTH DEPTH WEIGHT PHYSICAL DIMENSIONS (2)[...]

INST ALLA TION A-4 A-4 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAFETY PRECAUTIONS SELECT SUIT ABLE LOCA TION MOUNTING Environmental Rating The PRECISION TIG® 225 power source carries an IP2[...]

INST ALLA TION A-5 A-5 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC MACHINE GROUNDING AND HIGH FRE- QUENCY INTERFERENCE PROTECTION Locate the Precision TIG® 225 away from radio controlled machin[...]

INST ALLA TION A-6 A-6 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC INPUT RECONNECT PROCEDURE On multiple input voltage welders, be sure the machine is connected per the following instructions fo[...]

INST ALLA TION A-7 A-7 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC CONNECTIONS FOR TIG (GT A W) WELDING TIG TORCH CONNECTION A PT A-17 T wist-Mate TIG welding torch with cable and connector is s[...]

Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES A-8 A-8 PRECISION TIG® 225[...]

T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 O p e r a t i o n .............................................................................. B - 1 S a f e t y P r e c a u t i o n s .........................................................[...]

OPERA TION B-2 B-2 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet cloth- ing. • Insulate yourself f[...]

OPERA TION B-3 B-3 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRODUCT DESCRIPTION The PRECISION TIG® 225 is a member of our field acclaimed PRECISION TIG® family of industrial arc welding pow[...]

OPERA TION B-4 B-4 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC CONTROL FUNCTIONALITY 1. POWER SWITCH – Input line switch turns input power ON or OFF , as indicated by the on or off sta- tus of[...]

OPERA TION B-5 B-5 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC 8. PULSE TIG CONTROL – The Pulse TIG feature built into the PRECISION TIG® 225 is simplified to be a single knob control which s[...]

OPERA TION B-6 B-6 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC CASE REAR COMPONENTS 1. INPUT CABLE– This #6-3 (208/230V) or #12-3 (380V and higher) heavy duty cable with cable clamp is factory[...]

OPERA TION B-7 B-7 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC OPERA TING STEPS WELDING IN TIG MODE 1. Connect the TIG torch and cable T wist-Mate™ quick connect plug to the Electrode/Gas outp[...]

OPERA TION B-8 B-8 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC REMOTE CONTROL OPERA TION A Foot Amptrol is included with the PRECISION TIG® 225 Ready-Pak models and available for other models ([...]

OPERA TION B-9 B-9 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING IN STICK MODE 1. Put the electrode holder and cable quick connect plug into the electrode output receptacle. T urn clock- w[...]

Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES B-10 B-10 PRECISION TIG® 225[...]

T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 A c c e s s o r i e s............................................................................ C - 1 S t a n d a r d E q u i p m e n t P a c k a g e s .......................................[...]

ACCESSORIES C-2 C-2 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC T ABLE C.1 ST ANDARD EQUIPMENT P ACKAGES The PRECISION TIG® 225 will be available in two Factory-Configured Welding Packages: 1. [...]

ACCESSORIES C-3 C-3 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC F ACTOR Y INST ALLED OPTIONS The PRECISION TIG® 225 will be available in two Factory-Configured Welding Packages: 1. PRECISION TI[...]

ACCESSORIES C-4 C-4 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC FIELD INST ALLED OPTIONS The following Options/Accessories are available for the PRECISION TIG® 225: • K2348-1 Under-Storage Ca[...]

T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 M a i n t e n a n c e ........................................................................... D - 1 S a f e t y P r e c a u t i o n s .......................................................[...]

MAINTENANCE D-2 D-2 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this maintenance. • T urn the input po[...]

T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 T h e o r y o f O p e r a t i o n ..................................................................... E - 1 G e n e r a l D e s c r i p t i o n .......................................[...]

THEOR Y OF OPERA TION E-2 E-2 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC GENERAL DESCRIPTION The PRECISION TIG® 225 is a member of our field acclaimed PRECISION TIG® family of industrial arc [...]

THEOR Y OF OPERA TION E-3 E-3 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC OUTPUT RECTIFICA TION AND FEEDBACK CONTROL The AC output from the main transformer secondary is rectified and controlled[...]

THEOR Y OF OPERA TION E-4 E-4 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC HIGH VOL T AGE / HIGH FREQUENCY CIRCUIT The control board passes the 1 15V AC voltage to the primary of the high voltage[...]

THEOR Y OF OPERA TION E-5 E-5 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC DC WELDING OUTPUT When the polarity switch is placed in either DC position, the AC voltage from the main transformer sec[...]

THEOR Y OF OPERA TION E-6 E-6 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC AC WELDING OUTPUT Rotating the polarity switch to the AC position changes the welding power circuit. One lead (X1) of th[...]

THEOR Y OF OPERA TION E-7 E-7 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SCR OPERA TION A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to [...]

THEOR Y OF OPERA TION E-8 E-8 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PROTECTIVE CIRCUITS Protective circuits are designed into the PRECISION TIG® 185 to sense trouble and shut down the mac[...]

T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 T roubleshooting and Repair.............................................................................................................................F-1 How to Use T roubleshooting G[...]

TROUBLESHOOTING AND REP AIR F-2 F-2 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow[...]

TROUBLESHOOTING AND REP AIR F-3 F-3 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor e[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE TROUBLESHOOTING AND REP AIR F-15 F-15 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC W ARNING Service and repair should be performed by only Lincoln Electri[...]

.020 Spark Gap LEFT SIDE OF MACHINE FIGURE F .1 – SP ARK GAP ASSEMBL Y HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-16 F-16 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return t[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

PRECISION TIG 225 CONTROL BOARD J2 J3 J4 PIN 4 (LEAD #201) PIN 3 (LEAD #204) PIN 7 (LEAD #210) PIN 8 (LEAD #209) PIN 3 (LEAD #232) PIN 2 (LEAD #260) T1 TRANSFORMER TEST (continued) 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. [...]

T1 TRANSFORMER TEST (continued) PROCEDURE 6. If all of the secondary voltages are correct the T1 transformer is functioning properly . A. If all of the secondary voltages are missing or incorrect make certain that the correct input voltage is being applied to the correct primary leads. See T able F .1. B. If the correct input voltage is being appli[...]

Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-20 F-20 PRECISION TIG® 225[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

PLUG J2 REMOVED PRECISION TIG 225 CONTROL J2 J3 J4 ST A TIC SCR TEST (continued) TEST PROCEDURE 1. Remove main supply power to the TIG 225 and remove the case wrap-around cover . 2. Locate and remove plug J2 from the control board. See Figure F .3. TROUBLESHOOTING AND REP AIR F-22 F-22 PRECISION TIG® 225 Return to Section T OC Return to Section T [...]

CASE COVER REMOV AL AND REPLACEMENT PROCEDURE (continued) TEST PROCEDURE (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 resistance is indicated in either direction SCR1 is faulty . Replace SCR Bridge Assembly . See [...]

Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-24 F-24 PRECISION TIG® 225[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

FIGURE F .5 – ACTIVE SCR TEST SETUP ACTIVE SCR TEST (continued) TEST PROCEDURE 1. Remove main supply power to the TIG 225 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. Repeat test for all four SCRs. See Figure F. 6 . 4. Construct the circuit outlined in Figure[...]

FIGURE F .6 – SCR GA TE LOCA TIONS ACTIVE SCR TEST (continued) TEST PROCEDURE (continued) 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. If the voltmeter reads higher than zero the SCR is shorted. 8. With swi[...]

Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-28 F-28 PRECISION TIG® 225[...]

This is the typical AC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division rep- resents 2 milliseconds in time. Note: Scope probes connected at machine output terminals: (+) probe to electrode, (–) probe to work. SCOPE SETTINGS V olts/Div .....[...]

This is the typical DC (+) output volt- age waveform generated from a prop- erly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time. Note: Scope probes connected at machine output terminals: (+) probe to electrode, (–) probe to work. SCOPE SETTINGS V olts/Div[...]

This is the typical AC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division rep- resents 2 milliseconds in time. Note: Scope probes connected at machine output terminals: (+) probe to electrode, (–) probe to work. SCOPE SETTINGS V olts/Div .....[...]

This is the typical DC (+) output volt- age waveform generated from a prop- erly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time. Note: Scope probes connected at machine output studs: (+) probe to electrode, (–) probe to work. SCOPE SETTINGS V olts/Div ...[...]

MACHINE LOADED TO 180 AMPS A T 16VDC. This is the typical AC output voltage wave- form generated from a properly operating machine. Note that each vertical division represents 10 volts and that each horizontal division represents 2 milliseconds in time. The machine was loaded with a resistance grid bank. The grid load meters read 180 amps and 16VDC[...]

MACHINE LOADED TO 180 AMPS A T 16VDC. This is the typical DC (+) output voltage wave- form generated from a properly operating machine. Note that each vertical division repre- sents 10 volts and that each horizontal division represents 2 milliseconds in time. The machine was loaded with a resistance grid bank. The grid load meters read 180 amps and[...]

MACHINE LOADED TO 180 AMPS A T 26VDC. This is the typical AC output voltage wave- form generated from a properly operating machine. Note that each vertical division represents 10 volts and that each horizontal division represents 2 milliseconds in time. The machine was loaded with a resistance grid bank. The grid load meters read 180 amps and 26VDC[...]

MACHINE LOADED TO 180 AMPS A T 26VDC. This is the typical AC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 10 volts and that each horizontal division repre- sents 2 milliseconds in time. The machine was loaded with a resistance grid bank. The grid load meters read 180 amps and 26VDC[...]

This is NOT the typical DC (+) output voltage waveform. One output SCR is not functioning. Note the “gap”in the waveform. One SCR gate was discon- nected to simulate an open or non- functioning output SCR. Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time. Note: Scope probes[...]

Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-38 F-38 PRECISION TIG® 225[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

FIGURE F .7 – CASE BACK MOUNTING SCREWS SCR BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Remove input power to the TIG 225 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. 4. Using the 3[...]

FIGURE F .8 – FRONT P ANEL MOUNTING SCREWS SCR BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE (continued) 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 SC[...]

PLUG J2 REMOVED PRECISION TIG 225 CONTROL J2 J3 J4 FIGURE F .9 – PLUG J2 ON CONTROL BOARD SCR BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-42 F-42 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T[...]

SCR BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT PROCEDURE (continued) 16. With the 3/8” wrench remove the four mount- ing screws holding the SCR bridge assembly to the main transformer frame. Note insulator placement. 17. Carefully remove the SCR bridge assembly from the TIG 225 cutting any necessary cable ties. REPLACEMENT PROCEDURE 1. Carefully p[...]

Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-44 F-44 PRECISION TIG® 225[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

POLARITY SWITCH REMOV AL AND REPLACEMENT PROCEDURE (continued) REMOV AL PROCEDURE 1. Remove the input power to the TIG 225 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. 4. Using the Phillips head screwdriver remove the screw from the polarity switch[...]

POLARITY SWITCH REMOV AL 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 correctly . 2. Solder leads #31 1 and #312 to the micro - switch. 3. Assemble and tighten the two nuts and washers that h[...]

Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-48 F-48 PRECISION TIG® 225[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

FIGURE F .1 1 – SECONDARY LEADS A T HIGH FREQUENCY ST ARTER BOARD HIGH VOL T AGE TRANSFORMER REMOV AL AND REPLACEMENT PROCEDURE (continued) REMOV AL PROCEDURE 1. Remove input power to the TIG 225 machine. 2. Using the 3/8” nutdriver remove the case wrap- around cover . 3. With the needle nose pliers remove the two secondary leads from the quick[...]

FIGURE F .12 – HIGH VOL T AGE TRANSFORMER MOUNTING INSULA TORS HIGH VOL T AGE TRANSFORMER REMOV AL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the new high voltage trans- former in place in the two rear mounting insula- tors. See Figure F .12. 2. Install the front mounting insulators and mount- ing screw . 3.[...]

Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-52 F-52 PRECISION TIG® 225[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBL Y REMOV AL AND REPLACEMENT PROCEDURE (continued) REMOV AL PROCEDURE 1. Remove input power to the TIG 225 machine. 2. Perform the SCR Bridge Assembly Removal Procedure. 3. Unsolder the two 1 15V AC leads and leads B231 and B232 from the main transformer leads. Label leads for reassembly . See wiring diagram.[...]

Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-55 F-55 PRECISION TIG® 225 RETEST AFTER REP AIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could af[...]

Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-56 F-56 PRECISION TIG® 225[...]

T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 E l e c t r i c a l D i a g r a m s ..................................................................... G - 1 W i r i n g D i a g r a m ( G 5 6 4 6 ) .............................................[...]

ELECTRICAL DIAGRAMS G-2 PRECISION TIG® 225 WIRING DIAGRAM - COMPLETE MACHINE - ALL CODES (G5646) R CLEVELA N D , O HI O G5646 A S CR 4 S CR 2 S CR 1 D C B A R EAR GANG L1 ELEC TRO DE T3 NC N O MI CRO -SWI TC H T2 L2 L3 C3 S CR 3 H1 H G 311A 312A OP EN CLOS ED C LOS E D G4 216 G3 2 1 8 G2 G1 217 220 AC E F PC BO ARD CO NT R OL PC BOA RD D1 S2 SV1 G[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-3 PRECISION TIG® 225 SCHEMA TIC - COMPLETE MACHINE - ALL CODES (G5647) E N - 1 7 0 S O L I D E D G E E NGI N EE RI NG CO NT RO LLE D M A N U F A C T U RE R[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-4 PRECISION TIG® 225 SCHEMA TIC - CONTROL PC BOARD #1 (G5640) G-4 NOTE: This diagram is for reference only . It may not be accurate for all machines covere[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-5 PRECISION TIG® 225 SCHEMA TIC - CONTROL PC BOARD #2 (G5640) G-5 NOTE: This diagram is for reference only . It may not be accurate for all machines covere[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-6 PRECISION TIG® 225 SCHEMA TIC - CONTROL PC BOARD #3 (G5640) G-6 NOTE: This diagram is for reference only . It may not be accurate for all machines covere[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric . This information is pro- vided for reference only . Lincoln Electric discourages board level trou[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric . This information is pro- vided for reference only . Lincoln Electric discourages board level trou[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-9 PRECISION TIG® 225 SCHEMA TIC - BYP ASS PRINTED CIRCUIT BOARD (S22530) EN-164 S O L I D E D G E S22530- 1B0 BYPASS/ ST ABI L I Z ER BOAR D SCH EM AT I C [...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric . This information is pro- vided for reference only . Lincoln Electric discourages board level trou[...]