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Lincoln Electric SVM186-A User's Manual

1. c S Oo Qo 119809 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED FROMXA 02 Top rear MANUFACTURER No DISPLAY PRESET AT IDLE 15V 5V 24V 216A SEE CONNECTION DETAIL Center of machine BYPASS ASSEMBLY Attached to Power Switch O ACTUAL AMP WHEN WELDING i 5J2 ARO ONE Gb 216 C1 D 49 NO HOLD FUNCTION 6J2 SEG CATE a G4 44 15 20 OHM MAIN 3J2 BI GALE r G3 3 G3 SCR3 GATE CATHODE TRANSFORMER G4 UN 3 DIGIT FIRE_SCR 8J2 Rear of machine attached to N G2 0047 250VAC METER m SCR m 2J2 SCFG SCFe CATHODE 218 base below fan 2 Ge RESISTANCE TYP olo GATING amp SNUBBER 1J2 SOR CATHODE 217 M 220 MASOR JS POWER SWITCH DISP1 4J2 SORACATHODE 216 O R4 O 220A RECTIFIER cle OUTPUT CONTROL amp wo 7J2 SCRISOHANCDE 229 L LA EI MEN ve MODE SETTINGS ARE 5 K X2 sic MEMORIZED AT POWER ON S E e SE o a DOWNAND RECALLED METER BACKGROUND RESISTORS 218 Y 80 VAC 1 a C INTERFACE Z 218A POWER UP SEQUENOE ma eee 216A SERENA BG MICRO START io cio M ME INLINE OONNECTOR J7 ww Right Side of SCR Bridge LENA METER AND MODE DISPLAY THE PREVIOUS OUTPUT Rv CIRCUIT r BACKGROUND Say Inside sleeving at top left side of Penta Rectifier Top of Machine CNN CONTROL AND MODE SETTINGS FAN RUNS FOR 5 i DISABLED IN STICK 12J3 a BACKGROUND ACINPUT 240 Main Rectifier 5 behind Choke RECONNECT IS DONE AT i SECONDS IF MODE IS TIG GAS FLOWS FORA TIVE 415V POWER SWITCH SET BY
2. SCR3 ANODE SCR4 CATHODE 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 Close switch SW 1 switch SW 2 should open voltmeter should read zero If the voltmeter reads higher than zero the SCR is shorted With switch SW 1 closed close switch SW 2 for two seconds and release The voltmeter should read 3 to 6 volts before and after switch SW 2 is released If the voltmeter does not read or reads only while SW 2 is depressed the SCR or battery is defective repeat Battery Test Procedure above Open switch SW 1 disconnect the gate lead C and reverse the A and C leads on the SCR Close switch SW 1 The voltmeter should read PLUG J7 i 3 4 SCR3 SCR4 SCR1 SCR2 1 2 24018 4 INSERTION SIDE SCR GATE LEADS TEST POINTS zero If the voltage is higher than zero the SCR is shorted 10 Replace SCR Bridge Assembly if any SCRs do not pass the test in Step Bridge Assembl Removal Replacement 11 Replace plug J2 into the control board and 12 Replace the case wrap around cover PRECISION TIG 225 LINCOLN NOTES din PRECISION TIGO 225 LINCOLN E F 28 NOL 19IS8 A 0 uunjeu NOL 191S8 A 0 UINISY NOL Je1Se A 0 UINISY NOL 191S8 A 01 UINISY DOL Uuo l99S oj UNAY DOL Uon9es o UNY DOL Uuo l99S oj UNY DOL uoroes oj UNAY ea TROUBLESHOOTING AND REPAIR dini NORMAL OPEN CI
3. hiie MAMMA SOT a LAST NO USED GENERAL INFORMATION R 220 A 1 X 1 amp OCS ELECTRICAL SYMBOLS PER E1537 c 13 a wa m CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED Lit e E ie ave a RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS DIODES 1A 400V UNLESS OTHERWISE SPECIFIED AU SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT Y COMMON CONNECTION 1 17 FRAME CONNECTION EARTH GROUND CONNECTION OF LINCOLN GLOBAL INC SINCE COMPONENTS OR CIRCUITRY ON A EQUIPMENT TYPE PRECISION TIG 185 225 THE IDRAWN BY 2 8 2008 DOCUMENT DOCUME Mic pao ET ES SUBJECT SCHEMATIC CONTROL PCB DOCUM PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL TO OTER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION HAVING A EON CODE NUMBER J APPROVED Dis Ale 2 15 2008 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual PRECISION TIG 225 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO lo O O RE e r HE E oiz 9 9 3E oO cc ff Return to Section TOC Return to Master TOC G 5 ELECTRICAL DIAGRAMS SCHEMATIC CONTROL PC BOARD 2 G5640 J2 T lt n 1 Ti E iw 415V 50V La mo PTH
4. AC DC Stick amp Bal TIG w 60 4 with Max Aux load or E 50 Auto Bal TIG w o Aux 5 409 AC Auto Bal TIG with 2 Max Aux Load 6 30 20 10 0 50 70 90 110 130 150 170 190 210 230 Output Amps Output Limits allow for continuous max rated load on 115vac auxiliary receptacle Wiring and protection based on the 2005 U S National Electric Code 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 PRECISION TIGO 225 LINCOLN a INSTALLATION a TECHNICAL SPECIFICATIONS CANADIAN K2533 2 INTERNATIONAL K2534 1 K2533 2 INPUT at Rated Output Voltage Phase Freq Current Power Factor Idle Current 460 575 1 60 18 A 15 A Effective 0 62 Min 1 3 A 1 0 A Max 42 A 33 A Max E C US Return to Section TOC Return to Master TOC K2534 1 INPUT at Rated Output Voltage Phase Freq Current Power Factor Idle Current 380 400 415 1 50 60 21 A 20 A Effective 0 62 Min 1 5 A 1 4 A Max 50 A 48 A Max INS0 eS OUTPUT RANGE Max OCV Weld Current Output Type 75 V AC 5 230 A AC CC Constant Current 66 V DC 5 230 A DC AC or DC RATED OUTPUT Process Duty Cycle Weld Current Weld Voltage NEMA Return to Section TOC Return to Master TOC SMAW 15 225 A AC DC 29 0 V 20 18
5. Carefully rotate the polarity switch assembly to gain access to the micro switch Carefully unsolder the two leads 311 and 312 from the micro switch located on the polarity switch assembly See wiring diagram Label leads and connection points for reassembly Carefully remove the polarity switch assembly from the machine PRECISION TIG 225 LINCOLN F 46 ind TROUBLESHOOTING AND REPAIR ini POLARITY SWITCH 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 correctly Return to Section TOC Return to Master TOC 2 Solder leads 311 and 312 to the micro switch 3 Assemble and tighten the two nuts and washers that hold the polarity switch to the front panel 4 Assemble the X1 secondary lead to the polarity switch Make certain washers are in place and the nut is tight 5 Assemble the choke lead to the polarity switch Make certain washers are in place and the nut is tight Return to Section TOC Return to Master TOC 6 Assemble the flat copper leads to the polarity switch Make certain they are connected to the proper terminals and the nuts are tightened 7 Assemble the flex lead from diode D1 to the rear gang of the polarity switch Make certain washers are in place and the nut is tight 8 Assemble the flex lead from
6. Do not touch electrically hot parts Always connect the PRECISION TIGO 225 to a power supply grounded per the National Electrical Code and any local codes SELECT SUITABLE LOCATION MOUNTING Environmental Rating The PRECISION TIGO 225 power source carries an IP21S environmental 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 The PRECISION TIG 225 must be located where there is free circulation of clean air such that air movement in and out the back air vents will not be restricted Dirt and dust that can be drawn into the PRECISION TIGO 225 should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown GRINDING Do not direct grinding particles towards the welder An abundance of conductive material can cause mainte nance problems STACKING PRECISION TIG 225 cannot be stacked LIFTING AND MOVING The PRECISION TIGO 225 models are provided with an Eyebolt used for lifting the unit with a hoist To install remove the plug button from the case top and screw the Eyebolt securely into the threaded bracket beneath the case top per the below instruc tions
7. ma TROUBLESHOOTING AND REPAIR E TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED DC STICK MODE 44 CAUTION HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC Return to Master TOC O lo O o j slo Y 50 volts olz 9 29 0 volts c j 5 j 3 oilo cc lf 2ms MACHINE LOADED TO 180 AMPS AT 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 QO lo O o j C O J 2 0 Ola a 3 9 FS cre 5 j 3 lo cic Note Scope probes connected at machine output terminals probe to electrode probe to work SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN did TROUBLESHOOTING AND REPAIR didi ABNORMAL OPEN CIRCUIT VOLTAGE DC TIG MODE ONE OUTPUT SCR NOT FUNCTIONING A CAUTION HIGH VOLTAGE HIGH FREQUENCY can damage test equipment e Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC R
8. A Foot Amptrol is included with the PRECISION TIGO 225 Ready Pak models and available for other models See Accessorfes Section 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 TIG modes activating the Amptrol energizes the electrode terminal and varies the output welding current from its minimum value of 5 Amp DC or AC to the maximum value set by the Current Control on the control panel This helps elimi nate accidental high current damage to the work piece and or tungsten and provides a fine control of the cur rent 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 reli
9. 2 thoriated tungsten PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O j O EP C O J 2 0 Ola A 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC n OPERATION ndi 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 4 Place the electrode in the electrode holder A WARNING Ke In Stick Mode the output terminal and electrode will be electrically hot whenever the power switch is turned on 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 fre quency TIG arc starter are disabled RECOMMENDED ELECTRODE AMPERAGE RANGES PRECISION TIG 225 The PRECISION TIG 225 is rated from 5 225 Amps SMAW Process Welding Amp Range for Stick Electrode Size Mild steel procedures are based on recommended procedures listed in C2 10 8 94 and t
10. o C102 En zer ETI QO O O O E E CIS HE E oiz 9 9 3E oO rc fc O E R189 o m 20 gt L3 N 8 80 9 00 909009 E ME G5641 2CO NK COVPONENI SIDE x a CODE TEST PER E4238 C CQAT WITH E1844 AND E3668 2 COATS SCHEMATIC REFERENCE G5640 2C0 MAKE DETAIL MANUFACTUR PER E1911 RoHS BUY BLANK COMPLETE li BOARDS PER PANEL 4 LAYER BOARD BLANK PANEL SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC MANUFA UHIN OLEHAN PEH 056 CLEVELAND SCALE xur jenne or gk ME AE EQUIPMENT TYPE PRECISION TIG 185 225 PAGE oF 2 0 Ie ONALL ANGLES IS SOFADEGREE i r PRINTED SUBJECT CONTROL PC BOARD ASSEMBLY rogue DOCUMENT MATERIAL TOLERANCE 1 TOAGREE owners Teng Nen PRESSE REFERENCE G5641 2 DO NOT SCALE THIS DRAWING INCH _ oisposttion UF Moves CRM36266 G4551 1 A SOLID EDGE EN 170 Insight Return to Section TOC Return to Master TOC 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
11. 78VAC 115VAC 311A O 311 PULSE 115VAC E 115VAC s2A Y V coNTROL O DISPLAY l e X2 x7 0 231 L 72 T1 A REAR VIEW SHOWN IN AC POSITION QO lo O O E E Cil E oiz o 5 3E Q oO cc Ir Return to Section TOC Return to Master TOC LINCOLN E WORK ELECTRODE O PULSE S FREQ LED J1 1 221 THERMAL 2 gt R 222 LED idi POSTFLOW D did i NEDA CONTROL ie 2 B OUTPUT D E rr TCC CONTROL 3i J6 lt CONTROL PC BOARD 3 L3 L2 239 238 SPARK GAP STARTER AS BLY C3 T3 BYPASS STABILIZER PC BOARD 285 284 L NCOLN ELECTRIC 3 0 BY PASS CAPACITORS 0047 250VAC HIGH VOLTAGE CAPACITOR 0025 10kV PHASE SHIFT CAPACITOR 15 250VAC BY PASS CAPACITORS 22 400VDC 20A CIRCUIT BREAKER 208V 230V ONLY 6A CIRCUIT BREAKER 380V AND ABOVE FREE WHEELING DIODE 284 284B OUTPUT INDUCTOR CHOKE R2 R1 HIGH FREQUENCY INDUCTORS RF TOROID CHOKES 285 285B HOLDING RESISTORS 100 100W PHASE SHIFT RESISTOR 200 100W MICRO START RESISTORS 12 100W INPUT POWER SWITCH POLARITY SWITCH MICROSWITCH ON POLARITY SWITCH MAIN CHOKE THERMOSTAT MAIN POWER SCR S GAS SOLENOID VALVE 115VAC MAIN TRANSFORMER HIGH VOLTAGE TRANSFORMER HIGH FREQUENCY TRANSFORMER CLEVELAND OHIO GAS VALVE e 23 O PS SV1 COMPONENT VALUE LEAD COLORING CODE UNITS RESISTORS OHMS WATTS CAPACITORS
12. C4 S 12 5 OHM TYP 0015 12KV near front D RED 4 GREEN us 2J4 FAN 115VAC 560 15 250 5 5 OHMS O NEXT TO MODE SWITCH NEXT TO MODE SWITCH TYP 145 KOHMS SPARK HIGH FREQ Tomororrocesson TISVAC TYP 12 5 OHM TYP GAP 020 TRANSFORMER OUTPUT INDUCTOR QO 2 o ANDSCRGATING a C6 Ly 5000V L3 rab LED6 PHASE Y q 22 400V F RYAN N 285 e Qo 2 LED 4 LED 5 j E ac Sa Nr REHMA He 231B B Center front AUTOBALANCE X 7 FREQUENCY olo GREEN 7 GREEN V YELLOW HAY AV YELLOW ENT 231A HI FREQ CIRCUIT WORK 8 TN E NEXT TO BALANCEFOT NEXT TO PULSE NEXT TO METER NEXT TO METER 239 E c OFF IN STIOKAND DC TIG OF IN ST HING AT benca n 233 oH FREQUENCY RATE 232A EM d 2 9 e 20A 208V 230V CB1 41 GAS ELECTRODE a12 Bi m z PA GBON ia Right Side SOLENOID Right front GANG LOCATIONS ARE oic 24V DONOT REVERSE LEADS lt VIEWED FROM REAR OF oc cC PHASE TIMING 235 231 gt MOUNTING HOLE SWITCH 15V O e TRIGGER TRIGGER 45V O c X5 232 232 INTERFACE TOMCPO s5Vref oO CONTROL BOARD SUPBLY A 435O NS TYP Ti POLARITY SWITCH MICRO SWITCH 15V O ITI ma AC AC D E B F OPEN AUTOLOCAL REMOTE siden DC B D C E A F G H CLOSED STICK MODE ALWAYS LOCAL Ti 42 TIBVAD a FAN RUNS FOR 5 S AT POWER UP EVAG DC B D A E C F G H q TIG MODE REVOTE IF PLUGGED OHMS TYP STOPS AT IDLE 8 MINUTES SCR1 ee A AAA LOCAL IF UNPLUGGED 2 PIN o E 4
13. 208 230 1 60 Machine K2533 1 9 ft 2 7m Input Cable with NEMA 6 50P Plug 1 PRECISION TIGO 225 Ready Pak K2535 1 NEMA 6 50R Receptacle Integrated 10 ft 3 1m Work Lead w Clamp 208 230 1 60 Machine K2533 1 Gas Regulator with 10 ft 3 1m Hose 9 ft 2 7m Input Cable with NEMA 6 50P Plug PTA 17 12 5 Ultra Flex Torch K1782 12 Includes NEMA 6 50R Receptacle 9 32 2 Th Tungsten Integrated 10 ft 3 1m Work Lead w Clamp 3 32 Collet 10N24 e Gas Regulator with 10 ft 3 1m Hose 3 32 Collet Body 10N32 e PTA 17 12 5 Ultra Flex Torch K1782 12 Includes 7 Alumina Nozzle 10N47 3 32 2 Th Tungsten 3 32 Collet 10N24 Foot Amptrol K870 3 32 Collet Body 10N32 TIG Slide Rule WC332 47 Alumina Nozzle 10N47 GTAW Book JFLF 834 Foot Amptrol K870 Lift Eyebolt TIG Slide Rule WC332 Under Storage Cart K2348 1 GTAW Book JFLF 834 e Lift Eyebolt Included with K2533 1 Machine Only model The PRECISION TIGO 225 will also be available as Basic models with Domestic Canadian and International input voltages for user configuration with optional accessories See Table C 2 TABLE C 2 Select Machine 208 230 1 60 Machine with 9 ft 2 7m NEMA 6 50P Plug Cable and Receptacle K2533 1 460 575 1 60 Machine only with Cable K2533 2 380 400 415 1 50 60 Machine only with Cable K2534 1 Optional Water Cooled System Air Cooled System ll K2267 1 TIG Mate 20 Torch Starter Kit K
14. 4 The control board may be faulty Replace 1 Possible gas supply problems Consult your local welder gas dis tributor 44 CAUTION 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 troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIGO 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS cre 5 3 lo cic Return to Section TOC Return to Master TOC diis TROUBLESHOOTING AND REPAIR PIS Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS When AC TIG welding the arc is 1 The tungsten electrode may be Check components R3 and C4 erratic and there is a loss of too small for the process Use in the high voltage transformer cleaning of the work piece a larger diameter tungsten or a primary circuit pure tungsten If a helium blend is used as a Perform the SCR Bridge Test shielding gas then reduce the percentage of helium The end of the tungsten electrode 1 The welding current is too high 1 This may be a welding proce melts away for the electrode type and or dure problem size See Table B 1 in the Operatio
15. 630V 596 BOX R16 R17 R30 R81 R32 i C11 C14 C19 C21 C22 R51 R60 R61 R92 7 C33 C48 C50 C51 C52 P167 Riad Rios R08 15 S25000 1001SMT RESISTOR SMD METAL FILM 1 10W 1 00K 1 S0805 i C55 C56 C62 C64 C66 R212 R215 O C68 C74 C75 C76 C79 S25020 3SMT CAPACITOR SMD CERAMIC 0 1MF 50V 10 X7R S0805 R18 1 S25000 5622SMT RESISTOR SMD METAL FILM 1 10W 56 2K 1 S0805 C80 C81 C82 C83 C85 R19 R64 R157 R160 C93 C98 C100 C105 R165 R170 R217 R218 10 S25001 47R5SMT RESISTOR SMD 47 50HMS 1 4W 1206 1 TR C107 C108 C112 R219 R220 O O C15 C63 S25020 4SMT CAPACITOR SMD CERAMIC 820pF 50V 5 COG S0805 R20 R36 R41 R54 4 S25003 15ROSMT RESISTOR SMD 1W 15 00HMS 1 O O C16 C40 C113 S25020 14SMT CAPACITOR SMD CERAMIC 330pF 100V 5 C0OG S0805 R21 1 S25000 7681SMT RESISTOR SMD METAL FILM 1 10W 7 68K 1 S0805 E C27 C36 C37 S25020 7SMT CAPACITOR SMD CERAMIC 0 22MF 50V 20 X7R S1812 R22 1 25000 4752SMT RESISTOR SMD METAL FILM 1 10W 47 5K 1 S0805 po C28 S25020 248MT CAPACITOR SMD CERAMIC 1 0MF 25V 10 X7R 51206 R23 R79 2 _ S25000 2213SMT RESISTOR SMD METAL FILM 1 10W 221K 1 S0805 c Pa X XXX X O DISP1 LED2 C46 C49 S13490 199 CAPACITOR ALEL 220 25V 20 LOW ESR R24 1 S25001 2210SMT RESISTOR SMD 221OHMS 1 4W 1206 1 TR O o i j gt X LEDI C47 13490 179 CAPACITOR ALEL 1000 35V 20 R25 R75 2 S25006 10ROSMT RESISTOR SMD METAL FILM 1 2W 100HMS 1 S2010 B 0 X O a ee Ha ka T11577 52K CAPACITOR
16. 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 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the 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 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker expo sure level should be checked upon installation and periodi cally thereafter t
17. CD 0047 005 1400V 20 R88 nag R 2 S25008 1002SMT RESISTOR SMD PREC MF 1 10W 10 0K 0 596 80805 D U X X C57 C61 C65 313490 197 CAPACITOR ALEL 82 35V 20 LOW ESR Bi SA Riga 6 S25001 10008MT RESISTOR SMD 1000HMS 1 4W 1206 196 TR UN 2 X X XX X S a LED6 C67 C77 R37 R85 R106 3 S25000 3322SMT RESISTOR SMD METAL FILM 1 10W 33 2K 1 S0805 O C71 C72 C87 C88 C102 T11577 58K CAPACITOR CD 0047 3000V 20 R39 R81 R82 R98 Q q lS D3 D5 D7 D8 T kuz Lw E ind E a 13 S25000 4751SMT RESISTOR SMD METAL FILM 1 10W 4 75K 1 S0805 ie a gem LE S25040 1SMT DIODE SMD 1A 400V FAST RECOVERY DO 214BA e D21 D22 R211 a D4 D6 D16 D18 D19 R40 R46 R47 R73 R74 2 4 D20 D28 D31 D32 D35 S25040 5SMT DIODE SMD DUAL 0 200A 70V UFR R76 R77 R86 R96 R97 14 S25001 4751SMT RESISTOR SMD 4 75K 1 4W 1206 1 TR Qo 0 D40 D41 R141 R142 R179 R180 tc cc even is pes Ras R199 R209 H213 5 S25000 2210SMT RESISTOR SMD METAL FILM 1 10W 221OHMS 1 S0805 DIS D17 D23 D29 47 s25040 25MT _ DIODE SMD 1A 400V D0 214BA AC R214 D30 D33 D34 D36 D37 R59 R136 2 S25000 4750SMT RESISTOR SMD METAL FILM 1 10W 475OHMS 1 S0805 O O O O D38 D39 R62 1 S25000 1000SMT TRESISTOR SMD METAL FILM 1 10W 100OHMS 1 S0805 D24 D25 D26 D27 4 925040 10SMT DIODE SMD 3A 400V D0 214AB R63 R120 2 S25000 8251SMT RESISTOR SMD METAL FILM 1 10W 8 25K 1 S0805 DISP1 1 S17395 11 LED DISPLAY 7 SEGMENT CC 3 DIGIT
18. E 8 Overload ProteCUON CP E 8 FIGURE E 1 PRECISION TIG 225 BLOCK LOGIC DIAGRAM BY PASS BOARD gt WORK SWITCH ELECTRODE MAIN HI FREQUENCY TRANSFORMER TRANSFORMER INPUT POWER SWITCH BYPASS ASBLY H1 E X1 H2 o HIGH VOLTAGE TRANSFORMER H3 E CIRCUIT ji E E Ll B A C K CY YN YN CY E 115VAC amp CONTROL 115 VAC BOARD olaa Receptacle DISPLAY Circuit Breaker Protected MODE eS SWITCH REMOTE E RECEPTACLE THERMAL GAS oru OUTPUT LIGHT VALVE CONTROL AUTO PULSE TIG STICK AC PULSE POSTFLOW BALANCE FREQ LED LED BALANCE CONTROL CONTROL LED LED CONTROL PRECISION TIGO 225 LINCOLN Return to Section TOC Return to Master TOC QO O E 9 O U D r Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC in THEORY OF OPERATION ais FIGURE E 2 General Description amp Input Power Circuit MAIN TRANSFORMER BYPASS LY ASB H1 al X1 le H3 uH g O gt O gt U TI TI TI 115 VAC Receptacle Circuit Breaker Protected REMOTE RECEPTACLE RN AUTO PULSE TIG STICK BALANCE FREQ LED LED LED EED GENERAL DESCRIPTION The PRECISION TIGO 225 is a member of our field acclaimed PRECISION TIGO family of industrial arc welding power sources Premium features include 1 Precise constant current output 2 Full rang
19. Lincoln Electric This information is pro vided for reference only 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 Improper PC board repairs could result in damage to the LINCOLN o i Tinco A machine PRECISION TIG 225 za ELECTRICAL DIAGRAMS G 8 PC BOARD ASSEMBLY CONTROL 2 G5641 Q O O 2 wW9S9 ENGINEERING CONTROLLED CHANGE DETAIL NEW ITEM USED WITH QTY ocn 1 S15000 348MT IC SMD OPTOCOUPLER HMA124 c a MANUFACTURER Yes 1 1 G5641 C PC BOARD BLANK OCI2 OCI3 OCI4 OCI5 4 S15000 16 OPTOCOUPLER TRIAC DRIVER ZV C 3083 Qo 2 TAM TRIB X5 Q1 Q6 2 T825051 11SMT TRANSISTOR SMD NMF DPAK TO 252 48A 100V SS O 4 3 TRI TRIS X5 8 TE106A 13 6 LOCK WASHER Q2 Q3 Q5 Q7 Q9 Q10 A Y 4 TAM TRI X5 Q12 Q13 Q15 Q16 12 S25050 1SMT TRANSISTOR SMD NPN 0 5A 40V SOT 23 MMBTA4401L T1 gs 5 TRI TAB X5 sw Uig 2 2 6 1 526585 4 PSOG SOFTWARE Q4 Q8 Q11 Q14 4 525050 2SMT TRANSISTOR SMD PNP SOT23 0 5A 40V MMBT4403LT1 7 AS REQIE2861 SEALANT R1 R2 R3 3 T10812 116 POT SINGLE TURN 0 25W 10K 10 olo 8 AS REQ E2519 1 SEALANT R4 R49 R50 R68 R69 4 e i R72 R107 R122
20. 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 Improper PC board repairs could result in damage to the LINCOLN E machine PRECISION TIGO 225 ELECTRIC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO lo O O RE e r HE E oiz 9 9 3E oO cc ff Return to Section TOC Return to Master TOC G 9 ELECTRICAL DIAGRAMS G 9 SCHEMATIC BYPASS PRINTED CIRCUIT BOARD S22530 LINCOLN amp ENGINEERING CONTROLLED CHANGE DETAIL NEW 08 L O S6CS MANUFACTURER No ARC STABILIZER CAPACITOR ARC STABILIZER RESISTOR C9 15 10 CE 5W CONNECTION MADE THROUGH CONNECTION MADE THROUGH HOLE WITH SOLDER PAD HOLE WITH SOLDER PAD C1 C2 C3 C4 TP TP2 C5 C6 C7 C8 Graphic 05 05 05 05 y et 05 DE raphic p 600V 600V 600V 600V a 160 160 600V 600V 600V OON GND TX GND CONNECTION MADE THROUGH SOLDER PAD AND SCREW TO STEEL STANDOFF ON MACHINE THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIA TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC EQUIPMENT TYPE BYPASS STABILIZER BOARD page tort 2250 Lacer o ONET vu DeL L RO NOTE This diagram is for reference only It
21. MFD VOLTS B BLACK R RED G GREEN W WHITE CONNECTOR PIN NUMBERS EXAMPLE THIS IS PIN 7 OF CONNECTOR J4 VIEW OF CONNECTOR ON PC BOARD ELECTRICAL SYMBOLS PER E1537 G5646 A NOTE This diagram is for reference only lt 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 PRECISION TIGO 225 G 3 SCHEMATIC COMPLETE MACHINE ALL CODES G5647 ELECTRICAL DIAGRAMS
22. O J 2 0 Ola a 3 9 FS cre 5 j 3 lo cic Return to Section TOC Return to Master TOC dii TROUBLESHOOTING AND REPAIR A Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Machine regularly over heats Machine regularly over heats ther 1 The thermostat s may be thermostat opens Yellow light on mostat opens Yellow light on front faulty Check or replace front panel glows The fan runs panel glows The fan runs but the but the machine has no output machine has no output The control board may be faulty The machine does not have output The machine does not have output 1 Check the Stick TIG switch S3 in the Stick mode The machine in the Stick mode The machine and associated leads See operates correctly in the TIG mode operates correctly in the TIG mode wiring diagram 2 The control board may be faulty 44 CAUTION 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 troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIGO 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j Cl O J 2 0 Ola a 3 9 FS cre sla Jl cic Return to Se
23. R65 R66 R94 R95 ji XXXXXX XXXXXX MA NN CER a 6 s25008 4751SMT RESISTOR SMD PREC MF 1 10W 4 75K 0 5 S0805 i X X DZ2 DZ3 2 S25046 38MT ZENER DIODE SMD 0 5W 18V 5 SOD123 R67 1 S25000 1003SMT RESISTOR SMD METAL FILM 1 10W 100K 1 S0805 l X X HS vv E IDE 2 2 2 RO P RIM RIZ 6 S25000 3321SMT RESISTOR SMD METAL FILM 1 10W 3 32K 1 S0805 H DZ5 DZ6 2 S25045 31SMT ZENER DIODE SMD 225mW 12V 596 SOT 23 R202 R204 i cama X C X DZ7 DZ9 2 S25044 35MT ZENER DIODE SMD 3W 12V 5 SMB R71 1 S25000 1004SMT RESISTOR SMD METAL FILM 1 10W 1 00M 1 S0805 X X J1 1 S24020 2G CONNECTOR MOLEX MINI PCB 2 PIN GOLD R78 1 S25001 1002SMT RESISTOR SMD 10K 1 4W 1206 196 TR y i J2 1 S24020 8 CONNECTOR MOLEX MINI PCB 8 PIN TIN R80 R83 R216 3 S25000 1212SMT RESISTOR SMD METAL FILM 1 10W 12 1K 1 S0805 EX o X NC J3 1 S24020 12 CONNECTOR MOLEX MINI PCB 12 P IN TIN R87 R88 R89 R99 Ev ya 1 S24020 4 CONNECTOR MOLEX MINI PCB 4 PIN TIN R100 R101 R102 R205 10 S25000 47R5SMT RESISTOR SMD METAL FILM 1 10W 47 50HMS 1 S0805 AXXXX J5 R206 R207 LED5 J6 1 18248 4 CONNECTOR MOLEX MINI PCB 4 PIN R93 1 25000 2671SMT RESISTOR SMD METAL FILM 1 10W 2 67K 1 S0805 O O L1 L2 L3 L4 L5 5 T12218 9 CHOKE RF 390UH 5 225MA CONFORMAL R105 R110 2 S25003 47R5SMT RESISTOR SMD 1W 47 5OHMS 1 Q O LED1 R114 1 S25000 6811SMT RESISTOR SMD METAL FILM 1 10W 6 81K 1 S0805 O y LED2 LED6 T13657 14 LED T 1
24. TIG 225 and remove the case wrap around cover 2 Locate and remove plug J2 from the control board See Figure F 3 O j O O o EP C OFT 1 0 Ola A 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN rez TROUBLESHOOTING AND REPAIR ee CASE COVER REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 4 SCR TEST POINTS SCR2 CATHODE Return to Section TOC Return to Master TOC SCR1 ANODE I SCR3 CATHODE SCR4 ANODE Return to Section TOC Return to Master TOC SCR3 ANODE SCR4 CATHODE TEST PROCEDURE continued 3 Using an analog ohmmeter test the resistance from anode to cathode of SCH1 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 Bridge Assembl Removal and Replacement 4 Repeat Step 3 testing SCR2 SCR3 and SCR4 OTTO O o j C O J 2 0 Ola A 3 9 FS c j 5 j 3 Dio cla 5 The further check the SCR s functions use an SCR tester and proceed to the Active SCR Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN NOTES didi PRECISION TIGO 225 LINCOLN E F 24 JO Je1sey 0 uJh 9H NOL Je1Se A 0 Winey NOL Je1Se A 0 Winey NOL Je1Se A 01 Winey DOL Uuo l99S oj UNAY DOL Uuo
25. a radio transmitter may cause radio TV and electronic equip ment 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 unground ed metallic objects Keeping these contributing factors in mind installing equipment per the following instructions should minimize problems 1 Keep the welder power supply lines as short as possi ble 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 con tact between this conduit and the welder case ground Both ends of the conduit should be connected to a dri ven ground and the entire length should be continuous 2 Keep the work and electrode leads as short as possi ble 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 frequency leak age 4 Keep the torch in good repair and all connections tight to reduce high frequency leakage 5 The work piec
26. and CGA publication P I 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 Return to Master TOC Return to Master TOC O O 0 U gt 9 c E r Return to Master TOC PR CAUTIONS DE S RET 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 Les circuits l lectrode et a la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact 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 princi
27. and leads B231 and B232 to the main transformer leads See wiring diagram Insulate connections Replace any previously removed cable ties Glear leads and check for shorts or grounds 12 Perform the SCR Bridge Assembl Replacement Procedure PRECISION TIG 225 LINCOLN F 55 NOTES F 55 RETEST AFTER 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 Return to Section TOC Return to Master TOC INPUT IDLE AMPS Input Volts Hertz Maximum Idle Amps 208 60 2 70 Amps 230 60 3 00 Amps OPEN CIRCUIT VOLTAGES AC 70 75VAC Stick Mode OCV DC 55 66VDC TIG Mode OCV AC 70 BOVAC DC 60 66VDC MAXIMUM ACCEPTABLE OUTPUT VOLTAGE AT MINIMUM OUTPUT SETTINGS MINIMUM ACCEPTABLE OUTPUT VOLTAGE AT MAXIMUM OUTPUT SETTINGS RECOMMENDED METERS FOR MACHINE OUTPUT TESTS Return to Section TOC Return to Master TOC Q O O O EE E x O J 2 1 0 Q 2 9 9 c j 5 35 olo tlm VOLTMETER AC and DC True RMS Meter Fluke 8922A or equivalent AMMETER Columbia Type AX AC or DC Tong Ammeter IMPORTANT IF OTHER TYPE METERS ARE USED RESULTS MAY NOT BE ACCURATE Return to Section TOC Return to Master TOC PRECISION TIGO 225 LINCOLN NOTES ii PRECISION TIGO 225 LI
28. bridge assembly 11 Using the 7 16 wrench disconnect the diode pigtail connection from the polarity switch lead See Figure F 10 Cut any necessary cable ties and remove insulating sleeving Note placement of sleeving and cable ties for reassembly 12 Using the 7 16 wrench remove the X2 sec ondary transformer lead from the left side AC SCR heat sink With the 7 16 wrench remove the shunt from the SCR bridge left side negative heat sink Using the 7 16 wrench remove the polarity switch lead from the right side AC SCR heat sink Using the 7 16 wrench remove the positive lead from the right side positive heat sink PRECISION TIG 225 LINCOLN F 41 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C con Be 1 Ola a 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC Aa TROUBLESHOOTING AND REPAIR poe SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 9 PLUG J2 ON CONTROL BOARD PLUG J2 REMOVED PRECISION TIG 225 CONTROL FIGURE F 10 DIODE PIGTAIL CONNECTION TO POLARITY SWITCH LEAD DIODE PIGTAIL CONNECTION PRECISION TIG 225 LINCOLN dii TROUBLESH
29. horizontal division represents 2 milliseconds in time QO j O O o j C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Note Scope probes connected at machine output terminals probe to electrode probe to work SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN nd TROUBLESHOOTING AND REPAIR id NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM AC STICK MODE A CAUTION HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC Return to Master TOC 50 volts O volts Return to Section TOC Return to Master TOC 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 QO j O O o j C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Note Scope probes connected at machine output terminals probe to electrode probe to work SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN a TROUBLESHOOTING AND REPAIR oe NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM DC STI
30. input cable strain relief to allow movement of case back Using the 3 8 nutdriver remove the two lower screws from the case back See Figure F 7 With the 5 16 nutdriver remove the two screws holding the case back to the internal divider panel See Figure F 7 Remove the gas hose from the gas solenoid valve Carefully pull the case back and fan assembly REAR PANEL MOUNTING SCREWS away to allow access to the SCR Bridge Assembly Support the case back so as not to stress the fan motor leads It is not necessary to disconnect the fan motor leads Using the 5 16 nutdriver remove the two screws holding the front panel assembly to the base See Figure F 8 PRECISION TIG 225 LINCOLN F 40 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola A 3 9 FS c j 5 j 3 lo cic Return to Section TOC Return to Master TOC A TROUBLESHOOTING AND REPAIR SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 8 FRONT PANEL MOUNTING SCREWS FRONT PANEL MOUNTING SCREWS PROCEDURE continued 13 9 Remove plug J2 from the control board See Figure F 9 Also remove plug and lead harness 44 from internal divider panel 10 Carefully slide the internal divider panel away a few inches to allow access to the SCR 15
31. installed on all models The Domestic models 208 230V also are equipped with a NEMA 6 50P plug 2 GAS INPUT CONNECTOR This is a 5 8 18 right hand thread female fitting for connection of input gas supply 3 COOLING AIR VENTS Air is drawn in through the upper vents and exhausted out through the lower vents The louver baffle steers exhaust air down and prevents it from re entering the upper vents 4 MACHINE RATING PLATE 5 RECEPTACLE AND CIRCUIT BREAKER 115vac auxiliary NEMA 6 20R PRECISION TIG 225 LINCOLN i OPERATION OPERATING STEPS WELDING IN TIG MODE 1 Connect the TIG torch and cable Twist Mate quick connect plug to the Electrode Gas output recepta cle This receptacle also contains an integral gas connection for the torch Connect the work clamp to the work piece Return to Section TOC Return to Master TOC 2 Set the TIG STICK switch to TIQ 3 Set the Polarity Switch to DC for welding steel or stainless steel or to AC for welding aluminum 4 Connect the Foot 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 NOTE There will be a 15 second gas flow when the power is turned on 7 Preset the Output Control on the control panel to the maximum desired amps as read on the digital meter Return to Section TOC Return to Master TOC 8 Depress the Foot Amptrol
32. l998S o UNY DOL Uuo l99S oj UNY DOL uo l998S oj UNAY Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j Cin O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC F 25 TROUBLESHOOTING AND REPAIR ACTIVE SCR TEST A WARNING 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 throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will determine if the device is able to be gated ON and conduct current from anode to cathode MATERIALS NEEDED An SCR tester as outlined in this procedure PRECISION TIGO 225 Wiring Diagrams 3 8 nutdriver PRECISION TIGO 225 LINCOLN F 25 disa TROUBLESHOOTING AND REPAIR dii ACTIVE SCR TEST continued FIGURE F 5 ACTIVE SCR TEST SETUP Return to Section TOC Return to Master TOC oW1 H2 Ls 6volt L antern Batter
33. may not be accurate for all machines covered by this manual UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS x 02 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS XO NOT SCALE THIS DRAWING L peroo NONE S22530 1B0 PRECISION TIGO 225 G 10 ELECTRICAL DIAGRAMS G 10 PC BOARD ASSEMBLY BYPASS L10121 e LC LO L1 ANDER RES NE CHANGE DETAIL REVISED P C BOARD BLANK INFORMATION REFERENCES PART NUMBER DESCRIPTION CT C2 Ca C4 C5 C6 C7 C8 8 T1157758K CAPACITOR CD 0047 3000V 20 CAPACITOR POLYPROPYLENE METALLIZED P C BOARD BLANK INFORMATION BUY COMPLETE AS L10121 D 2 LAYER BOARD PER E3281 CAPACITORS MFD VOLTS WITH LEAD FREE HASL SURFACE FINISH INDUCTANCE HENRYS MAKES 12 BOARDS PER PANEL SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION QO O 9 p QO Oo U O a J D ag Return to Master TOC ITEM REQ D PART NO IDENTIFICATION TEST PER E3553 B OJO O O Flr e a E e hs oiz 9 9 cic D e Qo D rc fc O SS XXXXXXXXXXXXXSS B x P e r e Ww EN x lt NOTES MANUFACTURED AS x d N C SQUEEZE TOGETHER ITEMS C1 C4 TP1 AND A a x C5 C9 TP2 BEFORE APPLYING SEALANT O lo E L10121 3D0 OIIO s a N D APPLY SEALANT AS SHOWN RE Im el SS N F KEEP THIS AREA FREE OF ENCAPSULATION T
34. nnnm F 29 re Normal Open Circuit Voltage Waveform DC TIG Mode E kk kK kK F 30 Normal Open Circuit Voltage Waveform AC Stick Mode ooooononiccnincccconnnnonnncon con keke keke ka kek ek keke F 31 ts Normal Open Circuit Voltage Waveform DC Stick Mode ooocccccccoccccccconcnncoconononocononononnanonncononcnnnos F 32 Typical Output Voltage Waveform Machine Loaded AC TIG Mode coooccccccnocccccccncccnccnnnccnnnnnanonononanoss F 33 Typical Output Voltage Waveform Machine Loaded DC TIG MOde iSSil kez F 34 Typical Output Voltage Waveform Machine Loaded AC Stick Mode occcoocccccncccccccccncnoncnononononnncnnnnas F 35 Typical Output Voltage Waveform Machine Loaded DC Stick MOde Ei kk EEE F 36 Abnormal Open Circuit Voltage DC TIG Mode One SCR not Functioning ssssesse F 37 Q Replacement Procedures p SCR Bridge Assembly Removal and Replacement kk KAK F 39 E Polarity Switch Removal and Replace ment kk kk kak kk k nnn nnns F 45 High Voltage Transformer Removal and Replacement cccseccccseeeccceeeeceeeeecaeeeeeeeeeeeseeeeeseseesaeeees F 49 O c Main Transformer and Output Choke Removal and Replacement EE F 53 or Retest ANG AAA PP e o O o EI F 55 O O E 9 v U gt 9 c 2 D LE PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO
35. 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 A SOUDER A TRANSFORMATEUR ET A REDRESSEUR Relier a 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 Mar 93 Return to Master TOC Return to Master TOC O O 0 U gt 9 c E r Return to Master TOC SAFETY 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 89 336 EEC lt was manufactured in conformity with a national standard that implements a harmonized
36. power may be left on and the reset should occur within a 15 minute period If the fan is not functioning properly or the air intake louvers are obstructed then the input power must be removed and the fan problem or air obstruction corrected OVERLOAD PROTECTION The machine is electronically protected from producing excessively high output currents The output is limited to 200 amps 115 VAC RECEPTACLE The auxiliary receptacle is circuit breaker protected Canadian K2J33 2 and International K2J34 1 modes are 6 amps K2533 1 and K2535 1 2 208 230 1 60 modes are rated 20 amps PRECISION TIG 225 LINCOLN Fl TABLE OF CONTENTS TROUBLESHOOTING AND REPAIR F 1 O O Tr ollbi sh oolilig and Re Dal is i cares ects M F 1 2 2 How to Use Troubleshooting Guide kk kk kk kk kK ek kk kK KK KK K KAK k KA KK KA K KK K KK KK KK kk F 2 PC Board Troubleshooting Procedures and Replace ment kk kk F 3 Troubleshooting QUIE asciassasatai rtnttepaelaosro celtics n XZzBa x mggmgmmmmm F 4 Test Procedures High Frequency Circuit Disable Procedure ccccseececcsseecceesecceescecseuseeceseecsseeesausecsseeesseeeessanees F 15 TI TEATS Jy N E NE F 17 Static SCR mc F 21 E Active SOR TOS Tl eat F 25 a Oscilloscope Waveforms jo Normal Open Circuit Voltage Waveform AC TIG Mode i kk
37. screws EP INSTALLATION da INPUT LEADS L1 amp L2 S e LEAD H1 DO NOT REMOVE FOR LOWEST RATED VOLTAGE H2 CONNECTED FOR HIGHEST RATED VOLTAGE H3 CONNECTED BACK VIEW OF LINE SWITCH j FIGURE A 1 Reconnect Leads QUTPUT CONNECTIONS ELECTRODE GAS OUTLET RECEPTACLE TWIST MATE FIGURE A 2 Location of Output Connections CONNECTIONS FOR TIG GTAW WELDING TIG TORCH CONNECTION Refer to Included Equipment in the Operation Section of this manual for TIG welding equipment which is included with the PRECISION TIG 225 PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O j O EP C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC aad INSTALLATION aud CONNECTIONS FOR TIG GTAW WELDING TIG TORCH CONNECTION A PTA 17 Twist Mate TIG welding torch with cable and connector is supplied with the Ready Pak Models and available for other models See Section Turn the Power Switch OFF Connect the orch cable Twist Mate quick connect plug into the Electrode Gas Output Receptacle on the front of the welder and turn it clockwise until it is tight This is a Twist Mate
38. to Section TOC Return to Master TOC a TROUBLESHOOTING AND REPAIR a Observe Safety Guidelines detailed in the beginning of this manual High frequency spark is present 1 at tungsten electrode but operator is unable to establish a welding arc Machine has normal open cir 2 cuit voltage Refer to Specifications in the Installation Chapter 3 OUTPUT PROBLEMS The torch may be faulty Check or replace The current control may be set too low The tungsten electrode may be contaminated Replace or sharpen The electrode may be too large for the process If a helium blend is being used as a shielding gas then reduce the percentage of helium Check the welding cables for loose or faulty connections PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION 1 This may be a welding proce dure problem Contact The Lincoln Electric Service Department 1 888 935 3877 44 CAUTION 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 troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIGO 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS cre 5 3 lo cic Return to Section TOC Ret
39. to energize the torch and establish an an arc with the work piece The digital meter reads the actual amps while welding NOTE When the TIG STICK switch is set to TIG depressing the remote control will start a 0 5 second gas pre flow before energizing the TIG torch When the remote control is released the TIG torch is de energized and gas flow will con tinue for the time set by the Post Flow Time control When the polarity switch is set to DC the TIG Arc Starter will turn on and off auto matically 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 QO j O O j O EP Cin O J 2 0 Ola A 3 9 FS c j 5 3 Dio cla PULSE TIG CONTROL Use this knob to set the frequency or the number of pulses per second pps from 0 1pps to 20pps This setting adjusts heat output and bead shape for travel speed Thinner plate that is welded with faster travel speed will require higher frequency than thick er plate with slower travel speed 2 3pps is a typical starting point Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O j O EP Cin O J 2 0 Ola A 3 9 FS c j 5 3 Dio cla Return to Section TOC Return to Master TOC ES OPERATION uli REMOTE CONTROL OPERATION
40. 0 AAC DC 27 2 V 100 90 A AC DC 23 4 V 225 A AC DC 180 A AC DC 90 A AC DC Bal 80 A AC Auto Bal Inputs and ratings include a 6 amp rated load on the 115vac receptacle Based on a 10 minute cycle PHYSICAL DIMENSIONS 2 Machine Only 20 71 in 14 48 in 25 62 in Approx 192 lbs K2533 1 2 526 mm 368 mm 751 mm 87 1 kgs K2534 1 Ready Pak 20 71 in 14 48 in 25 62 in Approx 212lbs K2535 1 526 mm 368 mm 651 mm 96 2 kgs Ready PakW Cart 31 24 in 81 in 01 in Approx 258lbs K2535 2 794 mm 117 0 kgs O j O O o EP C O J 2 Ola A 3 9 FS c j 5 j 3 lo cic 2 Dimensions are without Lift Eyebolt and Torch Holder ENVIRONMENTAL RANGES Operating Temperature 4 F to 104 F 20 C to 40 C Storage Temperature 40 F to 185 F 40 C to 85 C Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O j O EP C O J 2 0 Ola A 3 9 FS c j 5 3 Dio cla Return to Section TOC Return to Master TOC du INSTALLATION Bes SAFETY PRECAUTIONS Read entire installation section before starting installation A 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
41. 2266 1 TIG Mate Torch Starter Select one Includes Kit Includes 200A PTW 20 12 5 ft 3 81m Torch 150A PTA 17 12 5 ft 3 81m Torch KP510 Parts Kit KP508 Parts Kit Regulator amp Hose Regulator amp Hose K1622 4 Twist Mate Torch Adapter K1622 1 Twist Mate Torch Adapter Water Hose amp Hose Coupler e Work Cable amp Clamp Not required for PRECI e Work Cable amp Clamp Not required for SION TIGO 225 PRECISION TIGO 225 Water Cooler K1813 1 115V 50 60Hz Cool Arc 40 Not Applicable Optional Under Storage Cart K2348 1 Optional Remote K814 Arc Start Switch Trigger Device K870 Foot Amptrol Select one K963 3 Hand Amptrol PRECISION TIG 225 LINCOLN di ACCESSORIES uii FIELD INSTALLED OPTIONS e Magnum Pro Torch TIG Torch assemblies and E E Accessories ELE The following Options Accessories are available for the Requires Twist Mate Adapter 6 3 PRECISION TIG 225 K1622 1 for PTA 9 17 E K1622 3 for PTA 26 0 2 K2348 1 Under Storage Cart K1622 4 for PTW water cooled torch g Includes a front magnetic latch storage drawer and s rear storage bin on a single bottle undercarriage Harris 3100211 Harris Argon Flow Regulator 2 2 L12225 Installation Instructions included Includes 10 ft 3 1m hose K870 Foot Amptrol K2374 1 Electrode Holder and Cable Single pedal foot activation of arc start switch and 200 amp Electrode Holder with 10 ft 3 1m cable output control with 25
42. 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC INPUT RECONNECT PROCEDURE On multiple input voltage welders be sure the machine is connected per the following instructions for the volt age being supplied to the welder 44 CAUTION Failure to follow these instructions can cause immediate failure of components within the welder and void machine s warranty Multiple voltage models are shipped connected for the highest voltage To change this connection refer to the following instructions ELECTRIC SHOCK can kill 0 Turn the input power OFF at the dis connect switch or fuse box before working on this equipment For the lowest rated voltage connection Refer to figure A 1 1 Remove the sheet metal left side cover 2 Disconnect lead H3 from the power switch and insu late with the insulation from the H2 lead 3 Connect lead H2 to the power switch where H3 was connected 4 Tighten connections 5 Replace sheet metal cover and all screws For the highest rated voltage connection Refer to Figure A 1 The machine is normally shipped connected for the highest rated voltage however verify the following 1 Remove the sheet metal left side cover 2 Disconnect lead H2 from the power switch and insu late with the insulation from the H3 lead 3 Connect lead H3 to the line switch where H2 was connected 4 Tighten connections 5 Replace sheet metal cover and all
43. 3 4 AMBER HIGH INTENSITY R115 1 S25000 2212SMT RESISTOR SMD METAL FILM 1 10W 22 1K 1 S0805 O LED3 LED4 LED5 T13657 3 LED T 1 3 4 GREEN HLMP 3502 R116 R153 R154 3 S25003 2002SMT RESISTOR SMD 1W 20 0K 1 E i LED7 LED8 LEDO R118 1 S25001 4752SMT RESISTOR SMD 47 5K 1 4W 1206 196 TR c u NC NE LED10 LED15 LED16 S25080 28MT LED SMD GREEN CLEAR 1206 R123 R133 2 S25000 2211SMT RESISTOR SMD METAL FILM 1 10W 2 21K 1 S0805 O O XEM R124 R125 R127 R171 6 525003 2000SMT RESISTOR SMD 1W 2000HMS 1 O 2 i N C N D NH 3 PLACES LED14 R126 R138 2 S25001 1213SMT RESISTOR SMD 121K 1 4W 1206 1 TR D i MOV1 1 T13640 16 MOV 150VRMS 80J 20MM R129 1 S25000 2001SMT RESISTOR SMD METAL FILM 1 10W 2 00K 1 S0805 o 2 Vide MOV3 MOVA 4 T13640 25 MOV 130VRMS 90J 20MM R134 1 S25000 6813SMT RESISTOR SMD METAL FILM 1 10W 681K 1 S0805 O wove TOV MOVE a OU SVENS T50 20V a EE 1 25000 3323SMT RESISTOR SMD METAL FILM 1 10W 332K 1 S0805 9 nm OPPOSITE COMPONENT SIDE CAPACITORS MED VOLTS R186 R190 R192 R193 8 S25001 26708MT RESISTOR SMD 2670HMS 1 4W 1206 1 TR c c RESISTORS OHVS R151 R152 R155 R156 R158 R159 R163 R164 12 S25001 1821SMT RESISTOR SMD 1 82K 1 4W 1206 1 TR 5 J 3 R168 R169 R175 R176 po R161 1 S25001 7500SMT RESISTOR SMD 750OHMS 1 4W 1206 1 TR o C i R183 1 25000 1502SMT TRESISTOR SMD METAL FILM 1 10W 15 0K 1 S0805 tc R201 1 25001 2211SMT RESISTOR
44. 80 amps and 16VDC QO lo O o j C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Note Scope probes connected at machine out put terminals probe to electrode probe to work SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN iiid TROUBLESHOOTING AND REPAIR iiid TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED AC STICK MODE 44 CAUTION HIGH VOLTAGE HIGH FREQUENCY can damage test equipment e Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MACHINE LOADED TO 180 AMPS AT 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 QO lo O o j C O J 2 0 Ola a 3 9 FS c j 5 j 3 lo cic Note Scope probes connected at machine output terminals probe to electrode probe to work SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN
45. A FREE WHEELING DIODE MOV Aou PTH nova xi twv iW SCRI amp SERA ANODES js J2 7 lt C3 Rto E age J Ras oF 55 1 FIRE SCR 16 022 05 de R 3 O Xu lt SHT 1 3 4 B a 8 Haz 2 7 PEN LOV lt ix p di n SERI SNUBBER iov 63ov PTH eno 24V 5 1A FR 50V 2000H PTH D 1A FR M 400V sors GATE a AR 15V 50V J2 1 lt 4 E el iw ES E aio 45K a Sal E 40V PTH 100V Res Fo z ies e 4 pA MO R97 MY xu ES mW ie BOH fv Sk tsa any lt EW5 eno 15K die e SER3 SNUBBER 1000F V aw PTH m ONS 121 p 121 eliz lin 1121 8 iw aw Ll iw iw J SCRA CATHODE SCR3 ANODE 1 W 18VAC Pm paar 1 iw 1400 A n 400v 400V lt 8 OAL p SCR GATING amp SNUBBER 630V pe ee ees Se ated ls A A A AAA AA ea A cai cy a a a a di ea ee ee TT TT TUT an K TN UNES lj Spi ai D 2 i gt sir c59 a gt o inae Xie 24 ON EG TR 0 005 7uF 01W 50V 50V VHCLAD Vicia a d Lin A e e JA 45Vref 424N SW 24V_SW sui 75K DIODES bb HET zwe xu ERE f EB us lt 72 BE Ra 400V 400 eke Renee 1 T3K WAW VED DA NOTE This diagram is for reference only It may not be accur
46. CHINE ALL CODES G5646 e H1 and H2 LOW TO POWER SWITCH H3NOT CONNECTED INSULATE Q 10 O O Fie S j 2 olc VOLTAGE RECONNECTION 2 SEE RATING PLATE FOR SPECIFIC VOLTAGES O 9 230 or 400 415 or 575 VOLT CONNECTION c AS SHOWN amp AS SHIPPED FROM FACTORY 5 e H1 and H3 HIGH TO POWER SWITCH plo e H2NOT CONNECTED INSULATE 115VAC Q c5 RECEPTACLE c X 208 or 380 or 460 VOLT CONNECTION BACK VIEW 231 6 380V AND ABOVE B G CONNECT GREEN LEAD TO GROUND PER TO SUPPLY CIRCUIT C e hc E v N NATIONAL AND LOCAL ELECTRICAL CODE ACROSS TRANSFORMER PRIMARIES T C2 233 232 L2 Gos AA 232A 208V 230V ONLY TO GROUND PER NATIONAL ELECTROD Eo m 1 G POWER 313 9 E SWITCH 314 0 Me 7 rai li A gt A CHOKE B B ame elo N e Return to Section TOC Return to Master TOC 3 ped 2 gt D D L5 a 5 10K A B le 3 E E s s 2 s2 s z is F 411 QI a 236 OPTIONAL 101110987654321 P7 REMOTE REMOTE Ce 2 44 J7 AMPTROL RECEPTACLE _ _ Y R3 231B 2 220A 218A MM J3 5995 d H3 HIGH 7 7 AUTO SAZ MODE H2 LOW BALANCE SWITCH LED N EWE C4 E ac PEN LIN TRIGGER 18VAC BAI ANGE TIS LEE AMO SEED 204 0 X4 260 231A G 209 9 X5 MICRO SWITCH CONTROL POWER 18VAC 3 T N 210 X6 X8 0 232 ZA 312A O 312 X1 lt 4 Ka DIGITAL
47. CK MODE A CAUTION HIGH VOLTAGE HIGH FREQUENCY can damage test equipment e Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC Return to Master TOC LLLLELLLL FAC LUPA LU f AN re AL LL Sk u 50 volts 0 volts Return to Section TOC Return to Master TOC 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 QO lo O o j C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Note Scope probes connected at machine output studs probe to electrode probe to work SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN Axa TROUBLESHOOTING AND REPAIR SS TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED AC TIG MODE CAUTION HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC Return to Master TOC QO O O o k E i 9 j 2 5 0 D 50 volts 09 o j 2 c j c 0 volts gt oO cc lf MACHINE LOADED TO 180 AMPS AT 16VDC This is the typical AC output
48. D IN DC ACROSS TRANSFORMER PRIMARIES e 2 ew DISA EO PUT Asan OPEN IN AC 284 285 QD BALANCE OONTROL IS BALANCE Rice ro Inside hi freq box on DISABLED IN STICK AND 424V Vref CHOKE TSTAT j ji j j O O DCTIG MAX CLEANING 10K right side of machine AUTO NORMALLY CLOSED near front E c y OPEN AT 135C TYP 2 5Vref gl AAA AAA A 3 2 DATA 1J6 PCB O 20HZ SCLK 2J6 PROGRAMMING CONNECTOR SCHEMATIC 522530 W 222 C tC lcw aie FOR SOFTWARE UPGRADE PCB AS BLY L10121 1 R 222 PULSE FREQUENCY IS PULSE FREQUENCY R2 agg DISABLED IN STICK 0 1HZ K 5Vref 4J6 5 ALUMINUM BAR SS V 5Vref 15V 30S lcw i SCR HEATSI POSTFLOW R3 qg In Front of main Inside hi freq box on 4 PHASE transformer right side of machine AA oO 10K MICRO p 115V CIRCUIT Attached to Base near front 1S PROCESSOR TRIGGER TRIAC 8 OPTO TRIAC 100109 Right side of machine FARTHEST RIGHT SCR V DRIVER pai iia front of gas solenoid eu T VEWEDFROM 5V Left side of Machine CONTINUOUS IN AC TIG altached to Base FROM FRONT PRONI 7GA FLEXLEAD near front HIGH VOLTAGE ARC STARTER ASSEMBLY O Y TRANSFORMER ra 200 100 mE Q LED INTERFACE T gt ea T2 238 y O O 236 R3 O L2 C3 Mounted to front side 1J4 _ GAS 115VAC 237 AA of hi freq box on 235 3 q E LED 1 LED 3 L a 236B e 6 AA g lo right side of machine V V7 3J4 115VAC IN N SEE 9 c u STICK lt TIG a 232A
49. DED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram A CAUTION 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 troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 225 LINCOLN F 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola A 3 9 FS c j 5 3 Dio cla Return to Section TOC Return to Master TOC idi TROUBLESHOOTING AND REPAI
50. EN r REM_SENSE y REM SENSE 14 p rr pata 20_LED C usps 4 ENCA Matos paja 221 553 gt un ENCA gt 2 zin pas 85 E EI o DET REM lt P2131 Pal FRESR FIRE SR 26 pote panje MODE O as EB gt ar s p25 P216 2 FRIGGERN gt FAN xres gt XRES SMP e Mane lt j TRIGGERN Q O O O E E cy HE E oiz 9 2 JE Q cc t GENERAL INFORMATION LAST NO USED Re a ELECTRICAL SYMBOLS PER E1537 c SEE PAGE MED 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohmes 1 4W UNLESS OTHERWISE SPECIFIED LABELS gt DIODES 1A400V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT NJ COMMON CONNECTION 7 7 FRAME CONNECTION L EARTH GROUND CONNECTION Y LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL TU men ANTE TAS PRO ET PURPOSE WITHOUT TRE EXPRESS WRITTEN PERMISSION DF LINCOLN GLOBAL INC STER CIR BOAR MAY ERAN EQUIPMENT TYPE PRECISION TIG 185 225 PAGE 03 OF 03 WITHOUT AFFECTING THE INTERCHANGE SUBJECT SCHEMATIC PSOC BLOCK DOMEN MATERIAL NA APPROVAL 2 15 2008 G5640 2C0 A Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual PRECISION TIG 225 e ELECTRICAL DIAGRAMS G 7 PC BOARD ASSEMBLY CONTROL 1 G5641 cWw9sD ENGINEERING CONTROLLED CHANGE DETAIL NEW MANUFACTURE
51. ERENCE EQUIPMENT TYPE Te FROMEOTTOM LEFT FROM FRONT OF MACHINE UNLESS STATED E pm Precision Tig 225 PAGE 1 or 1 O O e a CONNECTION TROUBLE SHOOTING LED S PRESENT ONLY ON SGHEMATIO C5640 Front Panel Top PENTIS ERE E SES wil e E A URN ASSEMBLY G5641 OTHERWISE E COM ENS er aes sur SUBJECT MACHINE SCHEMATIC NUMER avon R MATERIAL APPROVAL PROJECT a E f o o O Kake Gs647 a J 312 D Gc NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp ELECTRIC PRECISION TIG 225 G 4 ELECTRICAL DIAGRAMS G 4 SCHEMATIC CONTROL PC BOARD 1 G5640 AAA e ii iii tae 10Vref Return to Section TOC Return to Master TOC 5Vref L STICK TIG PP ASRS hT iRT T T MEES A A Mae T T bTT bT i aTR TiXiZ Z_ RRZRZZ TTrTii RT TTR sinters A AA lh SELLE IL rne ne nen n EL nin nd di nd nnn und d m Return to Section TOC Return to Master TOC 8 475K zi 2 OR Ct ETPNT 04W aE 02 53 id ES hook 8 dawn ka m A iw amp o1w 05 V en 02 12 monv 02A N 1 20 CONNECT TO PIN 2 OF Ji FOR COMMON lt t g M 5vref Cg R205 qaw n n R206 hiw XRES lt 3 lt R207 aw PROGRAMMING PORT QO O O O E F Ci HE E oiz 9 9 3E Q cc ff A id 1 R6 R 50 200my ag0a AW a E SHUNT 50V M M M
52. HIGH FREQUENCY CIRCUIT H3 gt O gt gt UJ ITI TI T OUTPUT The control board passes the 115VAC voltage to the primary of the high voltage transformer The secondary of the high voltage transformer is coupled to a spark gap generator and also to the high frequency trans former The high frequency transformer transfers the high frequency spark to the electrode terminal which is coupled to the TIG torch NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRECISION TIGO 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS c j 5 j 3 lo cic Return to Section TOC Return to Master TOC E THEORY OF OPERATION ES 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 Since the choke is in series with the negative leg of the bridge and also in series with the welding load a filtered DC is applied to the machine output terminals ELECTRODE O iT PRIMARY 10 x FIGURE E 5 DC Welding Current Generation O WORK PRECISION TIG 225 LINCOLN ES THEORY OF OPERATION ES AC WELDING OUTPUT Rotating th
53. J3 201 X3 AFTER WELDING a E 6 scna i traen cur 3 FAN gt SCR BRIDGE AND POLARITY SWITCH CONNECTION DETAIL RF a 3J3 204 e X4 V 260 TYP RPM a RECEPTACLE CHORES Left front ll SCR2 C 1600 RPM 60Hz Right rear side of Main an u 2 m uja 195 6 4 PIN WHITE Te sona Ew J Pm AUX WINDINGS OF RES tea LAL COMPONENT VALUE UNITS H p PROGRAMM MICRO PROCESSOR t MODE MAIN TRANSFORMER T1 Right front side of Between SCR Bridge halves CAPACITOR MFD VOLTS 10K pe N gt B 3J5 4 CONNECTOR X1 Main Transformer behind choke RESISTOR OHMSWATTS RIC 2J5 J6 J3 OUTPUT CONTROL NX CONNECTOR PIN NUMBERS SOFTWARE O O o B gt D gt 5J5 D VERSION LABEL EX 12 PINOONNECTOR O O o w gt lE 6J5 12 PIN 12 6 E E F Ax Bi NE Lol 000000 cli H POSTR OW ou ou iA c i To 2 O o L TOROID 6 PIN J5 eu d b P is 4 PIN pid PID OPTIONAL AMPTROL REMOTE START etes Tm VIEWOF CONNECTOR ON PC BOARD a CONTROL AND ARC START SWITCH PROPRIETARY amp CONFIDENTIAL 1 DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED TT CONTROL PCB MAIN COMPONENT amp DIANOSTIC LED LAYOUT TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC 2 COMPONENT LOCATION DESCRIPTIONS ARE AS VIEWED UN HI FREQ BYPASS CONNECTION HI FREO BYPASS VIEWED FROM COMPONENT SIDE CONTROL PC BOARD THE INFORMATION ON THIS REF
54. K KK kK KK KK pando B 8 Benefits of the PRECISION TIGO 225 ccc ccc kK KK KK KK KK KK KK KK KK KK kk kk kK kk kk a kk kk B 8 3 Welding in SliCck MODO s spasi 5 4 s sin ka kla a a aa raro Kur Done aa a dos B 9 Recommended Electrode Amperage Ranges kk kk kk kk kk KK KIR KI KK KK KIR KI KK KIR KK KK KK kK KK kk ka B 9 O O E v 9 c 2 D LE PRECISION TIG 225 LINCOLN Return to Section TOC Return to Section TOC Return to Master TOC QO lo O o j C O J 2 0 Ola a 3 9 FS cre 5 3 lo cic Return to Section TOC Return to Master TOC Return to Master TOC PE OPERATION uin SAFETY PRECAUTIONS Head and understand this entire section before operat ing the machine 44 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 Always wear dry insulating gloves 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 FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust at the arc or both to remove fumes and gases from breathing zone and general area WELDING SPARKS can cause fire or ES explosion 7 Keep flammable material away Do not weld on containers that have held c
55. LF 834 3 32 2 4mm Electrode and Parts Lift Eyebolt e Foot Amptrol K870 a Under Storage Cart K2348 1 TIG Slide Rule WC332 GTAW Book JFLF 834 Included with K2533 1 Machine Only model Lift Eyebolt The PRECISION TIGO 225 will also be available as Basic models with Domestic Canadian and International input voltages for user configuration with optional accessories See Table C 1 TABLE C 1 Select Machine 208 230 1 60 Machine with 9 ft 2 7m NEMA 6 50P Plug Cable and Receptacle K2533 1 460 575 1 60 Machine only with Cable K2533 2 380 400 415 1 50 60 Machine only with Cable K2534 1 Water Cooled System Air Cooled System Optional a K2267 1 TIG Mate 20 Torch Starter Kit K2266 1 TIG Mate Torch Starter K1813 1 115V 50 60Hz Cool Arc 40 Not Applicable Water Cooler Not Applicable K1813 1 115V 50 60Hz Cool Arc 40 Optional Under K2348 1 Storage Cart Optional R K814 Arc Start Switch pousse K870 Foot Amptrol Trigger Device K963 3 Hand Amptrol Select one PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO lo O o j C O J 2 0 Ola A 3 9 FS c j 5 3 Dio cla Return to Section TOC Return to Master TOC uii ACCESSORIES era FACTORY INSTALLED OPTIONS 2 PRECISION TIGO 225 Ready Pak w Cart K2535 2 The PRECISION TIGO 225 will be available in two Factory Configured Welding Packages
56. MITATIONS The PRECISION TIGO machines are not recommended for arc gouging due to its limited output capacity and are also not recommended for pipe thawing RECOMMENDED EQUIPMENT INTERFACE Seg Installed Options in or more details The PRECISION TIGO 225 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 with Domestic Canadian and International input voltages for user configuration with optional accessories Select Machine 208 230 1 60 Machine with NEMA 6 50P Plug Cable and Receptacle K2533 1 460 575 1 60 Machine only with cable K2533 2 380 400 415 1 50 60 Machine only with cable K2534 1 Water Cooled System TIG Mate TIG Mate 20 Torch Starter Kit Torch Starter Kit Not Applicable 115V 50 60Hz Cool Arc 40 K2348 Torch Starter Kit Select one Water Cooler Under Storage Cart Optional Optional Remote Trigger Device Select one Arc Start Switch Foot Amptrol Start Pedal Foot Amptrol Hand Amptrol 113 113 H 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 out put power coils and rectifiers The
57. NCOLN E F 56 NOL 19IS8 A 0 uunjeu NOL 191S8 A 0 UINISY NOL Je1Se A 0 UINISY NOL 191S8 A 01 UINISY DOL Uuo l99S oj UNAY DOL Uon9es o UNY DOL Uuo l99S oj UNY DOL uoroes oj UNAY Return to Master TOC Return to Master TOC O O 9 v U gt 9 c 2 r Return to Master TOC d TABLE OF CONTENTS DIAGRAM SECTION e Junge darc M PPT G 1 Wining Diagrami 50a40 P C L r G 2 Entire Machine Schematic G5647 2 nk nk kk kK kK KK KK KI KK KK KI KK KK KK KI KK KK KK KK KK KK KK kK KK kk a G 3 Control PC Board Schematic 1 G5640 2 002054 46464604600 KI KK KK KI KK KI KI KIRI KI KK KK KK KI KK KK KK KK K G 4 Control PC Board Schematic 2 G5640 Jk kk kK KK KK KK KI KK KK KK KI KK KIR KI KK KK KK KK KK KK KK KK k G 5 Control PC Board Schematic 3 G5640 kk kK KK KK KK KK KK KK KI KK KIR KI KK KK KK KK KK KK KK KK k G 6 Control PC Board Assembly 1 G5641 kk kk E KK KE KK KK KII KI er KK KK KI KK KK k G Control PC Board Assembly 2 G5641 1 22525 2b KK KI RR KIR KI KK eed KK KK KK KK KK k G 8 ByPass PC Board Schematic S22530 undo Rx d dde dad KI KK KK KK KI KK KK KK beeen ee ene KK KK ke G 9 ByPass PC Board Assembly L10121 kk kk kK dert KK KK KI KI KI KIRI KIR KI K KIRI KI KI KI KK KK KK KK KK k G 10 PRECISION TIG 225 LINCOLN G 2 ELECTRICAL DIAGRAMS me WIRING DIAGRAM COMPLETE MA
58. NEJI d kw dy d d a D 2 Routine and Periodic Maintenance llle KK kK kk kk a kk kk kk kk kk ka D 2 opak Gap Ad AP o an Alk bd QUE Yo a eb die II D 2 Fan Motor or Fan Blade Replacement kk kk kK KK KK KI KK KIR KIR KIRI KIR KIRI KI KK KK KI KK KIR KK KK kk D 2 PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O j O EP C O J 2 0 Ola A 3 9 FS c j 5 3 Dio cla Return to Section TOC Return to Master TOC ain MAINTENANCE uin SAFETY PRECAUTIONS A WARNING 0 ELECTRIC SHOCK can kill e Only qualified personnel should per form this maintenance Turn the input power OFF at the dis connect 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 fol lowing components thoroughly Main Transformer Electrode Gas Output Receptacle e Polarity Switch Rectifier Assembly Arc Starter Spark Gap Assembly PC Boards Fan Blades 3 Inspect welder output and control cables for fraying cuts and
59. OOTING AND REPAIR ind SCR BRIDGE ASSEMBLY REMOVAL 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 Return to Section TOC Return to Master TOC 17 Carefully remove the SCR bridge assembly from the TIG 225 cutting any necessary cable ties REPLACEMENT PROCEDURE 1 Carefully place the new SCR bridge assembly 11 position and install the case back and secure in position in the TIG 225 with the screws previously removed 2 Using the 3 8 wrench install the four mounting 49 screws taking special care that the insulators are in the correct positions 13 Tighten the input cable strain relief Install the gas hose onto the solenoid valve USE DOW CORNING 340 HEAT SINK COM 44 Assemble the case wrap around cover POUND ON ALL ALUMINUM CONNECTIONS Return to Section TOC Return to Master TOC 3 Assemble the positive lead to the right side pos itive heat sink 4 Assemble the lead from the polarity switch to the right side AC heat sink Note Also connect lead 216 5 Assemble the shunt to the SCR bridge left side negative heat sink 6 Assemble the X2 secondary transformer lead to the left side AC SCR heat sink Note Also con nect lead 7217 7 Assemble the diode pigtail lead to the polarity switch lead See Figure F 10 Be sure to replace sleeving and secure with cable tie
60. OP AND IDEN ATION CODE o 2 x BOTTOM OF BOARD T N G TIN ALL EXPOSED COPPER WITH SOLDER IN THIS AREA ois 300000000000 BOTH SIDES OF BOARD MAKE PER E1911 ROHS o 9 N H NO ICICLES OR SOLDER BLOBS ARE PERMITTED ENCAPSULATE WITH E1844 p WITHIN 0 5 BOTH SIDES 2 COATS Sz m ro Q rc fc SCHEMATIC REFERENCE S22530 3DO ALL COMPONENTS AND MATERIALS USED IN THIS ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 INCLUDE S22772PRINT THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC TT CALE EQUIPMENT TYPE SW TIG 175 amp 275 DIN O DAN DER UNLESS OTHERWISE SPECIFIED TOLERANCE ON 2 PLACE DECIMALS IS 02 in 0 5 mm 1 ON 3 PLACE DECIMALS IS 002 in 0 05 mm IF PRINTED DOCUMENT DOCUMENT SEDES EE azsize SUBJECT BYPASS STABILIZER P C BOARD ASSEMBLY J nomen REVISION WITH PUBLISHED STANDARDS UNITS MATERIAL APPROVAL PROJECT REFERENCE L1 01 21 3 DO NOT SCALE THIS DRAWING CA NH DISPOSITION UF pate 97 2007 NuMBER CHM34432 10121 4 C Insight 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 Elec
61. OTENTIOMETER BUSHING NJ WHEN ASSEMBUNG DISPLAY SPACE DISPLAY OFF THE BOARD 125 010 MEASURED ALL COMPONENTS AND MATERIALS USED IN THIS FROM BOTTOM OF DISPLAY TO PC BOARD SURFACE NK SQUEEZE COMPONENTS TOGETHER BEFORE ENCAPSULATION ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 N L SEAL COMPONENT BASE WITH ITEM8 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC i MANUFACTURING TOLERANCE PEN E2056 ON 2 PLACE DECIMALS IS 02 in 0 5 mm 1 1 25 EQUIPMENT TYPE PRECISION TIG 185 225 PAGE 2 OF 2 le OC DOCUMENT MEINES cr SUBJECT CONTROL PC BOARD ASSEMBLY _ rom o MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS UNITS MATERIAL APPROVAL PROJECT REFERENCE G5641 2 A DO NOT SCALE THIS DRAWING APPROVED INCH bisrosirion UF pare 2 15 2008 NUMBER CRM36266 G4551 1 Insight ON 3 PLACE DECIMALS IS 002 in 0 05 mm SOLID EDGE EN 170 QO O O O E E CIS ae gs H 2 9 9 3E A Q oO rc fc 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
62. PRECISION TIGO 225 machine uses Twist Mate output terminals therefore stud connection adapters such as LECO S19257 series cannot be used for torch connection If a PRECISION TIGO 225 is powered from an engine generator 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 TIGO 225 is rated at 225 amps 29 volts at 1096 duty cycle on a ten minute basis It is capable of higher duty cycles at lower output currents S pre err gms on specification sheet located in the Installation Section If the duty cycle is exceeded a thermal protector will shut off the output until the machine cools PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O j O EP C O J 2 0 Ola a 3 9 FS cre 5 3 lo cic Return to Section TOC Return to Master TOC sii OPERATION E CONTROLS AND SETTINGS All operator controls and adjustments are located on the front of the PRECISION TIG 225 Refer to Figure B 1 and corresponding explanations FIGURE B 1 CONTROL PANEL a 7 UT LIST L QQ CONTROL FUNCTIONALITY 1 POWER SWITCH Input line switch turns input power ON or OFF as indicated by the on or off sta tus
63. R Yes 1 5 00 6 00 5 80 E R10 _ m all R19 s s 8 El 8 E US ejm Qo 5 j E E PT185 225 o o N N o 8 C13 o o o av co lt r LO O a A co N gt gt o o o o o Return to Master TOC ce Return to Section TOC C12 R24 wm C18 o CD O QI 5 10 CONT ROL R36 al 2 E gt i R q e gt lt o y i l es CA TT B O os d A ma OTP1 p20 O o wow J a E 18 E z MOV5 eds TATAE e eje lee AM Sii mu NK _ Jli E r Sira s s E 818 6 R76 NB D15 i Q s o E 3 e g 8 8 3 u 2 2 iB on oj 9 c EE D i i El ow R97 R9 ot o X9 d x0 2 pm Dm Q13 DZ5 i R116 EX O E x g 8 El xe NIIS AGERE TP5 C52 C53 R107 Qn C55 ms o R197 R198 R208 D27 CY XXrn OOOO Return to Section TOC Return to Master TOC ces C68 O TP7 j E o in x l p o D28 QN lt a T Los s o e 8 fel e 8 op Oo aj pal Ol fa o oj o a a Ix gt fu N o e J of 9 o OJ jo Oj 10 Jo Le LO O El p co a El 77 y DZ6 R153 R154 DZ9 DZ7 093 o C87 o o B o o C88 o d l e o d x 4 OJ o V O O O O 579 li H li o Q Q o o o O O o Oo z le El 8 o 18 aj ej 8 i o amp im u E ul E Er E El E E
64. R dli PC BOARD TROUBLESHOOTING PROCEDURES A WARNING x e ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts 44 CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected ATTENTION to a grounded part of the Static Sensitive QUipment frame Devices Handle only at Static Safe Workstations If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent Static buil
65. R132 12 S25000 1002SMT RESISTOR SMD METAL FILM 1 10W 10 0K 1 S0805 c i REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW R162 R184 R200 Fun R5 1 25000 1301SMT RESISTOR SMD METAL FILM 1 10W 1 30K 1 S0805 5 5 REFERENCES QTY PARTNUMBER DESCRIPTION R6 1 825000 15008MT RESISTOR SMD METAL FILM 1 10W 1500HMS 1 S0805 i A1 1 M17789 4 ENCODER INCREMENTAL 2 BIT PEC12 R7 R9 R111 R112 rad D i C1 C3 C29 C39 C41 R113 R135 R143 R145 tC xX C42 C43 C58 C60 C78 R147 R149 R172 R173 18 S25001 1001SMT RESISTOR SMD 1K 1 4W 1206 1 TR C84 C89 C90 C91 C92 S25020 2SMT CAPACITOR SMD CERAMIC 0 022MF 50V 10 X7R S0805 R174 R178 R191 R196 C94 C95 C103 C104 R197 R198 NF NC ND NC N C NJ NC NL C109 C110 R8 R34 R203 3 S25000 6812SMT RESISTOR SMD METAL FILM 1 10W 68 1K 1 S0805 i C2 C10 C35 C111 S25020 9SMT CAPACITOR SMD CERAMIC 47pF 50V 5 COG S0805 R10 R11 R52 R53 R90 a C4 C23 C38 3 825024 2SMT CAPACITOR SMD TANTALUM 1 OMF 35V 10 S3528 R91 R103 R104 8 AS RESISTOR SUD LV AMOS C5 C20 C45 25020 12SMT CAPACITOR SMD CERAMIC 100pF 100V 5 COG S0805 R12 R13 R14 R15 R26 C6 C7 C9 C12 C17 R27 R28 R29 R42 R43 C C18 C24 C30 C31 C32 S25020 108MT CAPACITOR SMD CERAMIC 4700pF 50V 10 XR7 S0805 R44 R45 R55 Rs6 R57 16 525003 12105SMT RESISTOR SMD 1W 121OHMS 1 C34 C44 C53 C59 R58 C8 C13 C25 C26 S20500 17 CAPACITOR PPMF 0 1MF
66. RCUIT VOLTAGE WAVEFORM AC TIG MODE 44 CAUTION HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 QO lo O o j C O J 2 0 Ola a 3 9 FS cre 5 3 lo cic Note Scope probes connected at machine output terminals probe to electrode probe to work SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN p TROUBLESHOOTING AND REPAIR E NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM DC TIG MODE A CAUTION HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC Return to Master TOC Olo Cc P ojeg pe 2 N i 50 volts pe Pa 0 volts oic cc lf 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
67. Return to Master TOC Return to Master TOC O O E 9 i 49 2 g oO r Return to Master TOC View Safety Info View Safety Info O q 2 oO 4 U 2 gt View Safety Info RETURN TO MAIN MENU SVM186 A October 2008 PRECISION TIG 225 For use with machine code numbers 11317 11318 11319 11320 Ready Pak 11321 Ready Pak w Cart 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 DONOT 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 LINCOLN amp Copyright 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 1 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY 44 WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or oth
68. SMD 2 21K 1 4W 1206 196 TR 1 1 T13381 16 SWITCH PUSHBUTTON SPST T1 T2 2 T12737 2 TRANSFORMER PULSE 3 W INDING 1 1 1 TRI TRI2 TRIS TRI4 4 S15161 27 TRIAC TO220 8A 800V X1 1 S25073 128MT IC SMD CMOS PSOC 8 BIT CY8C27643 TFN49 SS i X2 1 S15128 27SMT TIC OP AMP SINGLE PRECISION LT1097S8 X3 X4 X14 3 T815128 28SMT IC OP AMP SMT QUAD HIGH PERF 33074ADT j X5 1 515128 6 IC VOLT REG FIXED 3 T 1A 15V TO220 NOTES X6 1 S15128 10SMT TIC SMD VOLTAGE REF ADJ PRECISION 4311 SOIC 8 j NA X7 1 M15102 4SMT TIC SMD ARRAY DRIVER PERIPHERAL NPN DARLINGTON NA THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 BEFORE X8 1 815128 58MT IC VOLT REG SMD FIXED 3 T 4 1A 5V HANDLING X9 1 S25072 28MT IC SMD ACT BUFFER OCTAL 3 STATE TSSOP 20 S5 NB PROGRAMX1 WITH ITEM6 X10 1 S15018 21SMT IC SMD CMOS DRIVER MOSFET 4451 SOIC 8 SS NC KEEP FREE OF ENCAPSULATION MATERIAL xi 1 817900 248MT __ IC SMD CMOS GATE NAND 2 INPUT QUAD SCHM SS8 ND SEAL COMPONENT BY APPLYING ITEM 7 AS SHOWN SO THAT ENCAPSULATION MATERIAL X12 1 S25065 3SMT IC SMD CMOS INVERTER SCHMITT HEX VHC14 SS DOES NOT GET INSIDE COMPONENT X13 1 S15018 18MT TIC SMD CMOS SWITCH ANALOG QUAD 201 SS N E KEEP FREE OF ENCAPSULATION MATERIAL 50 DIA MIN ON BOTH SIDES OF BOARD N F KEEP MOUNTING HOLES FREE OF ENCAPSULATION MATERIAL 5 PLACES NG COVER MOLEX WTH TAPE NH HAND TIGHT MOUNTING WASHER AND MOUNTING NUT TO P
69. THE POSTFLOW KNOB OUTPUT IS HOT IF DC MODE IS STICK IN TIG MODE OUTPUT IS COLD UNTIL 15V 15V Bimin Right side of Machine Front Panel Left side TH above Choke Coil Ua o t 4 toron NDUCTOR VOLTAGE RECONNECTION O 1 PHASE FIRE 1J1 SHUNT W 221 TOGGLE BETWEEN TIG amp a SEE RATING PLATE FOR SPECIFIC VOLTAGES TYPICAL OCV N Los B OUTPUT REGULATOR 2J1 suno mapa ai e r 65V INDC OONTROL PULSE is 1 ee N 230 or 400 415 or 575 VOLT CONNECTION 75V INAC FREQUENCY amp SETPOINT 48Vref LTEM On top of Main AS SHOWN amp AS SHIPPED FROM FACTORY SABLED Transformer L CBW CONNECTED e H1 and H3 HIGH TO POWER SWITCH qut BY SWTCH O 1 24V 15d DETERMINE IF H FFEQIS Lower left side of Elo way H2 NOT CONNECTED INSULATE OUTPUT CONTROL nn CONTINUOUS OR START Polarity Switch B SW NO O O METER ENCODER SWITCH LEDs ENCODER ONLY MIN CURRENT AND DC be E i 208 or 380 or 460 VOLT CONNECTION AND ALL FOTENTIOMETERS ARE BALANCE CONTROL O 5 230A A1 am ma 5J3 311 311 O MOLNTED ON FC BOARD ee erm mox aoe pene ROLE x H1 and H2 LOW TO POWER SWITCH a REM SENSE Hi Local e 6J3 312 CLOSED Gang F 52 e H3 NOT CONNECTED INSULATE ni a ING 6 ia ditu NDC 5 N C POLARITY SWITCH M M rom Auto LOG B ro HIE Front Panel Center C1 AND C2 MUST ALWAYS BE CONNECTED o THERMOSTAT THERMOSTAT INPUT i SE lisina O a MAX PENETRATION ES INTERFACE La 1J3 313 oo MICRO SWITCH CLOSE
70. TION Check the input power switch and associated wires for loose or faulty connections Perform the T1 Transformer Check for loose or faulty con nections on the heavy current carrying leads polarity switch output choke output terminals etc and functioning correctly 2 Perform the T1 Transformer 3 Perform the SCR Bridge Test e E 4 Check current control R1 for EE proper operation Normal ols resistance is 10 000 ohms 9 3 Also check associated leads 0 2 for loose or faulty connections 9 j 2 EJS 5 The control board may be 2 faulty Replace 44 CAUTION 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 troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIGO 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F 5 Fan runs No output from machine in either Stick or TIG modes and the yellow light on the control panel is on OUTPUT PROBLEMS 1 The welding application may have exceeded the recommend ed duty cycle Allow the unit to run until the fan cools the unit and the yellow light goes out The air louvers may be blocked Remove air obstruction and allow unit to cool The machine does not respond no 1 Make certain the m
71. TOC Return to Master TOC F 21 TROUBLESHOOTING AND REPAIR STATIC SCR TEST A WARNING 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 throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure is a quick check to determine if an SCR is shorted or leaky See machine waveform section for normal and abnormal SCR waveforms MATERIALS NEEDED Volt Ohm Meter Analog PRECISION TIGO 225 Wiring Diagrams 3 8 nutdriver SCR Heat Sink Assembly Drawing PRECISION TIG 225 LINCOLN F 21 ae TROUBLESHOOTING AND REPAIR im STATIC SCR TEST continued FIGURE F 3 Plug J2 Location on Control Board PLUG J2 REMOVED Return to Section TOC Return to Master TOC PRECISION TIG 225 CONTROL Return to Section TOC Return to Master TOC TEST PROCEDURE 1 Remove main supply power to the
72. TS OPERATION SECTION E O I alo y caste Oh 0 we ee E EE ewe oe ee ee ee B 1 gt 9 E Safety Precautions kk kk kk kk kk kK kk Re B 2 Cree Me as i s tora aa ye oe eee poe dre aa Ed B 2 PrOGUGCTIDCSCIDION yeso s ss cenan eos pee A k b y Ann G JJA A rada XEMA r W Sd pro B 3 Recommended Processes and Equipment kk kk kk kK kk KI KK KIRI KK KI KIR KIR KI KIR KIR KIR KIR KIR KK KK kk B 3 Recommended Processes 45 2 kk kk kk kk kk E kK e KK kk kk kk kk kk RE o oc EUR kk kk di kk lk kk kk ka B 3 O PROCESS LIMMMONONS M P DTTPUTTTTTPTTTE B 3 Recommended Equipment Interface ccce hr B 3 E zen mTI P B 3 welding GapabD lily escarpa sa 544 ee ee ns A SR ee ee ee a a ci B 3 5 E Controls o A hee aa ISA B 4 B 5 Power Up Sequence use cero etm joe kK kK kK kK KK kk kk KK kk kK kk kk kk kk kK kk kk KK kk kK kK KK KK KK kk B 5 Case Hear COIDOERIODIS z 3 sesgos kak xa a an an n a lA al ed ea ea dida d a B 6 geraten oeyomi i p gt PEDEE EEIEIEIkI I I I I IIE EIEIIIIE EEIEEEEI E B EI IIIIIIEIAVIIIE EIEEII EE TEDE B 7 Welding in Dia MOde ie so amos ca ab diw Rhee es daa aa sd a B 7 O Pulse TIG Mode 2 teu nau 26 ba be oe iia KK KK KK KK KK kk kk kk kk kk kK kk kk kk kk A kk KK kk kk kk B 7 E Remote Control Operation se dd dre at 3128 993 520 1823 KK KK KK KK KI KK don E edo A KK K
73. With the 1 2 wrench remove the positive flex lead from the polarity switch See wiring dia gram Label lead and connection point for reassembly With the 1 2 wrench remove the AC flex lead from the polarity switch This lead connects to the AC plate on the SCR bridge See wiring diagram Label lead and connection point for reassembly Using the 1 2 wrench remove the flex lead from the rear gang of the polarity switch This lead connects to the D1 diode on the SCR bridge See wiring diagram Label lead and connection point for reassembly Using the 1 2 wrench remove the flat copper lead from the polarity switch This lead con nects to the high frequency transformer coil and the by pass board See wiring diagram Label lead and connection point for reassembly Using the 1 2 wrench remove the other flat copper lead from the polarity switch This lead connects to the lower terminal on the by pass board and the work lead See wiring dia gram Label lead and connection point for reassembly Using the 1 2 wrench remove the choke lead from the polarity switch See wiring diagram Label lead and connection point for reassem bly With the 1 2 wrench remove the X1 sec ondary lead from the polarity switch See wiring diagram Label lead and connection point for reassembly With the 7 16 wrench remove the two nuts and washers that hold the polarity switch to the front panel
74. ably 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 over the full range of the machine To start the arc 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 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 Direct Current mode the PRECISION TIGO 225 will start a 3 32 2 thoriated tungsten electrode at 15 amperes provided the electrode tip is properly grounded and not contam inated BENEFITS OF THE PRECISION TIG 225 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 However the positive por tion may also cause the electrode to overheat at high currents causing tungsten spitting The negative por tion of the AC wave offers no cleaning action but con centrates more heat on the work The AC waveform of the PRECISION TIG 225 opti mizes cleaning and heating of the work The result is the capability to weld through the complete range in AC TIG or DC TIG requiring only one electrode a 3 32
75. achine is in gas flow no high frequency and no open circuit voltage when the arc the TIG mode start switch or Amptrol is activated 2 The Amptrol may be defective fan is working normally Check for continuity zero ohms between pins D and E on cable connector when the Amptrol is depressed TROUBLESHOOTING AND REPAIR F 5 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION One of the thermostats may be faulty Check or replace See wiring diagram Check for loose or faulty wires on the thermostats and associ ated circuitry See wiring dia gram Check the continuity zero ohms of the leads between the remote receptacle and plug J5 on the control board See wiring diagram Perform the T1 Transformer 3 The control board may be faulty Replace QO j O O o j C O J 2 0 Ola a 3 9 FS cre 5 3 lo cic 44 CAUTION 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 troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C
76. ance with the appropriate National Electrical Code all local codes and the information in this manual 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 208 230 volt models have a NEMA 6 50P plug attached to the 76 3 input power cord and a NEMA 6 50R receptacle is included with the Ready Pak models Other voltage models have an 12 3 input power cord but no plug or receptacle Have a qualified electrician provide input power supply to the receptacle or cord in accordance with all local and national electrical codes Use a single phase line or one phase of a two or three phase line Choose an input and grounding wire size according to local or national codes Refer to nc fee nical epecitications ade at the begin ning of this section Fuse the input circuit with the recom mended super lag fuses or delay type circuit breakers Using fuses or circuit breakers smaller than recommend ed may result in nuisance shut offs from welder inrush currents even if not welding at high currents TAlso 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 PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O j O EP C O J 2 0 Ola A
77. and warnings provided on the case top decal Save the removed plug button LE part No T10397 2 to cover the hole when the lift Eyebolt is removed An undercarriage provided on the Ready Pak w Cart model is also available to easily move the unit Refer to thel Accessories section bf this manual Do not attempt to lift the power source with an undercarriage attached The undercarriage is designed for hand moving only mechanized movement can lead to personal injury and or damage to the PRECISION TIG 225 TILTING Each machine must be placed on a secure level sur face either directly or on a recommended undercar riage The machine may topple over if this procedure is not followed PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO lo O o j C O J 2 0 Ola A 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC adi INSTALLATION idi MACHINE GROUNDING AND HIGH FRE QUENCY INTERFERENCE PROTECTION Locate the Precision TIGO 225 away from radio controlled machinery The normal operation of the Precision TIGO 225 may adversely affect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment This welder must be grounded See your local and national electrical codes for proper grounding meth ods The high frequency generator being similar to
78. any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts Exposure to EMF fields in welding may have other health when starting operating or repairing equipment effects which are now not known O O 9 v C gt 9 c E r All welders should use the following procedures in order to In some cases it may be necessary to remove safety minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 0 1 Route the electrode and work cables together Secure them with tape when possible 2 0 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not atte
79. ate for all machines covered by this manual LINCOLN amp GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED THERWISE MATERIAL DISPOSITION LABELS gt A SUPPLY VOLTAGE NET C POWER SUPPLY SOURCE POINT Y COMMON CONNECTION 3 y FRAME CONNECTION L EARTH GROUND CONNECTION DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL Te oie PARTIES OF USED POR ANY PURPOSE WITHOUT TRE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC CORD MAY CHANGE EQUIPMENT TYPE PRECISION TIG 185 225 PAGE 02 OF 03 INTERCHANGE 1 NM DOL eae eee SUBJECT SCHEMATIC CONTROL PCB ERE EWIN PROJECT CRM36266 G5640 200 A PRECISION TIG 225 G 6 ELECTRICAL DIAGRAMS G 6 SCHEMATIC CONTROL PC BOARD 3 G5640 Return to Section TOC Return to Master TOC Fir 5 o S 3 e o 2 POSTFLOW Y ol POLO psio T O Ea gt SE ANCE Pou PSI A O BALANCE poz PSIZ r ele SETPNTI_0UT LT SETPNTI_QUT_45 pora pe H2 gt ETPNTZ OUT ETPNT2_QUT 6 A 5 s our 5 pois PAN J toc gt lare porer patat B LS CC DATA 19 last ATA 22 g fr sax gt SQK 17g iier E me gt THERMAL SOn 16 PI PATI 3 G m PHASE FIRE 15 pyts par L DISPZ gt bisP2 cin L gt 22 pate paj2 26 DISP3 BISE
80. bare spots 4 Keep TIG torch and cables in good condition 5 Clean air louvers to ensure proper air flow and cool ing 6 The fan motor has sealed ball bearings which require no maintenance 7 SPARK GAP ADJUSTMENT The spark gap 020 5mm is set at the factory to a gap of 0 015 inches 0 4mm See Figure D 1 This setting is adequate for most applications Where less high frequency is desired the setting can be reduced to 0 015 inches 0 4mm WARNING Use extreme caution when working with a high fre quency circuit The high voltages developed can be lethal Turn the input power off using the dis connect switch or fuse box before working inside machine This is particularly important when work ing on the secondary circuit of the high voltage transformer T3 because the output voltage is dangerously high Refer to figure D 1 Note in highly dirty environments where there is an abundance of conductive contami nant s use a low pressure air stream or a firm piece of paper to clean the spark gap Do not disturb the facto ry setting To check the spark gap Turn off input power as specified above Remove the right side panel from the machine the spark gap box is located on the lower right side Check the spark gap with a feeler gauge If adjustment is needed Adjust the gap by loosening the allen head screw in one of the aluminum blocks near the front of the unit and tighten the screw in the new pos
81. ck interior connection of the small or too long to permit the heavy current carrying leads desired current to flow 3 The weld current may be set too low 44 CAUTION 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 troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O O o j C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC F 15 TROUBLESHOOTING AND REPAIR HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE 44 WARNING 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 throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will disable the high frequency circ
82. ction TOC Return to Master TOC il TROUBLESHOOTING AND REPAIR did Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Machine welds at a very low out 1 If welding in the TIG mode the 1 Check the polarity switch and put regardless of the current con remote control device may be associated leads trol setting defective Check the interior connections Make certain the input line volt of the heavy current carrying age is correct for the machine leads reconnect configuration Perform the SCR Bridge Test Check the welding cables and or torch for loose or faulty connec Perform thel T1 Transformer tions Check the current control for proper operation Normal resistance is 10k ohms See wiring diagram The control board may be faulty The machine welds at a very high 1 If welding in the TIG mode the 1 Perform the SCR Bridge Test output regardless of the current remote control device may be control setting defective 2 Perform the T1 Transformer Test 3 Check the current control for proper operation Normal resistance is 10k onms See wiring diagram 4 The control board may be faulty 44 CAUTION 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 fo
83. d convenient built in storage provisions for welding components and cable management ce m al The PRECISION TIGO 225 also provides advanced features such as Digital Meter e Presettable control adjustable Auto Balance Fan As Needed F A N Timers for fixed Preflow and variable Postflow shielding gas Built in easy to set single knob Pulse TIG control with a blinking light to indicate the pulse frequency setting e 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 An Auxiliary 115vac Receptacle with Circuit Breaker are included on the back panel of the PRECISION TIGO 225 models The Canadian K2533 2 and International K2534 1 models are rated 6 amps while the 208 230 1 60 models K2533 1 and K2535 1 2 are rated 20 amps for use with Lincoln s 115v SP and Power MIG models RECOMMENDED PROCESSES AND EQUIP MENT RECOMMENDED PROCESSES The PRECISION TIGO 225 is recommended for the TIG GTAW and Stick SMAW welding processes within its out put capacity range of 5 amps DC or AC to 225 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 LI
84. d up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag lf the PC board uses protective shorting jumpers don t remove them until installation is complete f 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 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the
85. e Figure F 11 4 Disconnect the in line splice quick connect from one primary lead to lead 231A Cut any nec essary cable ties 5 Remove the lead splice from the other primary lead that is connected to lead 236 and the C4 capacitor See wiring diagram Cut any neces sary cable ties 6 Using the phillips head screwdriver remove the db a PS A TRANSFORMER SECONDARY LEADS front mounting screws from the base of the high voltage transformer Take note of insulator placement for reassembly NOTE On some machines the mounting screw configuration may be different With phillips head screwdriver loosen the two rear mounting screws Carefully slide the transformer forward and remove from the TIG 225 machine PRECISION TIG 225 LINCOLN F 50 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO lo O o j C O J 2 0 Ola A 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC F 51 FRONT MOUNTING TROUBLESHOOTING AND REPAIR F 51 HIGH VOLTAGE TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 12 HIGH VOLTAGE TRANSFORMER MOUNTING INSULATORS SLOTTED REAR MOUNTING INSULATORS NOTE On some machines the mounting screw configuration may be 7 different INSULATORS REPLACEMENT PROCEDURE 1 Carefully position the new high voltage trans former in place in the two rear
86. e must be connected to an earth ground close to the work clamp using one of the following methods a A metal underground water pipe in direct contact with the earth for ten feet or more b A 3 4 19mm galvanized pipe or a 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 along pipe system can result in re radiation effectively making these members radiating antennas 6 Keep covers and all screws securely in place 7 Electrical conductors within 50 ft 15 2m of the welder should be enclosed in grounded rigid metallic conduit or equivalent shielding wherever possible Flexible metallic conduit is generally not suitable 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 proce dures can cause radio or TV and electronic equipment interference problems and result in unsatisfactory welding performance resulting from lost high frequency power INPUT AND GROUNDING CONNECTIONS Only a qualified electrician should connect the PRECI SION TIGG 225 Installation should be made in accor d
87. e 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 con nected to one of the AC connections on the SCR bridge The electrode terminal is connected to the other AC side of the bridge The choke is now electrically across the negative and positive SCR bridge connections With the ability of the choke to store energy and the SCRs to turn on at the appropriate times an AC square wave is developed and applied to the output terminals Return to Section TOC Return to Master TOC O o ls G CHOKE Ela S 3 ELECTRODE HE nile ele c 5 j 3 AHE PRIMARY is WORK FIGURE E 6 AC Square Wave Welding Current Generation QO lo O o j C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS c j 5 j 3 lo cic Return to Section TOC Return to Master TOC E THEORY OF OPERATION aid 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 f
88. e square wave AC DC TIG GTAW welding 3 Enhanced version of the patented MicroStart Technology for its lower Minimum 5amps to high er Maximum 225 amps output control range 4 Built in high frequency stabilization for DC TIG starting and continuous AC TIG welding 5 AC DC Stick SMAW capability SWITCH i CY Y HI FREQUENCY pm TRANSFORMER AC DC SCR HIGH VOLTAGE z O O TRANSFORMER n 2 THERMAL GAS LIGHT VALVE BY PASS BOARD gt WORK D ELECTRODE CIRCUIT 115VAC POWER N O DIGITAL DISPLAY CONTROL BOARD MODE SWITCH THERMO STATS OUTPUT CONTROL AC PULSE POSTFLOW BALANCE CONTROL CONTROL CONTROL INPUT POWER CIRCUIT The desired single phase input power is connected to the TIG 225 through an input power switch located in the front panel of the machine The machine can be configured for either 230VAC or 208VAC input voltage by connecting the appropriate lead H2 or H3 to the input power switch When the input power switch is turned ON the input voltage is applied directly to the primary of the main transformer The main transformer changes the high voltage low current input power to a low voltage high current out put which is available at the main secondary winding X1 and X2 In addition three auxiliary windings are incorporated in the main transformer The 115VAC winding supplies power to the fan motor the 115 VAC receptacle and also throu
89. e ten A ka k and UD Re ad a al ak a a A 4 Environmental RAUNO RENTRER P ss sana 3 Bulend ala 202 e Al ak dun Phase JE ew Den n d whee aa A 4 E o mm aa A 4 2E eka g DM 6MM FM FIe r lb ddBdB bwe n r aa A 4 Lillllio and MOVING s sa 3 sw an As y Cees ae ee ee eee dh d k Ee eee A 4 WING PONER CO gm eem r eae ney oe A 4 Machine Grounding and High Frequency Interference Protection 0 00 eee ee eee ee A 5 Input and Grounding Connections 333 3 9 92 0 4 933 9 kK kk kK KK KK kK KK KK kk kk a kk kK kk kk kk kk kk kk ka A 5 Input Reconnect Procedure J rr kk kk kK KK KK KK ee KK KK KK kK kK kK kk kK te kK kk kk KK KK kK kK ke A 6 OWIDUL CONMeCIIONS edecanes asa all dada AD W a aus dead ate dba pda y d A 6 Connections For Tig GTAW Welding cios sensor kK KK KK KK KK A KK KIR KI KIR K KI KI KI KI KK KI KK KK KK KK k A 7 Tig Toren ConnecllohlS ss s3 Geass alle OT A 2 arrasados A 7 Work Cable CONNGGIONS io ance cues Ped 234334 EIUS a woe ee Eee Cake di Red bi da ti A 7 Shielding Gas Connecl olt poros opaco eran kb l a xa l daa XA Row Ded Beni ds RUP SOR Rede e J r A 7 Remote Control Connection s saute eto ade kk dip iar a edo KK KK KK KK UR kk kk kk kk kk kk kk kk kk kk kk kk a A 7 Connections For Stick SMAW Welding 0 00 kk kK kk KK KI KK KK KK KK KI KK KI KK KK KK KK KK KK KK k A 7 Stick Electrode Cable and Work Cable Conn
90. ection kk kk kk kk KK KK KK eee eee A 7 PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O O j C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC ais INSTALLATION ii TECHNICAL SPECIFICATIONS PRECISION TIGO 225 K2533 1AND K2535 1 2 INPUT SINGLE PHASE ONLY Standard Voltage Input Current at Rated Output Power Factor Idle Current 208 230 1 60 Pe 42A 39A Effective 0 62 Min 3 0A 2 7A Max h and 94A 85A Maximum OUTPUT RANGE Output Current Maximum Open Type of Output Range Circuit Voltage STICK AND TIG CC Constant Current 5 230 Amps DC DC OCV 66 RATED OUTPUT Process Duty Cycle Weld Current Weld Voltage NEMA GTAW 10 Duty Cycle 225A AC DC 15 7 V AC DC 20 Duty Cycle 180A AC DC 15 2 V AC DC 100 Duty Cycle 90A AC DC BAL 14 1 V AC DC 14 0 V AC DC SMAW 10 Duty Cycle 225A AC DC 29 0 V AC DC 20 Duty Cycle 180A AC DC 27 2 V AC DC 100 Duty Cycle 90A AC DC 23 4 V AC DC Chart gives max rated Output Amps Duty Cycle Based on a 10 minute cycle Example 180A 20 for AC DC Stick and TIG Inputs and ratings include a 20 amp rated load on the 115vac receptacle AC DC Stick and Auto Balance TIG Output Limits Using provided input cable for protected i input supply 100 90 80 70 gt
91. ed 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 throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the high voltage transformer MATERIALS NEEDED 3 8 Nutdriver Phillips head screwdriver Needle nose pliers Wire cutters PRECISION TIG 225 LINCOLN F 49 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola A 3 9 FS c j 5 j 3 Dio cla Return to Section TOC Return to Master TOC F 50 TROUBLESHOOTING AND REPAIR HIGH VOLTAGE TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 11 SECONDARY LEADS AT HIGH FREQUENCY STARTER BOARD a REMOVAL 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 connects on the high frequency arc starter board assembly Se
92. er reproductive harm The Above For Diesel Engines The Above For Gasoline Engines Return to Master TOC ARC WELDING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding 4 Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS N FOR ENGINE amp 1h To avoid scalding do not remove the exl 5 a radiator pressure cap when the engine is powered equipment ANA O RE i 1 a Turn the engine off before troubleshooting and maintenance i work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated 23 areas or vent the engine exhaust fumes a outdoors Return to Master TOC 1 c Do not add the fuel near an open flame weld zs may be dangerous ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current flowing through
93. erform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS cre 5 j 3 lo cic F 9 The arc flutters when TIG weld ing The arc pulsates when AC TIG welding 1 OUTPUT PROBLEMS The tungsten electrode may be too large in diameter for the cur rent setting The tungsten tip may not be sharp enough The gas shielding may be insuf ficient Increase the gas flow and or reduce the tungsten stickout beyond the 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 Make sure the gas and proce dure are correct for the process being used TROUBLESHOOTING AND REPAIR F 9 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION 1 Check the polarity switch for proper operation and loose or faulty lead connections See wiring diagram Perform the SCR Bridge Test Check for loose or faulty con nections at the shunt leads 221 and 222 Check components R3 and C4 in the h
94. eturn to Master TOC olo O o JE E i O 2 o a 2 50 volt volts o j 2 E 0 volts lo e az ams 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 OTTO O o j C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Note Scope probes connected at machine output terminals probe to electrode probe to work SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN NOTES 1 99 PRECISION TIGO 225 LINCOLN E F 38 NOL 49IS8 A 0 uunjeu NOL 191S8 A 0 UINISY NOL Je1Se A 0 UINISY NOL 191S8 A 01 UINISY DOL uoroes oj UNAY DOL uorpoes oj UNY DOL uorpoes oj UNY DOL uoroes oj UNAY Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC F 39 TROUBLESHOOTING AND REPAIR SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE 44 WARNING Service and repair should be performed by only Lincoln Electric factory trained person
95. ft 7 6m plug cable and Twist Mate connector K963 3 Hand Amptrol Fastens to torch for convenient thumb activation of arc start switch and output control with 25 ft 7 6m plug cable K814 Arc Start Switch Needed for TIG welding without an Amptrol Includes 25 ft 7 6m plug cable and attaches to torch for con venient finger control TIG Mate Torch Starter Kits Includes Torch with Twist Mate adapter and acces sories listed below Return to Section TOC Return to Master TOC K2266 1 TIG Mate Torch Starter Kit Includes 150A PTA 17 12 5 ft 3 8m Torch e KP5068 Parts Kit Regulator amp Hose K1622 1 Twist Mate Torch Adapter Work Cable amp Clamp Not required for PRECISION TIGO 225 K2267 1 TIG Mate 20 Torch Starter Kit Includes 200A PTW 20 12 5 ft 3 8m Torch e KP510 Parts Kit Regulator amp Hose K1622 4 Twist Mate Torch Adapter e Water Hose amp Hose Coupler Work Cable amp Clamp Not required for PRECISION TIGO 225 QO j O O j O EP Cin O J 2 0 Ola A 3 9 FS c j 5 j 3 Dio cla Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN Return to Master TOC Return to Master TOC O O 9 v U gt 9 c 2 r Return to Master TOC D 1 TABLE OF CONTENTS MAINTENANCE SECTION di MAINMCNANCS s54 mc rc G n D 1 wisis PICCAQONS ERE 6 ax AA Wa CLE TTE TOTEM
96. gh the control board pow ers the gas solenoid valve and the high voltage trans former The 18VAC winding provides power to the trig ger circuitry The other 18VAC winding is rectified and regulated to a 15VDC supply which operates the cir cuitry on the control board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRECISION TIGO 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O j O O O EP C OFT 1 0 Ola a 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC E 3 THEORY OF OPERATION FIGURE E 2 Output Rectification amp Feedback Control BY PASS BOARD MAIN TRANSFORMER 115VAC uH gt Jg O AOPUUNITT Receptacle Circuit Breaker Protected CYY N YN CY de ee CONTROL 115 VAC BOARD De gt WORK SWITCH Q ELECTRODE INPUT POWER SWITCH BYPASS ASBLY Hi Hi X1 AC DC SCR H2 HIGH VOLTAGE d eme TRANSFORMER HI FREQUENCY TRANSFORMER CIRCUIT POWER N DIGITAL DISPLAY MODE SWITCH REMOTE RECEPTACLE THERMAL GAS TATE OUTPUT LIGHT VALVE CONTROL AUTO PULSE TIG STICK AC PULSE POSTFLOW BALANCE FREQ LED LED BALANCE CONTROL CONTROL LED LED CONTROL OUTPUT RECTIFICATION AND 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
97. he maximum rating of the PRECISION TIG 225 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 A Approximate Argon Electrode Tip Preparation Sharpened Balled Gas Flow Rate Electrode T use Ga EWTh 1 EWCe 2 EWTh 2 EWLa 1 EWZr C F H l min EWTh 1 EWTh 2 EWCe 2 EWLa 1 EWG Up to 80 A Up to 40 A Up to 60 A Up to 150 A Up to 100 A Up to 130 A Up to MAX A Up to 160 A Up to MAX A 13 17 X Upto MAX A X 15 23 7 11 Tungsten electrodes are classified as follows by the American Welding Society AWS mi EWP green TRI MIX OF ELEMENTS EWG3 gray 1 Thoria EWTh 1 yellow 2 Thoria EWTh 2 red 2 Ceria EWCe 2 orange 1 5 Lanthana EWLa 1 black 0 15 to 0 40 Zirconia EWZr brown Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications PRECISION TIGO 225 LINCOLN B 10 NOTES PRECISION TIGO 225 LINCOLN E B 10 NOL 49IS8 A 0 uunjeu NOL 191S8 A 0 UINISY NOL Je1Se A 0 UINISY NOL 191S8 A 01 UINISY DOL Uuo l99S oj UNAY DOL Uon9es o UNY DOL Uuo l99S oj UNY DOL uoroes oj UNAY Return to Master TOC Return to Master TOC O O 9 v C gt 9 c 2 r Return to Master TOC E TABLE OF CONTENTS ACCESSORIES SECTION
98. her alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing SAFETY LINCOLN Sa CYLINDER may explode ESE if damaged 7 a Use only compressed gas cylinders R 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 Cylinders should be located e Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode 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
99. igh voltage transformer primary circuit Replace if nec essary See wiring diagram The control board may be faulty Replace Check the micro switch S2A on the polarity switch It may be stuck closed See wiring dia gram 44 CAUTION 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 troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC iii TROUBLESHOOTING AND REPAIR dii Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS cre 5 3 lo cic Return to Section TOC Return to Master TOC Black areas along weld bead Weak high frequency machine has normal welding OUTPUT PROBLEMS Clean any oily or organic conta mination from the work piece Tungsten electrode may be con taminated Replace or sharpen Check for contaminated gas or leaks in the gas line torch or associated connections The gas shielding may be insuf ficient Increase gas flow reduce tungsten stickout beyond the gas cup Check for loose or faulty con nections at the torch and or welding cables The gas shielding
100. in that the correct input voltage is being applied to the correct primary leads See Table F 1 B If the correct input voltage is being applied to the primary leads and any or all of the sec ondary voltages are incorrect the T1 trans former may be faulty See Transformer and Output Choke Removal and Replacement Also check the leads for broken or loose connections between plugs J3 J4 and the T1 transformer 7 Replace case wrap around cover TABLE F 1 T1 TRANSFORMER VOLTAGE TEST POINTS ACCEPTABLE VOLTAGES SECONDARY WINDINGS SECONDARY VOLTAGES PLUG J3 PIN 8 LEAD 210 TO 18VAC PLUG J3 PIN 7 LEAD 209 PLUG J3 PIN 4 LEAD 201 TO PLUG J3 PIN 3 LEAD 204 PLUG J4 PIN 2 LEAD 260 CHECK DURING FIRST 5 SECONDS OF POWER UP TO 115VAC PLUG J4 PIN 3 LEAD 232 X1 TO X2 80 VAC PRIMARY WINDINGS PRIMARY VOLTAGES H1 TO H2 208VAC H1 TO H3 230VAC NOTE If the input voltages vary the secondary voltages will vary accordingly PRECISION TIGO 225 LINCOLN NOTES dis PRECISION TIGO 225 LINCOLN E F 20 NOL 49IS8 A 0 uunjeu NOL 191S8 A 0 UINISY NOL Je1Se A 0 UINISY NOL 191S8 A 01 UINISY DOL Uuo l99S oj UNAY DOL Uon9es o UNY DOL Uuo l99S oj UNY DOL uoroes oj UNAY Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Return to Section
101. ions 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 semiautomatic 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 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 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
102. ition If the gap is correct Replace the wraparound 8 Inspect gas hose and inlet fitting for cracks or leaks 9 Replace any unreadable labels or decal s 10 Verify that the machine and welding circuit is prop erly grounded FIGURE D 1 SPARK GAP 4 BELT Spark Gap FAN MOTOR OR FAN BLADE REPLACEMENT When installing a new fan blade or fan motor be sure to maintain proper shaft spacing per Figure D 2 below sole FIGURE D 2 PRECISION TIGO 225 LINCOLN Return to Master TOC Return to Master TOC O O 9 v U gt 9 c 2 r Return to Master TOC Et TABLE OF CONTENTS THEORY OF OPERATION SECTION E Theory of Operation uus ur oae ox ooo kk kk kk kk kk kk kk kk a kk kk kk kk ew kk kk kk kk a kk kk ka E 1 Cau BBC EFECTO TETTE TOR LOT ese Bees aspas E 2 ieu me ii a s stos a dla poe an a ke M AA wees Benet soe ewe ee es beatae a E 2 Output Rectification and Feedback Control kk kk kk kK KK kK KK KI KI KIRI KIRI KK KIR KIR KK KK KK KK KK kK kk a E 3 High Voltage High Frequency Circuit socia pom kk kk kK kK KK a KIR KK KK IK KK bbe kk kk kk kk a kk kk da E 4 DG Welding QUIDUE PP E 5 AG Welding QUIDUL cx sperede a a A a ab k Pendens Oe hee ae eee E 6 OCR ODETALUO N 26650064 oo oo awa ew And w Oboe gees as REUS ee eee See d r en d AA Qi d ka W d PS ES EP E E 7 giu uiegscdq P TTTPMPTTMTTTT E 8 Thermal i e m E
103. itioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the con nection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capaci tance selected according to national regulations O O 0 U gt 9 c E r Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applica tions 1 Portions of the p
104. j O O j O EP Cl O J 2 0 Ola a 3 9 j 2 c j sla Di cic Return to Section TOC Return to Master TOC F 2 TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE A 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 exhib 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 wire feeding problems and 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 RECOMMEN
105. low from anode to cathode In the ON state the SCR acts like a closed switch When the SCH is turned OFF there is no current flow from anode to cathode thus the device acts like an open switch As the name suggests the SCR is a rectifier so it pass es current only during positive half cycles of the AC supply The positive half cycle is the portion of the sine wave in which the anode of the SCR is more positive than the cathode When an AC supply voltage is applied to the SCH the device spends a certain portion of the AC cycle time in the on state and the remainder of the time in the off state The amount of time spent in the ON state is con trolled by the Gate An SCR is fired by a short burst of current into the gate This gate pulse must be more positive than the cath ode voltage Since there is a standard PN junction between gate and cathode the voltage between these terminals must be slightly greater than 0 6V Once the SCR has fired it is not necessary to continue the flow of gate current As long as current continues to flow from anode to cathode the SCR will remain on When the anode to cathode current drops below a minimum value called holding current the SCR will shut off This normally occurs as the AC supply voltage passes through zero into the negative portion of the sine wave If the SCR is turned on early in the positive half cycle the conduction time is longer resulting in greater SCR output If the gate firing occ
106. may be insuf ficient Increase gas flow reduce tungsten stickout beyond the gas cup Check spark gap operation and setting Normal is 0 015 PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION 1 This may be a welding proce dure problem Contact The Lincoln Electric Service Department 1 888 935 3877 1 Make sure that 115VAC is being applied to the primary of the high voltage transformer T3 See wiring diagram 2 Check for any open or arcing high frequency component Replace as required Examples C3 R3 C4 Refer to Maintenance section of 3 If spark is weak at the spark this manual The work and electrode cables may be in poor condition allow ing the high frequency to leak off Use good quality cables with a high natural rubber con tent such as Lincoln Stable Arc Cable Cables should be as short as possible gap check or replace the high frequency circuit Examples T3 L3 L4 44 CAUTION 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 troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIGO 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C con Be 1 Ola a 3 9 FS cre 5 j 3 lo cic Return
107. mounting insula tors See Figure F 12 Install the front mounting insulators and mount ing screw Using the phillips head screwdriver tighten all four mounting screws making certain the insu lators are positioned correctly Reconnect the two primary leads Reconnect the two secondary leads to the high frequency arc starter board assembly Replace any previously removed cable ties Replace the case wrap around cover PRECISION TIG 225 LINCOLN NOTES ia PRECISION TIGO 225 LINCOLN E F 52 NOL 19IS8 A 0 uunjeu NOL 191S8 A 0 UINISY NOL Je1Se A 0 UINISY NOL 191S8 A 01 UINISY DOL Uuo l99S oj UNAY DOL Uon9es o UNY DOL Uuo l99S oj UNY DOL uoroes oj UNAY Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j Cin O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC F 53 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE 44 WARNING 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 throughout this manual If for any reason you do not understa
108. mpt to override the governor or 2 d 3 Do not place your body between the electrode and idler by pushing on the throttle control rods work cables If the electrode cable is on your right while the engine is running side the work cable should also be on your right side NS Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while d 5 Do not work next to welding power source turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Return to Master TOC LINCOLN Return to Master TOC Return to Master TOC O O 0 U gt 9 c E r Return to Master TOC SAFETY 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 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 posit
109. n Section Contact The Lincoln Electric Service Department 1 888 935 3877 44 CAUTION 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 troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIGO 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS cre 5 3 lo cic Return to Section TOC Return to Master TOC Ai TROUBLESHOOTING AND REPAIR aA Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Stick electrode Blasts Off when 1 Weld current may be set too 1 Perform the SCR Bridge Test arc is struck high for electrode size Reduce current control setting or use a 2 The control board may be larger diameter electrode faulty Replace The stick electrode sticks in the 1 The weld current may be set too puddle low Increase the current control setting or use a smaller diameter electrode Variable or sluggish welding arc 1 Check work and electrode 1 Check the polarity switch for when welding in the Stick mode cables for loose or poor connec excessive wear or faulty connec tions tions 2 The weld cables may be too 2 Che
110. nd the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the main transformer and choke assembly MATERIALS NEEDED 3 8 Nutdriver 1 2 Wrench Wire cutters PRECISION TIGO 225 LINCOLN F 53 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O j O EP C O J 2 0 Ola a 3 9 FS cre 5 3 lo cic Return to Section TOC Return to Master TOC F 54 TROUBLESHOOTING AND REPAIR F 54 MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE continued REMOVAL PROCEDURE 1 Remove input power to the TIG 225 machine Perform the SCR Bridge Assembly Removal Unsolder the two 115VAC leads and leads B231 and B232 from the main transformer leads Label leads for reassembly See wiring diagram Unsolder leads W201 and W204 from the main transformer leads Label leads for reassembly See wiring diagram Unsolder leads R209 and U210 from the main transformer leads Label leads for reassembly See wiring diagram Using the 1 2 wrench remove the shunt assembly from the choke lead With the 3 8 wrench remove the H1 H2 or H3 lead from the input power switch See wiring diag
111. nel 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 throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the SCR assembly MATERIALS NEEDED 5 116 nutdriver 3 8 nutdriver Needle nose pliers 7 16 Wrench 3 8 Wrench Slot head screwdriver Dow Corning 340 Heat Sink compound PRECISION TIG 225 LINCOLN F 39 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j Cin O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC F 40 TROUBLESHOOTING AND REPAIR SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 7 CASE BACK MOUNTING SCREWS PROCEDURE 1 Remove input power to the TIG 225 machine Using the 3 8 nutdriver remove the case wrap around cover With the slot head screwdriver loosen the
112. o 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 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 ot
113. o be certain it is within applicable OSHA PEL and ACGIH TLV limits 5 c 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 prod ucts 5 d 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 5 e Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Aug 06 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 6 j 3 7 WELDING and CUTTING 4 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 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 t
114. o the welder and its clamp is connected to the work piece to complete the welding circuit Refer to Machine Grounding and High Frequency Interference Protection in the Installation section of this manual for the prop er procedure on grounding the work clamp and work piece to minimize high frequency interfer ence OPERATION Ho POWER UP SEQUENCE When the PRECISION TIGO 225 Power switch is ini tially turned On the following will be observed Refer to this Section Controls and Settings Figure The cooling fan will run for about 5 seconds The previous prior to Power Off settings of Mode and Maximum Output will be initiated If in TIG Mode the shielding gas solenoid valve will be activated for the time set by the Post Flow Time control PRECISION TIGO 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO lo O O j C O J 2 0 Ola A 3 9 FS c j 5 3 Dio cla Return to Section TOC Return to Master TOC EE OPERATION E CASE REAR COMPONENTS FIGURE B 2 HI T MIRAL IE 471 ELT E a a OTA SHA IOO I mI D C OCRE A HL CLL AAA EE EE e LIX NK IL jJ IL 14 4 LT JOUR JD 11 JE JI D Jzle E JBENSS TI pl di TIE ETE Ez LI JUSTE JET IES TIZ LWA AE BE EDIL ESK j TERS KE RE 1 INPUT CABLE This 6 3 208 230V or 12 3 380V and higher heavy duty cable with cable clamp is factory
115. oard Return to Section TOC Return to Master TOC PRECISION TIG 225 CONTROL BOARD PIN 7 LEAD 210 PIN 8 LEAD 209 PIN 3 LEAD 204 PIN 4 LEAD 201 PIN 3 LEAD 232 PIN 2 LEAD 260 Return to Section TOC Return to Master TOC PROCEDURE 1 Remove main supply power to the machine 2 Using the 3 8 nutdriver remove the case wrap around cover O j O O O EP C OTD 1 0 Ola a 3 9 FS c j 5 j 3 lo cic 3 Locate plugs J3 and J4 on the control board See Figure F 2 4 Carefully apply the correct input power making certain the reconnect configuration at the input switch is correct for the input voltage applied Turn the TIG 225 ON 5 Using the voltmeter carefully test for the correct transformer secondary voltages perl Table F 1 Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS c j 5 j 3 lo cic Return to Section TOC Return to Master TOC F 19 TROUBLESHOOTING AND REPAIR 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 certa
116. of the front panel digital display See Item 6 also see the following page for Power Up Sequence 2 POLARITY SWITCH The rotary power switch has 3 positions for DC AC and DC selections for the electrode output stud welding polarity 44 CAUTION Do not switch the polarity switch while welding or damage may result to the machine 3 MODE SWITCH The push button switch allows selection of the two machine welding modes as indi cated by colored mode lights STICK mode Top position Red light TIG mode Bottom position Green light 4 AC BALANCE CONTROL The potentiometer control permits AC TIG wave balance adjustment from Max Penetration 80 negative wave at full CW rotation setting to CCW rotation Max Cleaning 60 positive wave and includes POWER SWITCH POLARITY SWITCH MODE SWITCH AC BALANCE CONTROL MAXIMUM OUTPUT CONTROL AMPS DIGITAL METERS POST FLOW TIME PULSE TIG CONTROL 9 THERMAL SHUTDOWN LIGHT 10 REMOTE RECEPTACLE 11 ELECTRODE GAS OUTPUT RECEPTACLE 12 WORK CABLE 13 REMOVABLE LIFT EYEBOLT 9 N 9 OI N gt 2 Auto Balance position indicated by the Green panel light turning on This feature automatically provides the proper amount of cleaning and penetration for normal AC TIG welding 5 MAXIMUM OUTPUT CONTROL Presets the out put welding current over the rated output range of the machine With a Remote Current Control Amptrol connect ed to the Remo
117. ombustibles T e Wear eye ear and body Z 4 l i M protection Observe additional Safety Guidelines detailed in the beginning of this manual GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL INPUT POWER POSITIVE QUTPUT NEGATIVE OUTPUT DIRECT CURRENT PROTECTIVE GROUND WARNING OR CAUTION DO NOT SWITCH WHILE WELDING SINGLE PHASE TRANSFORMER AC AND RECTIFIER DC POWER SOURCE AN Qt Of O c PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO lo O o j C O J 2 0 Ola A 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC aa OPERATION a PRODUCT DESCRIPTION The PRECISION TIG 225 is a member of our field acclaimed PRECISION TIG family of industrial arc welding power sources Premium features include Precise constant current output Full range square wave AC DC TIG GTAW welding Enhanced version of the patented Micro Start IITV Technology for its lower Minimum 5 amps to higher Maximum 230 amps output control range 4 Built in high frequency stabilization for DC TIG starting and continuous AC TIG welding AC DC Stick SMAW capability A new undercarriage with gas bottle rack is available for field installation or is included with an available Ready Pak TIG Welding Package The PRECISION TIGO patente
118. palement 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 souder 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 vere 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 rayon nement de l arc et des projections 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 a proximit au soudage a l aide d crans appropri s et non inflammables Des gout
119. platform being careful notto allow the Under Storage Cart to roll Secure the cylinder in place with the provided chain Unload by following these steps in reverse REMOTE CONTROL CONNECTION A remote control receptacle is provided on the case front of the welder for connecting a remote control to to the machine A Foot Amptrol foot activated remote control is included with the PRECISION TIGO 225 Ready Pak models and available separately for dac ande Surio e DEIN cee of this manual for other available remote con trols CONNECTIONS FOR STICK WELDING SMAW STICK ELECTRODE CABLE AND WORK CABLE CONNECTION Refer to Field Installed Options in the Accessories Section of this manual for STICK welding equipment which is available for use with the PRECISION TIG 225 An electrode holder with Twist Mate cable and Twist Mate connector are available separately for use with the PRECISION TIGO 225 See Accessories Section Turn the Power Switch OFF Connect the Twist Mate quick connect plug into the Electrode Gas Output Receptacle and turn it clockwise until it is tight The work cable and work clamp are factory connected PRECISION TIG 225 LINCOLN A 8 NOTES PRECISION TIGO 225 LINCOLN E A 8 NOL 49IS8 A 0 uunjeu NOL 191S8 A 0 UINISY NOL Je1Se A 0 UINISY NOL 191S8 A 01 UINISY DOL Uuo l99S oj UNAY DOL Uon9es o UNY DOL Uuo l99S oj UNY DOL uoroes oj UNAY ui TABLE OF CONTEN
120. quick connect terminal and also provides the gas connection for the shielding gas to the torch 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 PRECISION TIG 225 To minimize high frequency interference refer to Input and Ground and High Frequency Interference Protection section of this manual for the proper procedure on grounding the work clamp and work piece SHIELDING GAS CONNECTION An adjustable gas pressure regulator with flow gage and hose is supplied with the PRECISION TIGO 225 Ready Pak models and available separately for A J Ll Ole necessary inert shielding gas 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 The available Under Storage Cart features a low plat form that simplifies loading and unloading of gas cylin ders CYLINDER could explode if damaged f Keep cylinder upright and chained to a support Keep cylinder away from areas where it could be damaged Never allow the torch to touch the cylinder Keep cylinder away from live electrical circuits Maximum inlet pressure 150 psi A cylinder is loaded by leaning it slightly sideways and rocking it up on the
121. r technical troubleshooting assistance before you proceed Call 1 888 935 3877 PRECISION TIGO 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C con Be 1 Ola a 3 9 FS cre 5 3 lo cic Return to Section TOC Return to Master TOC ih TROUBLESHOOTING AND REPAIR ihi Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Machine output is intermittently 1 The problem may be caused by 1 Check for loose or faulty con lost Gas flow and high frequency high frequency interference nection on the leads between are also interrupted Make sure that the machine is the remote receptacle and plug grounded properly according to J5 on the control board See the installation instructions If wiring diagram there are other high frequency sources in the area make cer 2 Check the plugs on the control tain that they are grounded board for loose connections properly 3 The control board may be 2 Make sure the Amptrol is operat faulty ing properly 3 Check to make sure that the input voltage is correct for the machine reconnect configura tion Refer to Reconnect Procedure in the Installation section of this manual 44 CAUTION If for any reason you do not understand the test procedures or are unable to p
122. ram Label the leads and connection points for reassembly Cut any necessary cable ties Remove plug J3 from the control board and push through the interior divider panel Using the 1 2 wrench remove the choke lead from the polarity switch See wiring diagram Label lead and connection point for reassembly 10 With the 1 2 wrench remove the X1 sec ondary lead from the polarity switch See wiring diagram Label lead and connection point for reassembly With the 1 2 wrench remove the four nuts and lock washers from the transformer mounting bolts at the base of the machine 12 Carefully hoist the transformer choke assem bly clear of the base Clear all leads REPLACEMENT PROCEDURE 1 Position the new transformer choke assembly onto the base and mounting bolts 2 Assemble the four nuts and washers to the mounting bolts on the base of the machine 3 Assemble the X1 secondary lead to the polarity switch 4 Assemble the choke lead to the polarity switch 5 Install the J3 plug into the control board 6 Assemble the H1 H2 or H3 lead onto the input power switch Insulate and secure the unused lead H2 or H3 7 Assemble the shunt assembly to the choke lead 8 Solder leads R209 and U210 to the main trans former leads See wiring diagram Insulate connections 9 Solder leads W201 and W204 to the main transformer leads See wiring diagram Insulate connections 10 Solder the two 115VAC leads
123. receding text are contained in EN 60974 10 Electromagnetic Compatibility EMC product standard for arc welding equipment L10093 3 1 96H Return to Master TOC LINCOLN MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Accessories ee eee a a a a a a a a a a a a a a a a a a a a a a a a ka aa Section C Maintenance cee a a a a a a a a a a a a a a a a a a a a a a a a a a a a eee eee eee eens Section D Theory of Operation oooooooo kaka a a a a a a a a a a a a a a a a a a a a a a a a a a a a hh Section E Troubleshooting and Repair 00 aa aa a aka kk a a a a a a a a a a a a a a a a a a a a a a a a kk kk a Section F Electrical Diagrams 00cc aa a aka aa kaka a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a aa Section G Parts Manual siii ri aa aka kk aka aka ka a a a a a a a a a a a a a a a a a a a a a P 536 P 210 R P 66 J 6 PRECISION TIG 225 LINCOLN Return to Master TOC Return to Master TOC QO O 9 0 U gt 9 c E r Return to Master TOC 5 TABLE OF CONTENTS INSTALLATION SECTION d noka Me A 1 Technical Specifications kk kk tra Roe rear p KK KK KK KK KK KK KK Re kk kk ce HE UR kk kk kk CR E kk a A 2 A 3 Sale PrecallllOl amp x todas ka a yt Se eed pero dora ee A 4 Select Sultable LOcatlol S uar chs ee
124. round Current level is typically optimized at a fixed 50 of Peak Pulse level setting Peak Pulse On time is typically optimized at a fixed 50 A Green light blinks with each Peak Pulse to indi cate the Pulse TIG Control setting before and dur ing welding THERMAL SHUTDOWN LIGHT E This Yellow LED panel light turns on if the machine output is shut down because internal overheating has occurred and turns off when cooled to reset REMOTE RECEPTACLE Provides for connec tion of remote control and or arc start switch only in TIG Mode There is no remote output control capability when stick welding e Plugging a remote current control Amptrol into this receptacle automatically switches the output control from the panel Max Output Control See Item 5 to the remote control The connected remote control will then control the output current between the Min range of the machine and the setting of the panel Max Output Control Switching Mode Switch See Item 3 to Stick will automatically disable the connected remote con trol and switch the output control back to the Max Output panel control ELECTRODE GAS OUTPUT RECEPTACLE This quick connect Twist Mate receptacle pro vides electrical connection to the electrode holder and cable for Stick welding and a combined electri cal and gas connection for the TIG torch when TIG welding WORK CABLE This 10ft 3 05m cable with work clamp is factory connected t
125. s Position with harness and secure with cable ties QO j O O j O EP Cin O J 2 0 Ola A 3 9 FS c j 5 3 Dio cla 8 Replace any previously removed cable ties 9 Position the internal divider panel and secure with the screws previously removed 10 Install the J2 plug into the control board and position the harness in the internal divider panel Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN NOTES ind PRECISION TIGO 225 LINCOLN E F 44 NOL 49IS8 A 0 uunjeu NOL 191S8 A 0 UINISY NOL Je1Se A 0 UINISY NOL 191S8 A 01 UINISY DOL Uuo l99S oj UNAY DOL Uon9es o UNY DOL Uuo l99S oj UNY DOL uoroes oj UNAY Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS c j 5 j 3 lo cic Return to Section TOC Return to Master TOC F 45 TROUBLESHOOTING AND REPAIR F 45 POLARITY SWITCH REMOVAL AND REPLACEMENT PROCEDURE 44 WARNING 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 throughout this manual If for any reason you do not understand the test procedure
126. s or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the polarity switch MATERIALS NEEDED 3 8 Nutdriver 1 2 Wrench 7 16 Wrench Phillips head screwdriver 5 64 Allen type Wrench Needle nose pliers Slot head screwdriver 2 required Wiring diagram PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola A 3 9 FS c j 5 3 Dio cla Return to Section TOC Return to Master TOC F 46 1 10 TROUBLESHOOTING AND REPAIR POLARITY SWITCH REMOVAL AND REPLACEMENT PROCEDURE continued REMOVAL PROCEDURE Remove the input power to the TIG 225 machine Using the 3 8 nutdriver remove the case wrap around cover Using the 3 32 Allen type wrench remove the output control knob Using the Phillips head screwdriver remove the screw from the polarity switch handle With the 2 slot head screwdrivers carefully pry the polarity switch handle from the shaft Remove the five plastic snap rivets holding the name plate to the case front These can be removed by gently prying at the rivet between the name plate and the case front Remove the name plate
127. standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work com plete with associated input filters In all cases electromagnetic disturbances must be red
128. substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC QO O E c 2 O D U r Return to Master TOC F 4 Machine is dead No output No fan No 115 VAC at receptacle The fan runs normally No output from the machine in either Stick or TIG modes OUTPUT PROBLEMS Make sure that the input power switch is in the ON position and the machine is plugged in Check the input voltage at the machine Input voltage must match the rating plate and volt age connection Refer to Reconnect Procedure lin the Installation section of this manu al Blown or missing fuses in the input line CB 1 circuit breaker open Check for proper input voltages per nameplate and voltage reconnect configuration Check to make sure the polarity switch is in the proper position 2 TROUBLESHOOTING AND REPAIR F 4 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF AC
129. te Receptacle See item 10 this knob sets the Maximum output current level set table with the remote Amptrol For Pulse TIG See Item 8 this knob sets the Peak Pulse level with the Remote Amptrol if used 6 DIGITAL METER A 3 digit LED meter is used to display the preset output current level before weld ing and actual output level while welding A lit display indicates input power is turned on See Item 1 7 POST FLOW TIME Sets the TIG mode shielding gas post flow time over the range of about 1 to 30 seconds after the arc is shut off Note Gas preflow time is fixed at 0 5 second only in TIG mode but no preflow time will occur if the arc is restarted during Post Flow time since shielding gas would not have stopped flowing PRECISION TIGO 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O j O EP C O J 2 0 Ola A 3 9 FS c j 5 3 Dio cla Return to Section TOC Return to Master TOC B 5 8 9 10 11 12 PULSE TIG CONTROL The Pulse TIG feature built into the PRECISION TIG 225 is simplified to be a single knob control which sets the Pulse Frequency over the peak pulses sec range of about 0 1 to 20 pulses per second Full CCW min setting of the control knob shuts off Pulse TIG 0 0 pps e Peak Pulse level is set by the Max Output Control and the Remote Amptrol if used Backg
130. ter TOC PRECISION TIG 225 LINCOLN je TROUBLESHOOTING AND REPAIR ER Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C con Be 1 Ola a 3 9 FS c j 5 j 3 lo cic Return to Section TOC Return to Master TOC F 17 TROUBLESHOOTING AND REPAIR T1 TRANSFORMER TEST A WARNING 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 throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will determine if the correct voltage is being applied to the primary of the T1 transformer and also if the correct voltages are being induced on the secondary wind ings of the transformer MATERIALS NEEDED Volt Ohm Meter PRECISION TIG 225 Wiring Diagrams 3 8 nutdriver PRECISION TIG 225 LINCOLN me TROUBLESHOOTING ANDREPAIR T1 TRANSFORMER TEST continued FIGURE F 2 Plugs J3 amp J4 on Control B
131. tes 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 o l on pique le laitier LINCOLN Huzn iv SAFETY iv 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 echauffement 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 cables de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des cables jusqu a ce qu ils se rompent Assurer une ventilation suffisante 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 metal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d
132. the AC bridge plate to the polarity switch Make certain washers are in place and the nut is tight 9 Assemble the positive flex lead to the polarity switch Make certain washers are in place and the nut is tight QO j O O o j C O J 2 0 Ola A 3 9 FS c j 5 j 3 Dio cla 10 Clear the leads and check for shorted or grounded leads 11 Position the name plate and fasten to the front with the previously removed snap rivets 12 Assemble the polarity switch handle in place with the Phillips head screw and check for cor rect switch operation 13 Using the Allen type wrench replace the output control knob 14 Replace the case wrap around cover Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN NOTES E PRECISION TIGO 225 LINCOLN E F 48 NOL 49IS8 A 0 uunjeu NOL 191S8 A 0 UINISY NOL Je1Se A 0 UINISY NOL 191S8 A 01 UINISY DOL Uuo l99S oj UNAY DOL Uon9es o UNY DOL Uuo l99S oj UNY DOL uoroes oj UNAY Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j Cin O J 2 0 Ola a 3 9 FS c j 5 j 3 lo cic Return to Section TOC Return to Master TOC F 49 TROUBLESHOOTING AND REPAIR HIGH VOLTAGE TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE 44 WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthoriz
133. tric This information is pro vided for reference only 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 Improper PC board repairs could result in damage to the LINCOLN go i Tinco A machine PRECISION TIG 225 EN 168 SOLID EDGE Return to Section TOC Return to Master TOC
134. uced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equip ment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers C computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h the time of day that welding or other activities are to be carried out L10093 3 1 96H LINCOLN vi SAFETY vi Electromagnetic Compatibility EMC The size of the surrounding area to be considered will depend on the str
135. ucture of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Return to Master TOC Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommen dations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanenily installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Return to Master TOC Welding Cables The welding cables should be kept as short as possible and should be pos
136. uil PCCCSSONGS e ES C 1 Standard Equipment Packages c sittar arrieros peda soda a kk C 2 Factory Installed DIOE soc s sa Kilk amd ana a aa A a alba carrer l ke iab d dar dh n C 3 Field installed OPIONS uz a sa 2s na na n d sa bre ab oes d oe w ki ahy kr n dr ow ae C 4 PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS c j 5 j 3 lo cic Return to Section TOC Return to Master TOC a ACCESSORIES EE STANDARD EQUIPMENT PACKAGES 2 PRECISION TIGO 225 Ready Pak w Cart K2535 2 The PRECISION TIGO 225 will be available in two Factory Configured Welding Packages 208 230 1 60 Machine K2533 1 9 ft 2 7m Input Cable with NEMA 6 50P Plug 1 PRECISION TIGO 225 Ready Pak K2535 1 NEMA 6 50R Receptacle Integrated 10 ft 3 1m Work Lead w Clamp 208 230 1 60 Machine K2533 1 Gas Regulator with 10 ft 3 1m Hose 9 ft 2 7m Input Cable with NEMA 6 50P Plug PTA 17 12 5 ft 3 8m One cable Superflex Torch with NEMA 6 50R Receptacle 3 32 2 4mm Electrode and Parts e Integrated 10 ft 3 1m Work Lead w Clamp Foot Amptrol K870 e Gas Regulator with 10 ft 3 1m Hose TIG Slide Rule WC332 PTA 17 12 5 318mm Ultra Flex Torch with GTAW Book JF
137. uit The technician will then be able to take voltage measurements without the possibility of high frequency damage to his test equipment MATERIALS NEEDED 3 8 Nutdriver 5 64 Allen type wrench 020 feeler gauge 44 WARNING HIGH VOLTAGE IS STILL PRESENT IN THE HIGH FREQUENCY CIRCUIT PRECISION TIGO 225 LINCOLN F 15 HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE continued FIGURE F 1 SPARK GAP ASSEMBLY Return to Section TOC Return to Master TOC QO O E c 2 O D U 2 r Return to Master TOC 9 LEFT SIDE OF MACHINE E PROCEDURE 212 7 When voltage testing and scope measurements D E 1 Remove input power to the TIG 225 machine are complete reset the spark gap electrodes to e O 020 air gap Tighten the set screw using the ele 2 Using the 3 8 nutdriver remove the right side 5 64 Allen wrench 3 5 2 2 panel eo 3 Locate the Spark Gap Assembly at the right side of the machine See Figure F 1 4 With the 5 64 Allen type wrench loosen the set screw holding the upper electrode in place 5 Increase the distance between the electrodes to at least 3 8 by sliding one electrode away from the other electrode Secure the one elec trode in this position 6 This should disable the high frequency circuit Visually check to make sure high frequency sparking is NOT present before connecting any test equipment to the TIG 225 machine Return to Section TOC Return to Mas
138. urn to Master TOC F 12 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual No high frequency Machine is in the TIG mode and has normal out put No gas flow when Amptrol is acti vated in the TIG mode Machine has normal output fan runs A click can be heard indicating that the gas solenoid valve is oper ating OUTPUT PROBLEMS If the machine location is in a highly dirty environment with conductive contaminant s check and clean the spark gap with a low pressure air stream per the maintenance instructions Check spark gap operation and setting Normal is 0 020 Refer tol Maintenance section of this manual The gas supply is either empty or not turned on The flow regulator may be set too low Check the gas hose for kinks or blockages Check the filter screen inside gas inlet fitting to solenoid valve PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION 1 Check the high voltage trans former T3 The normal resis tance of the secondary winding of the high voltage transformer is 12 5k ohms WARNING ELECTRIC SHOCK CAN KILL When 115VAC is applied to the primary of T3 A very high voltage is developed on the secondary winding For assistance call the Lincoln Electric Service Department 1 888 935 3877 2 Check the values of R3 and C4 3 Perform the T1 Transformer Test
139. urs later in the cycle the conduction time is less resulting in lower SCR output LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED FIGURE E 7 SCR Operation PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Return to Section TOC Return to Master TOC ES THEORY OF OPERATION ES PROTECTIVE CIRCUITS Protective circuits are designed into the PRECISION TIGO 185 to sense trouble and shut down the machine before the trouble damages the internal machine com ponents Both thermal protection and current overload are included Fan as needed F A N Fan runs for 5 seconds at power up and stops at idle 8 minutes after welding THERMAL PROTECTION OVER TEMPERATURE LIGHT E If the welder overheats due to blocked air flow high ambient air temperature or exceeded duty cycle an internal ther mostat will open disabling the welding output and this yellow light will illuminate The cooling fans will contin ue to run to cool the unit during this time The light will go out when the unit cools and the thermostat resets Once the light goes out the machine will again become available to weld Once the machine cools sufficiently the thermostats are self resetting If the thermostat shutdown is caused by excessive output or duty cycle and the fan is oper ating normally the
140. voltage signal and fed back to the control board The control board compares the commands of the mode switch output control AC balance control pulse control post flow control or remote control with the feedback infor mation The appropriate SCR gate firing signals are created by the control board and sent to the SCR bridge The control board controls the firing of the SCRs which control the output of the machine See SCR Operation The control board monitors the ther mostats and also controls the gas solenoid valve ther mal light auto balance LED pulse frequency LED TIG LED stick LED and the digital display NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC QO O E 9 O U D r Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC E THEORY OF OPERATION ES FIGURE E 2 High Voltage High Frequency Circuit BY PASS BOARD gt WORK SWITCH ELECTRODE MAIN TRANSFORMER INPUT POWER SWITCH BYPASS ASBLY E EH X1 AC apes SCR BRIDGE O O HI FREQUENCY TRANSFORMER HIGH VOLTAGE TRANSFORMER CIRCUIT 115VAC E um CONTROL r 115 VAC Fan BOARD ON DIGITAL Receptacle DISPLAY Circuit Breaker NA ia Protected MODE SWITCH REMOTE Te Seva RECEPTACLE THERMO THERMAL GAS STATS HIGH VOLTAGE
141. 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 OTTO O o j C O J 2 0 Ola a 3 9 FS c j 5 3 lo cic Note Scope probes connected at machine output terminals probe to electrode probe to work SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN didi TROUBLESHOOTING AND REPAIR iid TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED DC TIG MODE A CAUTION HIGH VOLTAGE HIGH FREQUENCY can damage test equipment Perform all voltage and waveform checks with high frequency circuit OFF Perform High Frequency Disable Procedure Return to Section TOC Return to Master TOC Olo O lo ELE E ojo IE o 50 volts o j 2 cle 2 0 volts cic pe yt P pep l1 IAE ASTIN IE A FEA il SU EY l ZL 2ms MACHINE LOADED TO 180 AMPS AT 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 1
142. y R1 4 ohms 10 watts R2 3 ohms 10 watts Return to Section TOC Return to Master TOC To test SCRs construct the circuit outlined above Resistor values are plus or minus ten percent The voltmeter scale should be low approximately 0 5 or 0 10 volts DC 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 4 Construct the circuit outlined in Figure F 5 One 6V lantern battery can be used Resistor values are 10 The voltmeter scale should be low approximately 0 5 or 0 10 volts QO j O O o j C O J 2 0 Ola a 3 9 FS c j 5 j 3 lo cic 5 Battery Test Check the battery by shorting leads A and C and then close switch SW 1 Re place battery if voltage is less than 4 5 volts Return to Section TOC Return to Master TOC PRECISION TIG 225 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO j O O o j C O J 2 0 Ola A 3 9 FS c j 5 j 3 lo cic Return to Section TOC Return to Master TOC F 27 TROUBLESHOOTING AND REPAIR F 27 ACTIVE SCR TEST continued FIGURE F 6 SCR GATE LOCATIONS SCR1 ANODE SCR1 CATHODE SCR2 ANODE SCR2 CATHODE SCR3 CATHODE SCR4 ANODE

Lincoln Electric SVM186-A User's Manual

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