Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAFETY i i FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ________________________________________________...
Page 3 - ii; ELECTRIC SHOCK can kill.
SAFETY ii ii Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC FUMES AND GASEScan be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation ...
Page 4 - iii
SAFETY iii iii Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Jan ‘07 FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
SAFETY iv iv Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Mar ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précauti...
Page 6 - b) radio and television transmitters and receivers
SAFETY v v Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Electromagnetic Compatibility (EMC) ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 3 May1989 on the approximation of the laws of the Member St...
Page 7 - Methods of Reducing Emissions
SAFETY vi vi Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and otheractivities that are taking place. The surrounding area may ...
Page 8 - - MASTER TABLE OF CONTENTS FOR ALL SECTIONS -; RETURN TO MAIN INDEX; Page; RETURN TO MAIN MENU
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS - I I PRECISION TIG® 225 RETURN TO MAIN INDEX Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . ....
Page 9 - TABLE OF CONTENTS - INSTALLATION SECTION
TABLE OF CONTENTS - INSTALLATION SECTION A-1 A-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 10 - INSTALLATION; GTAW; INPUT - SINGLE PHASE ONLY; AC/DC Stick and Auto-Balance TIG Output Limits; Using provided input cable for protected; Output
INSTALLATION A-2 A-2 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC TECHNICAL SPECIFICATIONS - PRECISION TIG® 225 (K2533-1AND K2535-1,-2) Weld Volta...
Page 11 - PHYSICAL DIMENSIONS
INSTALLATION A-3 A-3 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC TECHNICAL SPECIFICATIONS - CANADIAN (K2533-2), INTERNATIONAL K2534-1) MODEL HEIG...
Page 12 - SAFETY PRECAUTIONS; Read and follow; LIFTING AND MOVING; Accessories section; TILTING
INSTALLATION A-4 A-4 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAFETY PRECAUTIONS SELECT SUITABLE LOCATIONMOUNTING Environmental Rating The PRE...
Page 13 - INPUT AND GROUNDING CONNECTIONS; Technical Specifications
INSTALLATION A-5 A-5 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC MACHINE GROUNDING AND HIGH FRE-QUENCY INTERFERENCE PROTECTION Locate the Precisi...
Page 14 - INPUT RECONNECT PROCEDURE; Included Equipment; CAUTION; FIGURE A.1 Reconnect Leads; OUTPUT CONNECTIONS; FIGURE A.2 Location of Output Connections
INSTALLATION A-6 A-6 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC INPUT RECONNECT PROCEDURE On multiple input voltage welders, be sure the machine...
Page 15 - CONNECTIONS
INSTALLATION A-7 A-7 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC CONNECTIONS FOR TIG (GTAW) WELDING TIG TORCH CONNECTION A PTA-17 Twist-Mate TIG ...
Page 16 - NOTES
Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES A-8 A-8 PRECISION TIG® 225
Page 17 - TABLE OF CONTENTS - OPERATION SECTION
TABLE OF CONTENTS - OPERATION SECTION B-1 B-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 18 - OPERATION; have held combustibles.
OPERATION B-2 B-2 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC ELECTRIC SHOCKcan kill.• Do not touch electrically live partsor electrode with skin...
Page 19 - PRODUCT DESCRIPTION; Built-in high frequency stabilization for DC TIG starting; RECOMMENDED PROCESSES; Installed Options; EQUIPMENT LIMITATIONS; rated output graph
OPERATION B-3 B-3 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRODUCT DESCRIPTION The PRECISION TIG® 225 is a member of our fieldacclaimed PRECIS...
Page 20 - Remote Receptacle; CONTROLS AND SETTINGS
OPERATION B-4 B-4 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC CONTROL FUNCTIONALITY1. POWER SWITCH – Input line switch turns input power ON or OF...
Page 21 - Mode Switch
OPERATION B-5 B-5 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC 8. PULSE TIG CONTROL – The Pulse TIG feature built into the PRECISION TIG® 225 is s...
Page 22 - CASE REAR COMPONENTS; GAS INPUT CONNECTOR –; Air is drawn in through the; MACHINE RATING PLATE
OPERATION B-6 B-6 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC CASE REAR COMPONENTS 1. INPUT CABLE– This #6-3 (208/230V) or #12-3 (380V and higher...
Page 23 - OPERATING STEPS; WELDING IN TIG MODE
OPERATION B-7 B-7 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC OPERATING STEPS WELDING IN TIG MODE 1. Connect the TIG torch and cable Twist-Mate™ ...
Page 24 - REMOTE CONTROL OPERATION; Accessories Section; BENEFITS OF THE PRECISION TIG® 225 DESIGN
OPERATION B-8 B-8 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC REMOTE CONTROL OPERATION A Foot Amptrol is included with the PRECISION TIG®225 Read...
Page 25 - WELDING IN STICK MODE; Put the electrode holder and cable quick connect; • In Stick Mode the output terminal; Adjust the Current Control to the desired amps.; RECOMMENDED ELECTRODE AMPERAGE RANGES - PRECISION TIG 225; SMAW Process
OPERATION B-9 B-9 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING IN STICK MODE 1. Put the electrode holder and cable quick connect plug into...
Page 27 - TABLE OF CONTENTS - ACCESSORIES SECTION
TABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 28 - ACCESSORIES; STANDARD EQUIPMENT PACKAGES; Machine Only
ACCESSORIES C-2 C-2 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC TABLE C.1 STANDARD EQUIPMENT PACKAGES The PRECISION TIG® 225 will be available in...
Page 29 - FACTORY INSTALLED OPTIONS; Water Cooled System
ACCESSORIES C-3 C-3 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC FACTORY INSTALLED OPTIONS The PRECISION TIG® 225 will be available in twoFactory-...
Page 30 - FIELD INSTALLED OPTIONS; • K814 Arc Start Switch; assemblies and; • K2374-1 Electrode Holder and Cable
ACCESSORIES C-4 C-4 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC FIELD INSTALLED OPTIONS The following Options/Accessories are available for thePR...
Page 31 - TABLE OF CONTENTS - MAINTENANCE SECTION
TABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 32 - MAINTENANCE
MAINTENANCE D-2 D-2 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should per...
Page 33 - TABLE OF CONTENTS-THEORY OF OPERATION SECTION; FIGURE E.1 PRECISION TIG® 225 BLOCK LOGIC DIAGRAM
TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 E-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 34 - THEORY OF OPERATION; GENERAL DESCRIPTION; INPUT POWER CIRCUIT
THEORY OF OPERATION E-2 E-2 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC GENERAL DESCRIPTION The PRECISION TIG® 225 is a member of our fieldacclai...
Page 35 - OUTPUT; The control board controls the firing of the
THEORY OF OPERATION E-3 E-3 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC OUTPUT RECTIFICATION AND FEEDBACK CONTROL The AC output from the main tra...
Page 36 - NOTE: Unshaded areas of Block Logic
THEORY OF OPERATION E-4 E-4 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC HIGH VOLTAGE / HIGH FREQUENCYCIRCUIT The control board passes the 115VAC ...
Page 37 - DC WELDING OUTPUT; FIGURE E.5 DC Welding Current Generation.; CHOKE
THEORY OF OPERATION E-5 E-5 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC DC WELDING OUTPUT When the polarity switch is placed in either DC positio...
Page 38 - AC WELDING OUTPUT; FIGURE E.6 AC Square Wave Welding Current Generation.
THEORY OF OPERATION E-6 E-6 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC AC WELDING OUTPUT Rotating the polarity switch to the AC position changes...
Page 39 - SCR OPERATION; An SCR is fired by a short burst of current into the gate.; FIGURE E.7 SCR Operation
THEORY OF OPERATION E-7 E-7 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SCR OPERATION A silicon controlled rectifier (SCR) is a three terminaldev...
Page 40 - PROTECTIVE CIRCUITS; THERMAL PROTECTION; OVER TEMPERATURE LIGHT-; OVERLOAD PROTECTION
THEORY OF OPERATION E-8 E-8 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PROTECTIVE CIRCUITS Protective circuits are designed into the PRECISIONTI...
Page 41 - TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR; Test Procedures
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1 F-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 Troubleshooting and Repair...................................................................................................................
Page 42 - TROUBLESHOOTING AND REPAIR; HOW TO USE TROUBLESHOOTING GUIDE
TROUBLESHOOTING AND REPAIR F-2 F-2 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC This Troubleshooting Guide is provided tohelp you locate and repai...
Page 43 - PC board can be damaged by static electricity.; PC BOARD TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING AND REPAIR F-3 F-3 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Sometimes machine failures appear to be due to PCboard failures. T...
Page 45 - The welding application may
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 46 - The control board may be
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 48 - Reconnect
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 49 - SCR Bridge Test
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 50 - Maintenance
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 51 - Technical
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 53 - The tungsten electrode may be
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 55 - HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE; TEST DESCRIPTION; HIGH VOLTAGE IS STILL PRESENT IN THE HIGH FREQUENCY CIRCUIT.
HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE TROUBLESHOOTING AND REPAIR F-15 F-15 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WARNING Service and rep...
Page 56 - LEFT SIDE OF MACHINE; FIGURE F.1 – SPARK GAP ASSEMBLY; HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE (continued); PROCEDURE
.020 Spark Gap LEFT SIDE OF MACHINE FIGURE F.1 – SPARK GAP ASSEMBLY HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE (continued) TROUBLESHOOTING AND REPAIR F-16 F-16 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to...
Page 57 - T1 TRANSFORMER TEST
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 58 - Remove main supply power to the machine.; Plugs J3 & J4 on Control Board
PRECISION TIG 225 CONTROL BOARD J2 J3 J4 PIN 4 (LEAD #201) PIN 3 (LEAD #204) PIN 7 (LEAD #210) PIN 8 (LEAD #209) PIN 3 (LEAD #232)PIN 2 (LEAD #260) T1 TRANSFORMER TEST (continued) PROCEDURE 1. Remove main supply power to the machine. 2. Using the 3/8” nutdriver remove the case wrap- around cover. 3....
Page 59 - Main
T1 TRANSFORMER TEST (continued) PROCEDURE 6. If all of the secondary voltages are correct the T1 transformer is functioning properly. A. If all of the secondary voltages are missing or incorrect make certain that the correctinput voltage is being applied to the correctprimary leads. See Table F.1. B...
Page 61 - See; MATERIALS NEEDED; STATIC SCR TEST
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 62 - PLUG J2 REMOVED; TEST PROCEDURE; Remove main supply power to the TIG 225 and; FIGURE F.3 – Plug J2 Location on Control Board
PLUG J2 REMOVED PRECISION TIG 225 CONTROL J2 J3 J4 STATIC SCR TEST (continued) TEST PROCEDURE 1. Remove main supply power to the TIG 225 and remove the case wrap-around cover. 2. Locate and remove plug J2 from the control board. See Figure F.3. TROUBLESHOOTING AND REPAIR F-22 F-22 PRECISION TIG® 225...
Page 63 - CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued); Using an analog ohmmeter test the resistance; FIGURE F.4 – SCR TEST POINTS
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) TEST PROCEDURE (continued) 3. Using an analog ohmmeter test the resistance from anode to cathode of SCR1. Reverse the meter leads and check from cathode to anodeof SCR1. See Figure F.4. If a low resistance isindicated in either direction SCR1 ...
Page 65 - ACTIVE SCR TEST
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 66 - FIGURE F.5 – ACTIVE SCR TEST SETUP; Remove main supply power to the TIG 225
FIGURE F.5 – ACTIVE SCR TEST SETUP ACTIVE SCR TEST (continued) TEST PROCEDURE 1. Remove main supply power to the TIG 225 machine. 2. Locate and remove plug J2 from the control board. See Figure F.3 . 3. Perform test procedure as outlined in Figure F.5. Repeat test for all four SCRs. See Figure F.6 ....
Page 67 - FIGURE F.6 – SCR GATE LOCATIONS
FIGURE F.6 – SCR GATE LOCATIONS ACTIVE SCR TEST (continued) TEST PROCEDURE (continued) 6. Connect SCR into the test circuit as shown (A) lead to anode (C) lead to cathode and (G) leadto the gate. 7. Close switch SW-1 (switch SW-2 should open), voltmeter should read zero. If the voltmeterreads higher...
Page 69 - SCOPE SETTINGS; volts; HIGH VOLTAGE / HIGH FREQUENCY can damage test equipment.
This is the typical AC output voltagewaveform generated from a properlyoperating machine. Note that each vertical division represents 50 voltsand that each horizontal division rep-resents 2 milliseconds in time. Note: Scope probes connected at machine output terminals: (+) probe toelectrode, (–) pro...
Page 70 - NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
This is the typical DC (+) output volt-age waveform generated from a prop-erly operating machine. Note that each vertical division represents 50volts and that each horizontal divisionrepresents 2 milliseconds in time. Note: Scope probes connected at machine output terminals: (+) probe toelectrode, (...
Page 73 - Note that each vertical division; TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED; AC TIG MODE
MACHINE LOADED TO 180 AMPS AT16VDC. This is the typical AC output voltage wave-form generated from a properly operatingmachine. Note that each vertical division represents 10 volts and that each horizontaldivision represents 2 milliseconds in time.The machine was loaded with a resistancegrid bank. T...
Page 74 - MACHINE LOADED TO 180 AMPS AT 16VDC.; DC TIG MODE
MACHINE LOADED TO 180 AMPS AT 16VDC. This is the typical DC (+) output voltage wave-form generated from a properly operatingmachine. Note that each vertical division repre-sents 10 volts and that each horizontal divisionrepresents 2 milliseconds in time. The machinewas loaded with a resistance grid ...
Page 75 - TYPICAL OUTPUT VOLTAGE WAVEFORM; AC STICK MODE
MACHINE LOADED TO 180 AMPS AT26VDC. This is the typical AC output voltage wave-form generated from a properly operatingmachine. Note that each vertical division represents 10 volts and that each horizontaldivision represents 2 milliseconds in time.The machine was loaded with a resistancegrid bank. T...
Page 76 - DC STICK MODE
MACHINE LOADED TO 180 AMPS AT26VDC. This is the typical AC output voltage waveformgenerated from a properly operating machine.Note that each vertical division represents 10volts and that each horizontal division repre-sents 2 milliseconds in time. The machinewas loaded with a resistance grid bank. T...
Page 77 - ABNORMAL OPEN CIRCUIT VOLTAGE - DC TIG MODE
This is NOT the typical DC (+) outputvoltage waveform. One output SCR isnot functioning. Note the “gap”in thewaveform. One SCR gate was discon-nected to simulate an open or non-functioning output SCR. Note that each vertical division represents 50volts and that each horizontal divisionrepresents 2 m...
Page 79 - SCR BRIDGE ASSEMBLY
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 80 - FIGURE F.7 – CASE BACK MOUNTING SCREWS
FIGURE F.7 – CASE BACK MOUNTING SCREWS SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Remove input power to the TIG 225 machine. 2. Using the 3/8” nutdriver remove the case wrap- around cover. 3. With the slot head screwdriver loosen the input cable strain relief to a...
Page 81 - FIGURE F.8 – FRONT PANEL MOUNTING SCREWS
FIGURE F.8 – FRONT PANEL MOUNTING SCREWS SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) PROCEDURE (continued) 9. Remove plug J2 from the control board. (See Figure F.9 .) Also remove plug and lead harness from internal divider panel. 10. Carefully slide the internal divider panel ...
Page 82 - FIGURE F.9 – PLUG J2 ON CONTROL BOARD; FIGURE F.10 DIODE PIGTAIL CONNECTION TO POLARITY SWITCH LEAD.
PLUG J2 REMOVED PRECISION TIG 225 CONTROL J2 J3 J4 FIGURE F.9 – PLUG J2 ON CONTROL BOARD SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REPAIR F-42 F-42 PRECISION TIG® 225 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T ...
Page 83 - REPLACEMENT PROCEDURE
SCR BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) 16. With the 3/8” wrench remove the four mount- ing screws holding the SCR bridge assemblyto the main transformer frame. Note insulatorplacement. 17. Carefully remove the SCR bridge assembly from the TIG 225 cutting any necessary cabl...
Page 85 - POLARITY SWITCH
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 86 - REMOVAL PROCEDURE
POLARITY SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) REMOVAL PROCEDURE 1. Remove the input power to the TIG 225 machine. 2. Using the 3/8” nutdriver remove the case wrap- around cover. 3. Using the 3/32” Allen type wrench remove the output control knob. 4. Using the Phillips head screwdrive...
Page 89 - HIGH VOLTAGE TRANSFORMER
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 90 - FIGURE F.11 – SECONDARY LEADS AT HIGH FREQUENCY STARTER BOARD
FIGURE F.11 – SECONDARY LEADS AT HIGH FREQUENCY STARTER BOARD HIGH VOLTAGE TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) 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 t...
Page 91 - FIGURE F.12 – HIGH VOLTAGE TRANSFORMER MOUNTING INSULATORS
FIGURE F.12 – HIGH VOLTAGE TRANSFORMER MOUNTING INSULATORS HIGH VOLTAGE TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the new high voltage trans- former in place in the two rear mounting insula-tors. See Figure F.12. 2. Install the front mounti...
Page 93 - MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLY
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 technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 94 - SCR Bridge Assembly Removal; SCR
MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) REMOVAL PROCEDURE 1. Remove input power to the TIG 225 machine. 2. Perform the SCR Bridge Assembly Removal Procedure. 3. Unsolder the two 115VAC leads and leads B231 and B232 from the main transformerleads. Labe...
Page 95 - RETEST AFTER REPAIR; Maximum Idle Amps
Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-55 F-55 PRECISION TIG® 225 RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring ...
Page 97 - TABLE OF CONTENTS - DIAGRAM SECTION
TABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC PRECISION TIG® 225 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 98 - ELECTRICAL DIAGRAMS; VOLTAGE RECONNECTION
ELECTRICAL DIAGRAMS G-2 PRECISION TIG® 225 WIRING DIAGRAM - COMPLETE MACHINE - ALL CODES (G5646) R CLEVELAND , OHIO G5646 A SCR4 SCR2 SCR1 D C B A REAR GANG L1 ELECTRODE T3 NC NO MICRO-SWITCH T2 L2 L3 C3 SCR3 H1 H G 311A 312A OPENCLOSEDCLOSED G4 216 G3 218 G2 G1 217 220 AC E F PC BOARD CONTROL PC BO...
Page 103 - COMPONENT SIDE
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...
Page 105 - BYPASS/STABILIZER BOARD; NONE; MATERIAL; NA; DOCUMENT
R e tu rn to S e c ti o n T O C R e tu rn to S e c ti o n T O C R e tu rn to S e c ti o n T O C R e tu rn to S e c ti o n T O C R e tu rn to M a s te r T O C R e tu rn to M a s te r T O C R e tu rn to M a s te r T O C R e tu rn to M a s te r T O C ELECTRICAL DIAGRAMS G-9 PRECISION TIG® 225 SCHEMATIC...
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