Lincoln Electric SVM186-A User Manual

For use with machine code numbers:SVM186-AOctober, 2008Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety

INSTALLATIONA-2 A-2PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retur

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

INSTALLATIONA-3 A-3PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retur

INSTALLATIONA-4 A-4PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retur

INSTALLATIONA-5 A-5PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retur

INSTALLATIONA-6 A-6PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retur

INSTALLATIONA-7 A-7PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retur

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

TABLE OF CONTENTS - OPERATION SECTIONB-1 B-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPRECISION TIG® 225Opera

OPERATIONB-2 B-2PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

OPERATIONB-3 B-3PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSAFETYi iFOR ENGINEpowered equipment.1.a. Turn the engine off befor

OPERATIONB-4 B-4PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

OPERATIONB-5 B-5PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

OPERATIONB-6 B-6PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

OPERATIONB-7 B-7PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

OPERATIONB-8 B-8PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

OPERATIONB-9 B-9PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

TABLE OF CONTENTS - ACCESSORIES SECTIONC-1 C-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPRECISION TIG® 225Acc

ACCESSORIESC-2 C-2PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return

ACCESSORIESC-3 C-3PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return

SAFETYii iiReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFUMES AND GASEScan be dangerous.5.a. Welding may produce

ACCESSORIESC-4 C-4PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return

TABLE OF CONTENTS - MAINTENANCE SECTIOND-1 D-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPRECISION TIG® 225Mai

MAINTENANCED-2 D-2PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return

TABLE OF CONTENTS-THEORY OF OPERATION SECTIONE-1 E-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPRECISION TIG®

THEORY OF OPERATIONE-2 E-2PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TO

THEORY OF OPERATIONE-3 E-3PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TO

THEORY OF OPERATIONE-4 E-4PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TO

THEORY OF OPERATIONE-5 E-5PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TO

THEORY OF OPERATIONE-6 E-6PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TO

THEORY OF OPERATIONE-7 E-7PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TO

SAFETYiii iiiReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCJan ‘07FOR ELECTRICALLYpowered equipment.8.a. Turn off

THEORY OF OPERATIONE-8 E-8PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TO

TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIRF-1 F-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPRECISION TIG®

TROUBLESHOOTING AND REPAIRF-2 F-2PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING AND REPAIRF-3 F-3PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

SAFETYiv ivReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCMar ‘93PRÉCAUTIONS DE SÛRETÉPour votre propre protection

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

HIGH FREQUENCY CIRCUIT DISABLE PROCEDURETROUBLESHOOTING AND REPAIRF-15 F-15PRECISION TIG® 225Return to Section TOC Return to Section TOC Return to Sec

.020 Spark GapLEFT SIDE OF MACHINEFIGURE F.1 – SPARK GAP ASSEMBLYHIGH FREQUENCY CIRCUIT DISABLE PROCEDURE (continued)TROUBLESHOOTING AND REPAIRF-16 F-

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

PRECISION TIG 225 CONTROL BOARDJ2J3J4PIN 4 (LEAD #201)PIN 3 (LEAD #204)PIN 7 (LEAD #210)PIN 8 (LEAD #209)PIN 3 (LEAD #232)PIN 2 (LEAD #260)T1 TRANSFOR

T1 TRANSFORMER TEST (continued)PROCEDURE6. If all of the secondary voltages are correct theT1 transformer is functioning properly.A. If all of the sec

SAFETYv vReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectromagnetic Compatibility (EMC)ConformanceProducts dis

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

PLUG J2 REMOVEDPRECISION TIG 225 CONTROLJ2J3J4STATIC SCR TEST (continued)TEST PROCEDURE1. Remove main supply power to the TIG 225 andremove the case w

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)TEST PROCEDURE (continued)3. Using an analog ohmmeter test the resistancefrom anode to cathode

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

FIGURE F.5 – ACTIVE SCR TEST SETUPACTIVE SCR TEST (continued)TEST PROCEDURE1. Remove main supply power to the TIG 225machine.2. Locate and remove plug

FIGURE F.6 – SCR GATE LOCATIONSACTIVE SCR TEST (continued)TEST PROCEDURE (continued)6. Connect SCR into the test circuit as shown (A)lead to anode (C)

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

This is the typical AC output voltagewaveform generated from a properlyoperating machine. Note that eachvertical division represents 50 voltsand that

SAFETYvi viReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectromagnetic Compatibility (EMC)The size of the surro

This is the typical DC (+) output volt-age waveform generated from a prop-erly operating machine. Note thateach vertical division represents 50volts a

This is the typical AC output voltagewaveform generated from a properlyoperating machine. Note that eachvertical division represents 50 voltsand that

This is the typical DC (+) output volt-age waveform generated from a prop-erly operating machine. Note thateach vertical division represents 50volts a

MACHINE LOADED TO 180 AMPS AT16VDC.This is the typical AC output voltage wave-form generated from a properly operatingmachine. Note that each vertical

MACHINE LOADED TO 180 AMPS AT 16VDC.This is the typical DC (+) output voltage wave-form generated from a properly operatingmachine. Note that each ver

MACHINE LOADED TO 180 AMPS AT26VDC.This is the typical AC output voltage wave-form generated from a properly operatingmachine. Note that each vertical

MACHINE LOADED TO 180 AMPS AT26VDC.This is the typical AC output voltage waveformgenerated from a properly operating machine.Note that each vertical d

This is NOT the typical DC (+) outputvoltage waveform. One output SCR isnot functioning. Note the “gap”in thewaveform. One SCR gate was discon-nected

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -I IPRECISION TIG® 225RETURN TO MAIN INDEXPageSafety . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE F.7 – CASE BACK MOUNTING SCREWSSCR BRIDGE ASSEMBLYREMOVAL AND REPLACEMENT PROCEDURE (continued)PROCEDURE1. Remove input power to the TIG 225 ma

FIGURE F.8 – FRONT PANEL MOUNTING SCREWSSCR BRIDGE ASSEMBLYREMOVAL AND REPLACEMENT PROCEDURE (continued)PROCEDURE (continued)9. Remove plug J2 from th

PLUG J2 REMOVEDPRECISION TIG 225 CONTROLJ2J3J4FIGURE F.9 – PLUG J2 ON CONTROL BOARDSCR BRIDGE ASSEMBLYREMOVAL AND REPLACEMENT PROCEDURE (continued)TRO

SCR BRIDGE ASSEMBLYREMOVAL AND REPLACEMENT PROCEDURE (continued)16. With the 3/8” wrench remove the four mount-ing screws holding the SCR bridge assem

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

POLARITY SWITCHREMOVAL AND REPLACEMENT PROCEDURE (continued)REMOVAL PROCEDURE1. Remove the input power to the TIG 225machine.2. Using the 3/8” nutdriv

POLARITY SWITCHREMOVAL AND REPLACEMENT PROCEDURE (continued)REPLACEMENT PROCEDURE1. Carefully position the new polarity switch inposition on the front

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

TABLE OF CONTENTS - INSTALLATION SECTIONA-1 A-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPRECISION TIG® 225In

FIGURE F.11 – SECONDARY LEADS AT HIGH FREQUENCY STARTER BOARDHIGH VOLTAGE TRANSFORMERREMOVAL AND REPLACEMENT PROCEDURE (continued)REMOVAL PROCEDURE1.

FIGURE F.12 – HIGH VOLTAGE TRANSFORMER MOUNTING INSULATORSHIGH VOLTAGE TRANSFORMERREMOVAL AND REPLACEMENT PROCEDURE (continued)REPLACEMENT PROCEDURE1.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLYREMOVAL AND REPLACEMENT PROCEDURE (continued)REMOVAL PROCEDURE1. Remove input power to the TIG 225 machine.2

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

TABLE OF CONTENTS - DIAGRAM SECTIONG-1 G-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPRECISION TIG® 225Electri

ELECTRICAL DIAGRAMSG-2PRECISION TIG® 225WIRING DIAGRAM - COMPLETE MACHINE - ALL CODES (G5646)RCLEVELAND , OHIOG5646ASCR4SCR2SCR1DCBAREAR GANGL1ELECTRO

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC