Lincoln Electric Precision Tig Svm186 A Users Manual

SVM186-A to the manual 3f515961-cb22-4d7c-af7c-21c47f215bfc

2015-02-09

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SVM186-A
October, 2008

PRECISION TIG 225
®

For use with machine code numbers: 11317,

11318, 11319
(11320 Ready-Pak)
(11321 Ready-Pak w/Cart)

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Safety Depends on You

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Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.

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SERVICE MANUAL

• 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

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SAFETY

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines

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.

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Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” 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.

FOR ENGINE
powered equipment.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
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.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. 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
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.5. Do not work next to welding power source.

Mar ‘95

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ELECTRIC SHOCK can kill.

ARC RAYS can burn.

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.

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 ANSI Z87. I standards.

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.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

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 positions 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.

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.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable
and welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.

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SAFETY

3.h. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.

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 exposure level should be checked upon installation and periodically thereafter to 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 products.
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.

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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

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iii

WELDING and CUTTING
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.

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6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. 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.
6.d. 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).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. 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.

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iii

SAFETY

6.g. 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 other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.

CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• 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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“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.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

6.I. 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.

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6.j. Do not use a welding power source for pipe thawing.

Jan ‘07

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SAFETY

PRÉCAUTIONS DE SÛRETÉ

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.

8. S’assurer que la masse est connectée le plus prés 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
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

Mar ‘93

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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). It was manufactured in conformity with a national standard that implements a harmonized
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 complete with associated input filters. In all cases electromagnetic disturbances must be reduced 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 equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems 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;

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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

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SAFETY

Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions

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Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. 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 permanently 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 equipment 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.
Welding Cables
The welding cables should be kept as short as possible and should be positioned 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 connection 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 capacitance, selected according to national regulations.
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 applications. 1
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_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”

L10093

3-1-96H

- MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX

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Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-536, P-210-R, P-66-J.6

PRECISION TIG® 225

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A-1

TABLE OF CONTENTS - INSTALLATION SECTION

A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2,A-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Select Suitable Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Environmental Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

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Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Lifting and Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Machine Grounding and High Frequency Interference Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Input and Grounding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Input Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Connections For Tig (GTAW) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

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Tig Torch Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Work Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Shielding Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Remote Control Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Connections For Stick (SMAW) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

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Stick Electrode Cable and Work Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

PRECISION TIG® 225

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A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - PRECISION TIG® 225 (K2533-1AND K2535-1,-2)
INPUT - SINGLE PHASE ONLY
Standard Voltage
208/230/1/60

Input Current at Rated Output

Power Factor

Idle Current

42A / 39A Effective
and 94A / 85A Maximum

0.62 Min.

3.0A/2.7A Max.

OUTPUT RANGE
Output Current
Range
5-230 Amps (AC)
5-230 Amps (DC)

Maximum Open
Circuit Voltage

Type of Output

(STICK AND TIG)

CC (Constant Current)
AC/DC

AC OCV: 75
DC OCV: 66

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RATED OUTPUT
Process Duty Cycle**
GTAW
10% Duty Cycle
20% Duty Cycle
100% Duty Cycle
SMAW
10% Duty Cycle
20% Duty Cycle
100% Duty Cycle

Weld Current*

Weld Voltage (NEMA)

225A AC/DC
180A AC/DC
90A AC/DC (BAL.)
80A AC (AUTO-BAL.)

15.7
15.2
14.1
14.0

225A AC/DC
180A AC/DC
90A AC/DC

V AC/DC
V AC/DC
V AC/DC
V AC/DC

29.0 V AC/DC
27.2 V 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 1
2

100%

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90%
80%
Output Duty Cycle

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Using provided input cable for protected input supply

70%

AC/DC Stick & Bal.TIG
with Max. Aux. load or
Auto-Bal. TIG w/o Aux.

60%
50%

AC Auto-Bal. TIG with
Max. Aux. Load

40%
30%
20%
10%

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0%
50

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 TIG® 225

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A-3

INSTALLATION

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
42 A/33 A Max.

0.62 Min.

1.3 A/1.0 A Max.

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
50 A/48 A Max.

0.62 Min.

1.5 A/1.4 A Max.

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N80

OUTPUT RANGE
Max. OCV.

Weld Current

Output Type

75 V (AC)
66 V (DC)

5-230 A (AC)
5-230 A (DC)

CC (Constant Current)
AC or DC

RATED OUTPUT
Process Duty Cycle**

Weld Current*

Weld Voltage (NEMA)

SMAW
15%
20%
100%

225 A AC/DC
180 A AC/DC
90 A AC/DC

29.0 V
27.2 V
23.4 V

225 A AC/DC
180 A AC/DC
90 A AC/DC (Bal.)
80 A AC (Auto-Bal.)

15.7 V
15.2 V
14.1 V
14.0 v

GTAW
10%
20%
100%

* Inputs and ratings include a 6 amp rated load on the 115vac receptacle.
** Based on a 10 minute cycle.
PHYSICAL DIMENSIONS

(2)

MODEL

HEIGHT

WIDTH

DEPTH

WEIGHT

Machine Only
(K2533-1,-2)
(K2534-1)
Ready-Pak
(K2535-1)

20.71 in.
526 mm

14.48 in.
368 mm

25.62 in.
751 mm

Approx. 192 lbs.
87.1 kgs

20.71 in.
526 mm

14.48 in.
368 mm

25.62 in.
651 mm

Approx. 212lbs..
96.2 kgs.

Ready-PakW/Cart
(K2535-2)

31.24 in.
794 mm

19.81 in.
503 mm

38.01 in.
966 mm

Approx. 258lbs.
117.0 kgs.

(2) Dimensions are without Lift Eyebolt and Torch Holder

ENVIRONMENTAL RANGES
Operating Temperature
Storage Temperature

-4°F to 104°F (-20°C to 40°C)
-40°F to 185°F (-40°C to 85°C)

PRECISION TIG® 225

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A-4

SAFETY PRECAUTIONS
Read entire installation section before starting
installation.

WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.

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 instructions 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 the Accessories section of this manual.

WARNING

• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.

Do not attempt to lift the power
source with an undercarriage
attached.

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• Do not touch electrically hot parts.
• Always connect the PRECISION TIG® 225 to a
power supply grounded per the National Electrical
Code and any local codes.
----------------------------------------------------------------------------

SELECT SUITABLE LOCATION
MOUNTING
Environmental Rating
The PRECISION TIG® 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.

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 surface, either directly or on a recommended undercarriage. The machine may topple over if this procedure is
not followed.

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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
TIG® 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 maintenance problems.

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STACKING
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A-4

INSTALLATION

PRECISION TIG® 225 cannot be stacked.

LIFTING AND MOVING
The PRECISION TIG® 225 models are provided with
an Eyebolt used for lifting the unit with a hoist.
PRECISION TIG® 225

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A-5

INSTALLATION

MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION
Locate the Precision TIG® 225 away from radio controlled
machinery. The normal operation of the Precision TIG®
225 may adversely affect the operation of RF controlled
equipment, which may result in bodily injury or damage to
the equipment.

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The ground should be securely made and the grounding 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.

This welder must be grounded! See your local and
national electrical codes for proper grounding methods.

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.

The high frequency generator, being similar to a radio
transmitter, may cause radio, TV and electronic equipment interference problems. These problems may be the
result of radiated interference. Proper grounding methods
can reduce or eliminate radiated interference.

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.

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 ungrounded metallic objects.
Keeping these contributing factors in mind, installing
equipment per the following instructions should minimize
problems.

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A-5

1. Keep the welder power supply lines as short as possible 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 contact between this conduit and the welder case ground.
Both ends of the conduit should be connected to a driven ground and the entire length should be continuous.
2. Keep the work and electrode leads as short as possible 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 leakage.
4. Keep the torch in good repair and all connections tight
to reduce high frequency leakage.
5. The work piece 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.

Failure to observe these recommended installation procedures 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 PRECISION TIG® 225. Installation should be made in accordance 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 #6-3 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 the Technical Specifications page at the beginning of this section. Fuse the input circuit with the recommended super lag fuses or delay type1 circuit breakers.
Using fuses or circuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush
currents even if not welding at high currents.
1Also 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

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A-6

INPUT RECONNECT PROCEDURE
On multiple input voltage welders, be sure the machine
is connected per the following instructions for the voltage being supplied to the welder.

CAUTION

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INPUT LEADS
L1 & L2

LEAD H1
(DO NOT
REMOVE)

Failure to follow these instructions can cause
immediate failure of components within the welder
and void machineʼs warranty.
----------------------------------------------------------------------Multiple voltage models are shipped connected for
the highest voltage. To change this connection
refer to the following instructions.

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A-6

INSTALLATION

WARNING

FOR LOWEST RATED VOLTAGE
: H2 CONNECTED
FOR HIGHEST RATED VOLTAGE
: H3 CONNECTED

BACK VIEW OF LINE SWITCH

FIGURE A.1 Reconnect Leads

ELECTRIC SHOCK can kill.
• Turn the input power OFF at the disconnect switch or fuse box before
working on this equipment.

OUTPUT CONNECTIONS

-----------------------------------------------------------------------For the lowest rated voltage connection (Refer to figure A.1):
1. Remove the sheet metal left side cover.
ELECTRODE/GAS
OUTLET
RECEPTACLE
(TWIST-MATE)

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2. Disconnect lead H3 from the power switch and insulate with the insulation from the H2 lead.
3. Connect lead H2 to the power switch where H3 was
connected.
4. Tighten connections.

WORK CABLE & CLAMP

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:

FIGURE A.2 Location of Output Connections

1. Remove the sheet metal left side cover.

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2. Disconnect lead H2 from the power switch and insulate with the insulation from the H3 lead.
3. Connect lead H3 to the line switch where H2 was
connected.
4. Tighten 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.

5. Replace sheet metal cover and all screws.

PRECISION TIG® 225

A-7
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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 Accessories
Section). Turn the Power Switch “OFF”. Connect the
torch 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 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

WARNING
A work cable with attached work clamp is factory connected 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.

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SHIELDING GAS CONNECTION

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A-7

INSTALLATION

An adjustable gas pressure regulator with flow gage
and hose is supplied with the PRECISION TIG® 225
Ready-Pak™ models and available separately for
other models (See Accessories Section). Obtain the
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 platform that simplifies loading and unloading of gas cylinders.

WARNING
CYLINDER could explode
if damaged.
• 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 platform, being careful not to 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 TIG® 225
Ready-Pak™ models and available separately for
other models. Refer to the Optional Accessories
Section of this manual for other available remote controls.

CONNECTIONS
WELDING

FOR

STICK

(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 TIG® 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

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A-8

NOTES

PRECISION TIG® 225

A-8

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B-1

TABLE OF CONTENTS - OPERATION SECTION

B-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Graphic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

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Recommended Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Process Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Recommended Equipment/Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Equipment Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Welding Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4, B-5
Power-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Case Rear Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Operating Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

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Welding in TIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Pulse TIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Remote Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Benefits of the PRECISION TIG® 225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Welding in Stick Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9

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Recommended Electrode Amperage Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9

PRECISION TIG® 225

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B-2

OPERATION

GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

SAFETY PRECAUTIONS
Read and understand this entire section before operating the machine.

INPUT POWER

WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts
or electrode with skin or wet clothing.
• 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
explosion
• Keep flammable material away.
• Do not weld on containers that
have held combustibles.
-----------------------------------------------------------------------ARC RAYS can burn.
• Wear eye, ear and body
protection.

POSITIVE OUTPUT

NEGATIVE OUTPUT

DIRECT CURRENT
PROTECTIVE
GROUND
WARNING OR
CAUTION
DO NOT SWITCH
WHILE WELDING
SINGLE PHASE
TRANSFORMER AC AND
RECTIFIER DC POWER
SOURCE

OFF

-----------------------------------------------------------------------Observe additional Safety Guidelines detailed in
the beginning of this manual.
------------------------------------------------------------------------

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B-2

PRECISION TIG® 225

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B-3

PRODUCT DESCRIPTION

PROCESS LIMITATIONS

The PRECISION TIG® 225 is a member of our field
acclaimed PRECISION TIG® family of industrial arc welding
power sources. Premium features include:

The PRECISION TIG® machines are not recommended for
arc gouging due to its limited output capacity, and are also
not recommended for pipe thawing.

1. Precise constant current output.
2. Full range square wave AC/DC TIG (GTAW) welding.
3. Enhanced version of the patented Micro-Start II™
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.
5. 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 TIG® patented convenient
built-in storage provisions for welding components and
cable management.

RECOMMENDED EQUIPMENT/INTERFACE
(See Installed Options in Accessories Section for
more details)

The PRECISION TIG® 225 also provides advanced features
such as:
• Digital Meter
• 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.
• Auto-Sense remote control selection.
• Tool-less Twist-Mate™ electrode cable connection.
• Built-in work clamp cable permanently attached.

Select Machine

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 TIG® 225
models. The Canadian (K2533-2) and International (K25341) 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 EQUIPMENT

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RECOMMENDED PROCESSES
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B-3

OPERATION

The PRECISION TIG® 225 is recommended for the TIG
(GTAW) and Stick (SMAW) welding processes within its output 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.

The PRECISION TIG® 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.

Torch Starter Kit
(Select one)
Water Cooler
Under-Storage
Cart (Optional )
Optional Remote
Trigger Device
(Select one)

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)
Air Cooled System:
Water Cooled System:
TIG-Mate
TIG-Mate 20
Torch Starter Kit*
Torch Starter Kit*
Not Applicable
115V 50/60Hz
Cool-Arc 40*
K2348-(*)
Arc Start Switch*
Foot Amptrol*
Start Pedal Foot Amptrol*
Hand Amptrol*

*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 output power coils and rectifiers.
The PRECISION TIG® 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 TIG® 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 TIG® 225 is rated at 225 amps, 29 volts, at
10% duty cycle on a ten minute basis. It is capable of higher duty
cycles at lower output currents. See rated output graph, 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

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B-4

OPERATION

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
13

1. POWER SWITCH
2. POLARITY SWITCH
3. MODE SWITCH
4. AC BALANCE CONTROL
5. MAXIMUM OUTPUT CONTROL (AMPS)
6. DIGITAL METERS
7. POST FLOW TIME
8. PULSE TIG CONTROL
9. THERMAL SHUTDOWN LIGHT
10. REMOTE RECEPTACLE
11. ELECTRODE/GAS OUTPUT
RECEPTACLE
12. WORK CABLE
13. REMOVABLE LIFT EYEBOLT

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8
7
1

2
11
10
12

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CONTROL FUNCTIONALITY
1. POWER SWITCH – Input line switch turns input
power ON or OFF, as indicated by the on or off status 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.

CAUTION
• Do not switch the polarity switch
while welding or damage may result
to the machine.

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-----------------------------------------------------------------------3. MODE SWITCH – The push button switch allows
selection of the two machine welding modes as indicated 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:

• 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 output welding current over the rated output range of
the machine:
• With a Remote Current Control (Amptrol) connected to the Remote 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 welding, 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 TIG® 225

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B-5

OPERATION

8. 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).
• Peak Pulse level is set by the Max. Output
Control and the Remote Amptrol (if used).
• Background 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 indicate the Pulse TIG Control setting before and during welding.

B-5

POWER-UP SEQUENCE
When the PRECISION TIG® 225 Power switch is initially turned On , the following will be observed:
(Refer to this Section Controls and Settings Figure
B.1)
• 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.

9. THERMAL SHUTDOWN LIGHT This Yellow LED
panel light turns on if the machine output is shutdown because internal overheating has occurred,
and turns off when cooled to reset.
10. REMOTE RECEPTACLE – Provides for connection of remote control and/or arc start switch only in
TIG Mode: (There is no remote output control
capability when stick welding).
• 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 control and switch the output control back to the Max
Output panel control.
11. ELECTRODE/GAS OUTPUT RECEPTACLE This quick connect Twist-Mate™ receptacle provides electrical connection to the electrode holder
and cable for Stick welding and a combined electrical and gas connection for the TIG torch when TIG
welding.
12. WORK CABLE - This 10ft.(3.05m) cable with work
clamp is factory connected to 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 proper procedure on grounding the work clamp and
work piece to minimize high frequency interference.

PRECISION TIG® 225

B-6

CASE REAR COMPONENTS

FIGURE B.2

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B-6

OPERATION

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1. INPUT CABLE– This #6-3 (208/230V) or #12-3
(380V and higher) heavy duty cable with cable
clamp is factory 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 righthand 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.

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4. MACHINE RATING PLATE
5. RECEPTACLE AND CIRCUIT BREAKER-115vac
auxiliary NEMA 6-20R .

PRECISION TIG® 225

B-7

OPERATION

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OPERATING STEPS
WELDING IN TIG MODE
1. Connect the TIG torch and cable Twist-Mate™ quick
connect plug to the Electrode/Gas output receptacle. This receptacle also contains an integral gas
connection for the torch. Connect the work clamp to
the work piece.
2. Set the TIG/STICK switch to “TIG”.
3. Set the Polarity Switch to DC- for welding steel or
stainless steel; or to AC for welding aluminum.

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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.

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8. Depress the Foot Amptrol 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 continue 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 automatically 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.
PULSE TIG CONTROL

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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 thicker plate with slower travel speed. 2-3pps is a typical
starting point.

PRECISION TIG® 225

B-7

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B-8

OPERATION

B-8

REMOTE CONTROL OPERATION

BENEFITS OF THE PRECISION TIG® 225 DESIGN

A Foot Amptrol is included with the PRECISION TIG®
225 Ready-Pak models and available for other models
(See Accessories 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.

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 portion may also cause the electrode to overheat at high
currents causing “tungsten spitting”. The negative portion of the AC wave offers no cleaning action but concentrates more heat on the work.

Both the Hand and Foot Amptrol work in a similar manner. For simplicity, the following explanation will refer
only to “Amptrols”, meaning both Foot and Hand models. 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.

The AC waveform of the PRECISION TIG® 225 optimizes 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”
2% thoriated tungsten.

“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 eliminate accidental high current damage to the work piece
and/or tungsten, and provides a fine control of the current. 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
reliably, 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” tungsten 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 current control up and depress the Amptrol approximately
1/4 of the way down. Depressing the Amptrol to its minimum 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 TIG® 225 will start a 3/32”, 2%
thoriated tungsten electrode at 15 amperes provided
the electrode tip is properly grounded and not contaminated.

PRECISION TIG® 225

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B-9

OPERATION

WELDING IN STICK MODE

5. Turn the power switch to “ON”.

1. Put the electrode holder and cable quick connect
plug into the electrode output receptacle. Turn clockwise until tight. Connect the work clamp to the work
piece.

6. Adjust the Current Control to the desired amps.

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+).

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 frequency TIG arc starter are disabled.

4. Place the electrode in the electrode holder.

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WARNING
• In Stick Mode the output terminal
and electrode will be electrically hot
whenever the power switch is turned
on.
------------------------------------------------------------------------

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
ELECTRODE TYPE
POLARITY
3/32"
1/8"
5/32"
Fleetweld 5P, Fleetweld 5P+ E6010
DC+
40 - 70
75 - 130
90 - 175
Fleetweld 180
E6011
DC+
40 - 80
55 - 110
105 - 135
Fleetweld 37
E6013
DC+
70 - 95
100 - 135
145 - 180
Fleetweld 47
E7014
DC75 - 95
100 - 145
135 - 200
Excalibur
E7018
DC+
85 - 110
110 - 160
130 - 200
Blue Max Stainless
DC+
40 - 80
75 - 110
95 - 150
Red Baron Stainless
DC+
40 - 70
60 - 100
90 - 140
Mild steel procedures are based on recommended procedures listed in C2.10 8/94 and the 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

Electrode Polarity
Electrode Tip Preparation

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Electrode Type
Tungsten Size (in.)
.010
.020
.040
1/16
3/32
1/8

DCSharpened
EWTh-1, EWCe-2
EWTh-2, EWLa-1
EWG
Up to 15 A.
Up to 15 A.
Up to 80 A.
Up to 150 A.
Up to MAX. A.
X

GTAW Process
AC
Balled
EWZr
EWTh-1, EWTh-2
EWP
EWCe-2, EWLa-1
EWG
Up to 10 A.
Up to 15 A.
Up to 15 A.
Up to 20 A.
Up to 40 A.
Up to 60 A.
Up to 100 A.
Up to 130 A.
Up to 160 A.
Up to MAX. A.
Up to MAX. A.
X

Approximate Argon
Gas Flow Rate
C.F.H. (l/min.)

Aluminum
3-8
(2-4)
5-10
(3-5)
5-10
(3-5)
5-10
(3-5)
13-17 (6-8)
15-23 (7-11)

Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure ..................................EWP ........green
TRI-MIX OF ELEMENTS.............EWG.........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 TIG® 225

Stainless
Steel
3-8
(2-4)
5-10 (3-5)
5-10 (3-5)
9-13 (4-6)
11-15 (5-7)
11-15 (5-7)

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B-10

NOTES

PRECISION TIG® 225

B-10

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C-1

TABLE OF CONTENTS - ACCESSORIES SECTION

C-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Standard Equipment Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Factory Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3

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Field Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4

PRECISION TIG® 225

C-2

2. PRECISION TIG® 225 Ready-Pak w/Cart (K25352)

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STANDARD EQUIPMENT PACKAGES

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C-2

ACCESSORIES

The PRECISION TIG® 225 will be available in two
Factory-Configured Welding Packages:
1. PRECISION TIG® 225 Ready-Pak (K2535-1)
•
•
•
•
•
•

208/230/1/60 Machine (K2533-1)
9 ft. (2.7m) Input Cable with NEMA 6-50P Plug*
NEMA 6-50R Receptacle
Integrated 10 ft.(3.1m)Work Lead w/Clamp*
Gas Regulator with 10 ft.(3.1m). Hose
PTA-17 12.5”(318mm) Ultra=Flex Torch with
3/32”(2.4mm)Electrode and Parts
• Foot Amptrol (K870)
• TIG Slide Rule ( WC332)*
• GTAW Book (JFLF-834)*
• Lift Eyebolt*

• 208/230/1/60 Machine (K2533-1)
• 9 ft.(2.7m) Input Cable with NEMA 6-50P Plug*
• NEMA 6-50R Receptacle
• Integrated 10 ft.(3.1m) Work Lead w/Clamp*
• Gas Regulator with 10 ft.(3.1m) Hose
• PTA-17 12.5 ft.(3.8m) One cable Superflex Torch with
3/32”(2.4mm) Electrode and Parts
• Foot Amptrol (K870)
• TIG Slide Rule (WC332)*
• GTAW Book (JFLF-834)*
• Lift Eyebolt*
• Under-Storage Cart (K2348-1)
* Included with K2533-1 Machine Only model.

The PRECISION TIG® 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)

Optional
Torch Starter Kit
(Select one)

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Water Cooler
Optional UnderStorage Cart
Optional Remote
Trigger Device
(Select one)

Water Cooled System

Air Cooled System

K2267-1 TIG-Mate 20 Torch Starter Kit
K1813-1 115V 50/60Hz Cool-Arc 40
Not Applicable

K2266-1 TIG-Mate Torch Starter
Not Applicable
K1813-1 115V 50/60Hz Cool-Arc 40

K2348-1
K814 Arc Start Switch
K870 Foot Amptrol
K963-3 Hand Amptrol

PRECISION TIG® 225

C-3

2. PRECISION TIG® 225 Ready-Pak w/Cart (K25352)

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FACTORY INSTALLED OPTIONS

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C-3

ACCESSORIES

The PRECISION TIG® 225 will be available in two
Factory-Configured Welding Packages:
1. PRECISION TIG® 225 Ready-Pak (K2535-1)
• 208/230/1/60 Machine (K2533-1)
• 9 ft. (2.7m) Input Cable with NEMA 6-50P Plug*
• NEMA 6-50R Receptacle
• Integrated 10 ft.(3.1m)Work Lead w/Clamp*
• Gas Regulator with 10 ft.(3.1m). Hose
• PTA-17 12.5’ Ultra-Flex Torch (K1782-12) Includes:
- 3/32 2%Th Tungsten
- 3/32 Collet (10N24)
- 3/32 Collet Body (10N32)
- #7 Alumina Nozzle (10N47)
• Foot Amptrol (K870)
• TIG Slide Rule ( WC332)*
• GTAW Book (JFLF-834)*
• Lift Eyebolt*

•
•
•
•
•
•

208/230/1/60 Machine (K2533-1)
9 ft.(2.7m) Input Cable with NEMA 6-50P Plug*
NEMA 6-50R Receptacle
Integrated 10 ft.(3.1m) Work Lead w/Clamp*
Gas Regulator with 10 ft.(3.1m) Hose
PTA-17 12.5’ Ultra-Flex Torch (K1782-12) Includes:
- 3/32 2%Th Tungsten
- 3/32 Collet (10N24)
- 3/32 Collet Body (10N32)
- #7 Alumina Nozzle (10N47)

• Foot Amptrol (K870)
• TIG Slide Rule (WC332)*
• GTAW Book (JFLF-834)*
• Lift Eyebolt*
• Under-Storage Cart (K2348-1)
* Included with K2533-1 Machine Only model.

The PRECISION TIG® 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)

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380/400-415/1/50-60 Machine only with Cable (K2534-1)
Optional
Torch Starter Kit
(Select one)

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Water Cooler

Water Cooled System

Air Cooled System

K2267-1 TIG-Mate 20 Torch Starter Kit
Includes:
• 200A PTW-20 12.5 ft.(3.81m) Torch
• KP510 Parts Kit
• Regulator & Hose
• K1622-4 Twist Mate Torch Adapter
• Water Hose & Hose Coupler
• Work Cable & Clamp (Not required for
PRECISION TIG® 225)

K2266-1 TIG-Mate Torch Starter
Kit Includes:
• 150A PTA-17 12.5 ft.(3.81m) Torch.
• KP508 Parts Kit.
• Regulator & Hose.
• K1622-1 Twist Mate Torch Adapter.
• Work Cable & Clamp (Not required for PRECISION TIG® 225)

K1813-1 115V 50/60Hz Cool-Arc 40

Not Applicable

Optional UnderStorage Cart

K2348-1

Optional Remote
Trigger Device
(Select one)

K814 Arc Start Switch
K870 Foot Amptrol
K963-3 Hand Amptrol

PRECISION TIG® 225

C-4

ACCESSORIES

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FIELD INSTALLED OPTIONS
The following Options/Accessories are available for the
PRECISION TIG® 225:
• K2348-1 Under-Storage Cart
Includes a front magnetic latch storage drawer and
rear storage bin on a single bottle undercarriage.
(L12225 Installation Instructions included)

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• K870 Foot Amptrol
Single pedal foot activation of arc start switch and
output control, with 25 ft.(7.6m) plug cable.

C-4

• Magnum “Pro-Torch™ TIG Torch” assemblies and
Accessories.
Requires Twist-Mate™ Adapter:
K1622-1 for PTA-9/-17
K1622-3 for PTA-26
K1622-4 for PTW water cooled torch
• Harris #3100211 Harris Argon Flow Regulator
(Includes 10 ft.(3.1m) hose.)
• K2374-1 Electrode Holder and Cable
200 amp Electrode Holder with 10 ft.(3.1m) 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 convenient finger control.
• TIG-Mate Torch Starter Kits:
Includes Torch with Twist-Mate adapter and accessories listed below:
K2266-1 TIG-Mate Torch Starter Kit Includes:
• 150A PTA-17 12.5 ft.(3.8m) Torch
• KP508 Parts Kit
• Regulator & Hose
• K1622-1 Twist Mate Torch Adapter
• Work Cable & Clamp (Not required for PRECISION
TIG® 225)
K2267-1 TIG-Mate 20 Torch Starter Kit Includes:
• 200A PTW-20 12.5 ft.(3.8m) Torch
• KP510 Parts Kit
• Regulator & Hose
• K1622-4 Twist Mate Torch Adapter
• Water Hose & Hose Coupler
• Work Cable & Clamp
(Not required for PRECISION TIG® 225)

PRECISION TIG® 225

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D-1

TABLE OF CONTENTS - MAINTENANCE SECTION

D-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Spark Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

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Fan Motor or Fan Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

PRECISION TIG® 225

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D-2

WARNING

SAFETY PRECAUTIONS

WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this maintenance.
• Turn the input power OFF at the disconnect switch or fuse box before
working on this equipment.

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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.

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• Do not touch electrically hot parts.
------------------------------------------------------------------------

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D-2

MAINTENANCE

2. Periodically clean the inside of the machine with a
low pressure air system. Be sure to clean the following components thoroughly.
• Main Transformer
• Electrode/Gas Output Receptacle
• Polarity Switch
• Rectifier Assembly
• Arc Starter/Spark Gap Assembly
• PC Boards
• Fan Blades

Use extreme caution when working with a high frequency circuit. The high voltages developed can
be lethal. Turn the input power off using the disconnect switch or fuse box before working inside
machine. This is particularly important when working 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 contaminant's, use a low pressure air stream or a firm piece of
paper to clean the spark gap. Do not disturb the factory 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 position.
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 properly grounded.
FIGURE D.1 SPARK GAP

3. Inspect welder output and control cables for fraying,
cuts, and bare spots.
.020 Spark Gap

4. Keep TIG torch and cables in good condition.
5. Clean air louvers to ensure proper air flow and cooling.

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6. The fan motor has sealed ball bearings which
require no maintenance.

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.

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).
PRECISION TIG® 225

.30ł

FIGURE D.2

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E-1

TABLE OF CONTENTS-THEORY OF OPERATION SECTION

E-1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Output Rectification and Feedback Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
High Voltage/High Frequency Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

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DC Welding Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
AC Welding Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
Protective Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
FIGURE E.1 PRECISION TIG® 225 BLOCK LOGIC DIAGRAM
BY-PASS
BOARD
WORK

POLARITY
SWITCH

ELECTRODE

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MAIN
TRANSFORMER
INPUT
POWER
SWITCH

HI-FREQUENCY
TRANSFORMER

BYPASS
ASBLY
H1

C
H
O
K
E

AC
DC+
SCR
BRIDGE

DCF
E
E
D
B
A
C
K

115VAC

18VAC

CONTROL
BOARD

18VAC

115 VAC
FAN
Receptacle
Circuit Breaker
Protected

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HIGH VOLTAGE
TRANSFORMER
CIRCUIT

SHUNT

115VAC

POWER
"ON"
DIGITAL
DISPLAY

MODE
SWITCH
REMOTE
RECEPTACLE

THERMAL
LIGHT

GAS
VALVE

AUTO
PULSE TIG STICK
BALANCE FREQ. LED LED
LED
LED

PRECISION TIG® 225

THERMOSTATS

OUTPUT
CONTROL

AC
POSTFLOW
PULSE
BALANCE CONTROL CONTROL
CONTROL

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E-2

THEORY OF OPERATION
FIGURE E.2 - General Description & Input Power Circuit
BY-PASS
BOARD
WORK

POLARITY
SWITCH

ELECTRODE

MAIN
TRANSFORMER
INPUT
POWER
SWITCH

HI-FREQUENCY
TRANSFORMER

BYPASS
ASBLY
H1

C
H
O
K
E

AC
DC+
SCR
BRIDGE

HIGH VOLTAGE
TRANSFORMER
CIRCUIT

SHUNT

DCF
E
E
D
B
A
C
K

115VAC

18VAC

CONTROL
BOARD

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18VAC

115 VAC
FAN
Receptacle
Circuit Breaker
Protected

115VAC

MODE
SWITCH
REMOTE
RECEPTACLE

THERMAL
LIGHT

THERMOSTATS

OUTPUT
CONTROL

AC
POSTFLOW
PULSE
BALANCE CONTROL CONTROL
CONTROL

GENERAL DESCRIPTION

INPUT POWER CIRCUIT

The PRECISION TIG® 225 is a member of our field
acclaimed PRECISION TIG® family of industrial arc
welding power sources. Premium features include:

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.

1. Precise constant current output.
2. Full range square wave AC/DC TIG (GTAW)
welding.
3. Enhanced version of the patented MicroStartTM
Technology for its lower Minimum (5amps) to higher Maximum (225 amps) output control range.

5. AC/DC Stick (SMAW capability.)

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GAS
VALVE

AUTO
PULSE TIG STICK
BALANCE FREQ. LED LED
LED
LED

4. Built-in high frequency stabilization for DC TIG
starting and continuous AC TIG welding.

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POWER
"ON"
DIGITAL
DISPLAY

The main transformer changes the high voltage, low
current input power to a low voltage, high current output 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, through the control board, powers the gas solenoid valve and the high voltage transformer. The 18VAC winding provides power to the trigger circuitry. The other 18VAC winding is rectified and
regulated to a 15VDC supply which operates the circuitry on the control board.

NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
PRECISION TIG® 225

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E-3

THEORY OF OPERATION
FIGURE E.2 - Output Rectification & Feedback Control
BY-PASS
BOARD
WORK

POLARITY
SWITCH

ELECTRODE

MAIN
TRANSFORMER
INPUT
POWER
SWITCH

HI-FREQUENCY
TRANSFORMER

BYPASS
ASBLY
H1

C
H
O
K
E

AC
DC+
SCR
BRIDGE

HIGH VOLTAGE
TRANSFORMER
CIRCUIT

SHUNT

DCF
E
E
D
B
A
C
K

115VAC

18VAC

CONTROL
BOARD

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18VAC

115 VAC
FAN
Receptacle
Circuit Breaker
Protected

115VAC

MODE
SWITCH
REMOTE
RECEPTACLE

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THERMAL
LIGHT

GAS
VALVE

THERMOSTATS

OUTPUT
CONTROL

AUTO
PULSE TIG STICK
BALANCE FREQ. LED LED
LED
LED

OUTPUT RECTIFICATION
FEEDBACK CONTROL

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POWER
"ON"
DIGITAL
DISPLAY

AND

The AC output from the main transformer secondary is
rectified and controlled through the SCR bridge.
Output current is sensed at the shunt as a low voltage
signal and fed back to the control board. The control
board compares the commands of the mode switch,
output control, AC balance control, pulse control, postflow control, or remote control with the feedback information. 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 thermostats, and also controls the gas solenoid valve, thermal 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

AC
POSTFLOW
PULSE
BALANCE CONTROL CONTROL
CONTROL

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E-4

FIGURE E.2 - High Voltage/High Frequency Circuit.
BY-PASS
BOARD
WORK

POLARITY
SWITCH

INPUT
POWER
SWITCH

HI-FREQUENCY
TRANSFORMER

BYPASS
ASBLY

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C
H
O
K
E

AC
DC+
SCR
BRIDGE

HIGH VOLTAGE
TRANSFORMER
CIRCUIT

SHUNT

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ELECTRODE

MAIN
TRANSFORMER

DCF
E
E
D
B
A
C
K

115VAC

18VAC

CONTROL
BOARD

18VAC

115 VAC
FAN
Receptacle
Circuit Breaker
Protected

115VAC

POWER
"ON"
DIGITAL
DISPLAY

MODE
SWITCH
REMOTE
RECEPTACLE

THERMAL

GAS

THERMOSTATS

OUTPUT

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HIGH VOLTAGE / HIGH FREQUENCY
CIRCUIT

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E-4

THEORY OF OPERATION

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 transformer. 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 TIG® 225

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E-5

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.

CHOKE

PRIMARY
1Ø

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ELECTRODE

G
G

FIGURE E.5 DC Welding Current Generation.

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E-5

THEORY OF OPERATION

PRECISION TIG® 225

WORK

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E-6

THEORY OF OPERATION

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

CHOKE

ELECTRODE
G

PRIMARY
1Ø
WORK

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FIGURE E.6 AC Square Wave Welding Current Generation.

PRECISION TIG® 225

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E-7

THEORY OF OPERATION

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

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 occurs later in the cycle the
conduction time is less resulting in lower SCR output.

When an AC supply voltage is applied to the SCR, 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 controlled 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 cathode voltage. Since there is a standard PN junction

INPUT

CATHODE
ANODE

OUTPUT

NOTE: AS THE GATE
PULSE IS APPLIED
LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.

GATE

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GATE

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E-7

FIGURE E.7 SCR Operation

PRECISION TIG® 225

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E-8

THEORY OF OPERATION

PROTECTIVE CIRCUITS
Protective circuits are designed into the PRECISION
TIG® 185 to sense trouble and shut down the machine
before the trouble damages the internal machine components. 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.

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THERMAL PROTECTION
OVER TEMPERATURE LIGHTIf the welder
overheats due to blocked air flow, high ambient air
temperature, or exceeded duty cycle, an internal thermostat will open disabling the welding output and this
yellow light will illuminate. The cooling fans will continue 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.

E-8

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 operating normally, the 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

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F-1

TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR

F-1

Troubleshooting and Repair.............................................................................................................................F-1

How to Use Troubleshooting Guide .......................................................................................................F-2
PC Board Troubleshooting Procedures and Replacement ....................................................................F-3
Troubleshooting Guide ...........................................................................................................................F-4
Test Procedures
High Frequency Circuit Disable Procedure ..........................................................................................F-15
T1 Transformer Test .............................................................................................................................F-17

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Static SCR Test ....................................................................................................................................F-21
Active SCR Test ...................................................................................................................................F-25
Oscilloscope Waveforms
Normal Open Circuit Voltage Waveform-AC TIG Mode .......................................................................F-29
Normal Open Circuit Voltage Waveform-DC TIG Mode.......................................................................F-30
Normal Open Circuit Voltage Waveform-AC Stick Mode .....................................................................F-31
Normal Open Circuit Voltage Waveform-DC Stick Mode .....................................................................F-32
Typical Output Voltage Waveform-Machine Loaded AC TIG Mode .....................................................F-33
Typical Output Voltage Waveform-Machine Loaded DC TIG Mode.....................................................F-34
Typical Output Voltage Waveform-Machine Loaded AC Stick Mode ...................................................F-35
Typical Output Voltage Waveform-Machine Loaded DC Stick Mode...................................................F-36

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Abnormal Open Circuit Voltage-DC TIG Mode One SCR not Functioning ..........................................F-37
Replacement Procedures
SCR Bridge Assembly Removal and Replacement .............................................................................F-39
Polarity Switch Removal and Replacement .........................................................................................F-45
High Voltage Transformer Removal and Replacement........................................................................F-49
Main Transformer and Output Choke Removal and Replacement ......................................................F-53

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Retest after Repair......................................................................................................................................F-55

PRECISION TIG® 225

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F-2

TROUBLESHOOTING AND REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
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.
---------------------------------------------------------------------------------------------------------------------------

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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 possible symptoms that the machine may exhibit. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function problems, 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 contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.

Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
Course of Action” lists the most likely components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject component 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.

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

F-2

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F-3

TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
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.

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CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems 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.

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Return to Section TOC

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:

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F-3

PC board can be damaged by static electricity.
- Remove your body’s static
charge before opening the staticshielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
to a grounded part of the
ATTENTION
Static-Sensitive equipment frame.
Devices
- If you don’t have a wrist strap,
Handle only at touch an un-painted, grounded,
Static-Safe
part of the equipment frame. Keep
Workstations
touching the frame to prevent

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

static build-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.

PRECISION TIG® 225

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F-4

TROUBLESHOOTING AND REPAIR

F-4

Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Machine is dead. No output - No
fan - No 115 VAC at receptacle.

1. Make sure that the input power
switch is in the "ON" position
and the machine is plugged in.

1. Check the input power switch
and associated wires for loose
or faulty connections.

2. Check the input voltage at the
machine. Input voltage must
match the rating plate and voltage connection. Refer to
Reconnect Procedure in the
Installation section of this manual.

2. Perform the T1 Transformer
Test.

3. Blown or missing fuses in the
input line.
4. CB-1 circuit breaker open.
The fan runs normally. No output
from the machine in either Stick or
TIG modes.

1. Check for proper input voltages
per nameplate and voltage
reconnect configuration.
2. Check to make sure the polarity
switch is in the proper position
and functioning correctly.

1. Check for loose or faulty connections on the heavy current
carrying leads. (polarity switch,
output choke output terminals
etc.)
2. Perform the T1 Transformer
Test.

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3. Perform the SCR Bridge Test.
4. Check current control R1 for
proper operation. Normal
resistance is 10,000 ohms.
Also check associated leads
for loose or faulty connections.
5. The control board may be
faulty. Replace.

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

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F-5

TROUBLESHOOTING AND REPAIR

Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

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RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Fan runs - No output from
machine in either Stick or TIG
modes and the yellow light on the
control panel is on.

1. The welding application may
have exceeded the recommended duty cycle. Allow the unit to
run until the fan cools the unit
and the yellow light goes out.
2. The air louvers may be blocked.
Remove air obstruction and
allow unit to cool.

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F-5

The machine does not respond (no 1. Make certain the machine is in
the TIG mode.
gas flow, no high frequency and no
open circuit voltage) when the arc
start switch or Amptrol is activated 2. The Amptrol may be defective.
Check for continuity(zero ohms)
- fan is working normally.
between pins "D" and "E" on
cable connector when the
Amptrol is depressed.

1. One of the thermostats may be
faulty. Check or replace. See
wiring diagram.
2. Check for loose or faulty wires
on the thermostats and associated circuitry. See wiring diagram.

1. Check the continuity (zero
ohms) of the leads between the
remote receptacle and plug J5
on the control board. See
wiring diagram.
2. Perform the T1 Transformer
Test.

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3. The control board may be
faulty. Replace.

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

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F-6

TROUBLESHOOTING AND REPAIR

F-6

Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Machine regularly over heats thermostat opens. Yellow light on
front panel glows. The fan runs
but the machine has no output.

Machine regularly over heats - thermostat opens. Yellow light on front
panel glows. The fan runs but the
machine has no output.

The machine does not have output The machine does not have output
in the Stick mode. The machine
in the Stick mode. The machine
operates correctly in the TIG mode. operates correctly in the TIG mode.

1. The thermostat(s) may be
faulty. Check or replace.
2. The control board may be
faulty.

1. Check the Stick/TIG switch(S3)
and associated leads. See
wiring diagram.

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2. The control board may be
faulty.

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

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F-7

TROUBLESHOOTING AND REPAIR

F-7

Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Machine welds at a very low output regardless of the current control setting.

1. If welding in the TIG mode the
remote control device may be
defective.
2. Make certain the input line voltage is correct for the machine
reconnect configuration.

1. Check the polarity switch and
associated leads.
2. Check the interior connections
of the heavy current carrying
leads.

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3. Perform the SCR Bridge Test.
3. Check the welding cables and or
torch for loose or faulty connec- 4. Perform the T1 Transformer
Test.
tions.
5. Check the current control for
proper operation. Normal
resistance is 10k ohms. See
wiring diagram.
6. The control board may be
faulty.

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The machine welds at a very high
output regardless of the current
control setting.

1. If welding in the TIG mode the
remote control device may be
defective.

1. Perform the SCR Bridge Test.
2. Perform the T1 Transformer
Test.
3. Check the current control for
proper operation. Normal
resistance is 10k ohms. See
wiring diagram.
4. The control board may be
faulty.

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

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F-8

TROUBLESHOOTING AND REPAIR

F-8

Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Machine output is intermittently
lost. Gas flow and high frequency
are also interrupted.

1. The problem may be caused by
high frequency interference.
Make sure that the machine is
grounded properly according to
the installation instructions. If
there are other high frequency
sources in the area, make certain that they are grounded
properly.

1. Check for loose or faulty connection on the leads between
the remote receptacle and plug
J5 on the control board. See
wiring diagram.
2. Check the plugs on the control
board for loose connections.

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 configuration. Refer to Reconnect
Procedure in the Installation
section of this manual.

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

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F-9

TROUBLESHOOTING AND REPAIR

Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

The arc "flutters" when TIG welding.

1. The tungsten electrode may be
too large in diameter for the current setting.

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3. The gas shielding may be insufficient. Increase the gas flow
and or reduce the tungsten
stickout beyond the gas cup.
4. Check for contaminated gas or
leaks in the gas line, torch, or
connections.
5. If a helium blend is used as a
shielding gas then reduce the
percentage of helium.

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The arc "pulsates" when AC TIG
welding.

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RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS

2. The tungsten tip may not be
"sharp" enough.

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F-9

1. Make sure the gas and procedure are correct for the process
being used.

1. Check the polarity switch for
proper operation and loose or
faulty lead connections. See
wiring diagram.
2. Perform the SCR Bridge Test.
3. Check for loose or faulty connections at the shunt. ( leads
#221 and #222 ).
4. Check components R3 and C4
in the high voltage transformer
primary circuit. Replace if necessary. See wiring diagram.
5. The control board may be
faulty. Replace.

1. Check the micro switch S2A on
the polarity switch. It may be
stuck closed. See wiring diagram.

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

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F-10

TROUBLESHOOTING AND REPAIR

F-10

Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Black areas along weld bead.

1. Clean any oily or organic contamination from the work piece.

1. This may be a welding procedure problem.

2. Tungsten electrode may be contaminated. Replace or sharpen.

Contact The Lincoln Electric
Service Department, 1-888-9353877.

4. The gas shielding may be insufficient. Increase gas flow:
reduce tungsten stickout beyond
the gas cup.

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3. Check for contaminated gas or
leaks in the gas line, torch, or
associated connections.

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Weak high frequency - machine
has normal welding.

1. Check for loose or faulty connections at the torch and/or
welding cables.
2. The gas shielding may be insufficient. Increase gas flow:
reduce tungsten stickout beyond
the gas cup.

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)

3. Check spark gap operation and
setting. Normal is (0.015").
Refer to Maintenance section of 3. If spark is weak at the spark
gap, check or replace the high
this manual.
frequency circuit.
(Examples: T3, L3, L4).
4. The work and electrode cables
may be in poor condition allowing the high frequency to "leak
off". Use good quality cables
with a high natural rubber content, such as Lincoln Stable Arc
Cable. Cables should be as
short as possible.

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

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F-11

TROUBLESHOOTING AND REPAIR

F-11

Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
High frequency "spark" is present
1. The torch may be faulty. Check
at tungsten electrode, but operator
or replace.
is unable to establish a welding
arc. Machine has normal open cir- 2. The current control may be set
cuit voltage. Refer to Technical
too low.
Specifications in the Installation
Chapter.
3. The tungsten electrode may be
contaminated. Replace or
sharpen.

1. This may be a welding procedure problem.
Contact The Lincoln Electric
Service Department 1-888-9353877.

4. The electrode may be too large
for the process.
5. If a helium blend is being used
as a shielding gas, then reduce
the percentage of helium.
6. Check the welding cables for
loose or faulty connections.

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

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F-12

Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
No high frequency. Machine is in
the TIG mode and has normal output.

1. 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.

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2. Check spark gap operation and
setting. Normal is (0.020").
Refer to Maintenance section
of this manual.
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F-12

TROUBLESHOOTING AND REPAIR

1. Check the high voltage transformer (T3). The normal resistance 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 1-888-9353877.
---------------------------------------------2. Check the values of R3, and
C4.
3. Perform the T1 Transformer
Test.

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4. The control board may be
faulty. Replace.
1. The gas supply is either empty
No gas flow when Amptrol is actior not turned on.
vated in the TIG mode. Machine
has normal output - fan runs.
2. The flow regulator may be set
A "click" can be heard indicating
too low.
that the gas solenoid valve is operating.
3. Check the gas hose for kinks or
blockages.

1. Possible gas supply problems.
Consult your local welder/gas distributor.

4. Check the filter screen inside
gas inlet fitting to solenoid valve.

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

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F-13

TROUBLESHOOTING AND REPAIR

F-13

Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
When AC TIG welding, the arc is
erratic and there is a loss of
"cleaning" of the work piece.

The end of the tungsten electrode
melts away.

1. The tungsten electrode may be
too small for the process. Use
a larger diameter tungsten or a
pure tungsten.

1. Check components R3 and C4
in the high voltage transformer
primary circuit.

2. If a helium blend is used as a
shielding gas, then reduce the
percentage of helium.

2. Perform the SCR Bridge Test.

1. The welding current is too high
for the electrode type and or
size. See Table B.1 in the
Operation Section.

1. This may be a welding procedure problem.
Contact The Lincoln Electric
Service Department 1-888-9353877.

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

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F-14

TROUBLESHOOTING AND REPAIR

F-14

Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS
Stick electrode "Blasts Off" when
arc is struck.

1. Weld current may be set too
high for electrode size. Reduce
current control setting, or use a
larger diameter electrode.

1. Perform the SCR Bridge Test.
2. The control board may be
faulty. Replace.

The stick electrode "sticks" in the
puddle.

1. The weld current may be set too
low. Increase the current control
setting or use a smaller diameter
electrode.

Variable or sluggish welding arc
when welding in the Stick mode.

1. Check work and electrode
cables for loose or poor connections.

1. Check the polarity switch for
excessive wear or faulty connections.

2. The weld cables may be too
small or too long to permit the
desired current to flow.

2. Check interior connection of the
heavy current carrying leads.

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3. The weld current may be set too
low.

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

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F-15

TROUBLESHOOTING AND REPAIR
HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE

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.

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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 troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION
This procedure will disable the high frequency circuit. The technician will then be able to
take voltage measurements without the possibility of high frequency damage to his test
equipment.

MATERIALS NEEDED

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3/8” Nutdriver
5/64” Allen type wrench
.020” feeler gauge

WARNING
HIGH VOLTAGE IS STILL PRESENT IN THE HIGH FREQUENCY CIRCUIT.
----------------------------------------------------------------------------------------------------------------------

PRECISION TIG® 225

F-15

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F-16

TROUBLESHOOTING AND REPAIR
HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE (continued)
FIGURE F.1 – SPARK GAP ASSEMBLY

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.020 Spark Gap

LEFT SIDE OF MACHINE

PROCEDURE
1. Remove input power to the TIG 225 machine.
2. Using the 3/8” nutdriver remove the right side
panel.

7. When voltage testing and scope measurements
are complete reset the spark gap electrodes to
.020” air gap. Tighten the set screw using the
5/64” Allen wrench.

3. Locate the Spark Gap Assembly at the right
side of the machine. See Figure F.1.

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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 electrode 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.
PRECISION TIG® 225

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F-17

TROUBLESHOOTING AND REPAIR
T1 TRANSFORMER TEST

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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 windings of the transformer.

MATERIALS NEEDED

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Volt/Ohm Meter
PRECISION TIG® 225 Wiring Diagrams
3/8” nutdriver

PRECISION TIG® 225

F-17

TROUBLESHOOTING AND REPAIR

F-18

T1 TRANSFORMER TEST (continued)

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FIGURE F.2 –

Plugs J3 & J4 on Control Board

PRECISION TIG 225 CONTROL BOARD

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F-18

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PIN 3 (LEAD #204)
PIN 4 (LEAD #201)
J4

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PIN 7 (LEAD #210)
PIN 8 (LEAD #209)

PROCEDURE
1. Remove main supply power to the machine.
2. Using the 3/8” nutdriver remove the case wraparound cover.
3. Locate plugs J3 and J4 on the
control board. See Figure F.2.

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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 per Table F.1.

PRECISION TIG® 225

PIN 3 (LEAD #232)
PIN 2 (LEAD #260)

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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 certain 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 secondary voltages are incorrect the T1 transformer may be faulty.
See Main
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.

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TABLE F.1 T1 TRANSFORMER VOLTAGE
TEST POINTS

ACCEPTABLE VOLTAGES

SECONDARY WINDINGS

SECONDARY VOLTAGES

PLUG J3 PIN 8 (LEAD #210)
TO
PLUG J3 PIN 7 (LEAD #209)

18VAC

PLUG J3 PIN 4 (LEAD #201)
TO
PLUG J3 PIN 3 (LEAD #204)

18VAC

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PLUG J4 PIN 2 (LEAD #260)
TO
PLUG J4 PIN 3 (LEAD #232)

CHECK DURING FIRST 5 SECONDS OF POWER UP

115VAC

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 TIG® 225

F-19

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F-20

NOTES

PRECISION TIG® 225

F-20

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F-21

TROUBLESHOOTING AND REPAIR
STATIC SCR TEST

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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

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Volt/Ohm Meter (Analog)
PRECISION TIG® 225 Wiring Diagrams
3/8” nutdriver
SCR Heat Sink Assembly Drawing

PRECISION TIG® 225

F-21

TROUBLESHOOTING AND REPAIR
STATIC SCR TEST (continued)

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F-22

FIGURE F.3 – Plug J2 Location on Control Board

PLUG J2 REMOVED

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PRECISION TIG 225 CONTROL

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.

PRECISION TIG® 225

F-22

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F-23

TROUBLESHOOTING AND REPAIR

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.4 – SCR TEST POINTS

SCR2 CATHODE
SCR3 CATHODE

SCR1 ANODE

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SCR4 ANODE

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F-23

SCR1 CATHODE/SCR2 ANODE

SCR3 ANODE/SCR4 CATHODE

TEST PROCEDURE (continued)
3. Using an analog ohmmeter test the resistance
from anode to cathode of SCR1. Reverse the
meter leads and check from cathode to anode
of SCR1. See Figure F.4. If a low resistance is
indicated in either direction SCR1 is faulty.
Replace SCR Bridge Assembly. See SCR
Bridge
Assembly
Removal
and
Replacement.
4. Repeat Step #3 testing SCR2, SCR3 and
SCR4.
5. The further check the SCR’s functions use an
SCR tester and proceed to the Active SCR
Test.

PRECISION TIG® 225

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F-24

NOTES

PRECISION TIG® 225

F-24

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F-25

TROUBLESHOOTING AND REPAIR
ACTIVE SCR TEST

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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 TIG® 225 Wiring Diagrams
3/8” nutdriver

PRECISION TIG® 225

F-25

ACTIVE SCR TEST (continued)
FIGURE F.5 – ACTIVE SCR TEST SETUP

SW1

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V
6volt
Lantern
Battery

R1
A

SCR
under
test

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SW2

G
C

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
F.6.

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F-26

TROUBLESHOOTING AND REPAIR

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F-26

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.
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.

PRECISION TIG® 225

R1= 4 ohms /10 watts
R2= 3 ohms/ 10 watts

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F-27

TROUBLESHOOTING AND REPAIR
ACTIVE SCR TEST (continued)
FIGURE F.6 – SCR GATE LOCATIONS

SCR2 CATHODE
SCR3 CATHODE

SCR1 ANODE

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SCR4 ANODE

SCR1 CATHODE/SCR2 ANODE

SCR3 ANODE/SCR4 CATHODE
PLUG J7
4

3
SCR3

SCR4

SCR1

SCR2

S24018-4 (INSERTION SIDE)

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SCR GATE LEADS/TEST POINTS

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.

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7. Close switch SW-1 (switch SW-2 should open),
voltmeter should read zero. If the voltmeter
reads higher than zero the SCR is shorted.
8. With 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).

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 #3. See SCR
Bridge
Assembly
Removal
and
Replacement.
11. Replace plug J2 into the control board.
12. Replace the case wrap-around cover.

9. Open switch SW-1, disconnect the gate lead (G)
and reverse the (A) and (C) leads on the SCR.
Close switch SW-1. The voltmeter should read
PRECISION TIG® 225

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F-28

NOTES

PRECISION TIG® 225

F-28

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F-29

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
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.
____________________________________________________________________

50 volts
0 volts

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2ms

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 represents 2 milliseconds in time.

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Note: Scope probes connected at
machine output terminals: (+) probe to
electrode, (–) probe to work.

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F-29

TROUBLESHOOTING AND REPAIR

SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal

PRECISION TIG® 225

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F-30

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
DC 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.
____________________________________________________________________

50 volts
0 volts

2ms
This is the typical DC (+) output voltage waveform generated from a properly operating machine. Note that
each vertical division represents 50
volts and that each horizontal division
represents 2 milliseconds in time.

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Note: Scope probes connected at
machine output terminals: (+) probe to
electrode, (–) probe to work.

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F-30

TROUBLESHOOTING AND REPAIR

SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal

PRECISION TIG® 225

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F-31

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
AC STICK 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.
____________________________________________________________________

50 volts
0 volts

2ms

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Note: Scope probes connected at
machine output terminals: (+) probe to
electrode, (–) probe to work.

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F-31

TROUBLESHOOTING AND REPAIR

SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal

PRECISION TIG® 225

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F-32

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
DC STICK 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.
____________________________________________________________________

50 volts
0 volts

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Note: Scope probes connected at
machine output studs: (+) probe to
electrode, (–) probe to work.

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F-32

TROUBLESHOOTING AND REPAIR

SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal

PRECISION TIG® 225

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F-33

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.
____________________________________________________________________

50 volts
0 volts

2ms
MACHINE LOADED TO 180 AMPS AT
16VDC.
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 represents 2 milliseconds in time.
The machine was loaded with a resistance
grid bank. The grid load meters read 180
amps and 16VDC

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Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (–)
probe to work.
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F-33

TROUBLESHOOTING AND REPAIR

SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal

PRECISION TIG® 225

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F-34

TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
DC TIG MODE

50 volts
0 volts

2ms
MACHINE LOADED TO 180 AMPS AT 16VDC.
This is the typical DC (+) output voltage waveform 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

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Note: Scope probes connected at machine output terminals: (+) probe to electrode, (–) probe to
work.
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F-34

TROUBLESHOOTING AND REPAIR

SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal

PRECISION TIG® 225

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F-35

TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
AC STICK MODE

50 volts
0 volts

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 represents 2 milliseconds in time.
The machine was loaded with a resistance
grid bank. The grid load meters read 180
amps and 26VDC

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Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (–)
probe to work.
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F-35

TROUBLESHOOTING AND REPAIR

SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal

PRECISION TIG® 225

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F-36

TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
DC STICK MODE

50 volts
0 volts

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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 represents 2 milliseconds in time. The machine
was loaded with a resistance grid bank. The
grid load meters read 180 amps and 26VDC

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Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (–)
probe to work.
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F-36

TROUBLESHOOTING AND REPAIR

SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal

PRECISION TIG® 225

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F-37

ABNORMAL OPEN CIRCUIT VOLTAGE - DC TIG MODE
ONE OUTPUT SCR NOT FUNCTIONING
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.
____________________________________________________________________

50 volts
0 volts

2ms
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 disconnected to simulate an open or nonfunctioning output SCR. Note that
each vertical division represents 50
volts and that each horizontal division
represents 2 milliseconds in time.

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Note: Scope probes connected at
machine output terminals: (+) probe to
electrode, (–) probe to work.
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F-37

TROUBLESHOOTING AND REPAIR

SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal

PRECISION TIG® 225

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F-38

NOTES

PRECISION TIG® 225

F-38

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F-39

TROUBLESHOOTING AND REPAIR
SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE
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.

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TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the SCR assembly.

MATERIALS NEEDED
5/16” 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

F-39

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F-40

TROUBLESHOOTING AND REPAIR

F-40

SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.7 – CASE BACK MOUNTING SCREWS

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REAR PANEL
MOUNTING
SCREWS

PROCEDURE
1. Remove input power to the TIG 225 machine.
2. Using the 3/8” nutdriver remove the case wraparound cover.
3. With the slot head screwdriver loosen the input
cable strain relief to allow movement of case
back.

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.
8. Using the 5/16” nutdriver remove the two
screws holding the front panel assembly to the
base. See Figure F.8.

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4. Using the 3/8” nutdriver remove the two lower
screws from the case back. See Figure F.7.
5. With the 5/16” nutdriver remove the two screws
holding the case back to the internal divider
panel. See Figure F.7.
6. Remove the gas hose from the gas solenoid
valve.
7. Carefully pull the case back and fan assembly
PRECISION TIG® 225

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F-41

TROUBLESHOOTING AND REPAIR
SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.8 – FRONT PANEL MOUNTING SCREWS

FRONT PANEL
MOUNTING
SCREWS

PROCEDURE (continued)
9. Remove plug J2 from the control board. (See
Figure F.9.) Also remove plug and lead harness
from internal divider panel.
10. Carefully slide the internal divider panel away
a few inches to allow access to the SCR
bridge assembly.

13. With the 7/16” wrench remove the shunt from
the SCR bridge left side negative heat sink.
14. Using the 7/16” wrench remove the polarity
switch lead from the right side AC SCR heat
sink.
15. Using the 7/16” wrench remove the positive
lead from the right side positive heat sink.

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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.
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F-41

Note placement of sleeving and cable ties for
reassembly.
12. Using the 7/16” wrench remove the X2 secondary transformer lead from the left side AC
SCR heat sink.

PRECISION TIG® 225

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F-42

TROUBLESHOOTING AND REPAIR
SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.9 – PLUG J2 ON CONTROL BOARD

PLUG J2 REMOVED

PRECISION TIG 225 CONTROL

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FIGURE F.10 DIODE PIGTAIL CONNECTION TO POLARITY SWITCH LEAD.
DIODE
PIGTAIL
CONNECTION

PRECISION TIG® 225

F-42

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F-43

TROUBLESHOOTING AND REPAIR

F-43

SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (continued)
16. With the 3/8” wrench remove the four mounting screws holding the SCR bridge assembly
to the main transformer frame. Note insulator
placement.
17. Carefully remove the SCR bridge assembly
from the TIG 225 cutting any necessary cable
ties.

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REPLACEMENT PROCEDURE
1. Carefully place the new SCR bridge assembly
in position in the TIG 225.

11. Position and install the case back and secure
with the screws previously removed.

2. Using the 3/8” wrench install the four mounting
screws taking special care that the insulators
are in the correct positions.

12. Install the gas hose onto the solenoid valve.

USE DOW CORNING 340 HEAT SINK COMPOUND ON ALL ALUMINUM CONNECTIONS

14. Assemble the case wrap-around cover.

13. Tighten the input cable strain relief.

3. Assemble the positive lead to the right side positive heat sink.

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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 connect lead #217
7. Assemble the diode pigtail lead to the polarity
switch lead. See Figure F.10.
Be sure to
replace sleeving and secure with cable ties.
Position with harness and secure with cable
ties.

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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.
PRECISION TIG® 225

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F-44

NOTES

PRECISION TIG® 225

F-44

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F-45

TROUBLESHOOTING AND REPAIR
POLARITY SWITCH
REMOVAL AND REPLACEMENT PROCEDURE
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.

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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

F-45

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F-46

TROUBLESHOOTING AND REPAIR
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 wraparound cover.
3. Using the 3/32” Allen type wrench remove the
output control knob.

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4. Using the Phillips head screwdriver remove the
screw from the polarity switch handle.
5. With the 2 slot head screwdrivers carefully pry
the polarity switch handle from the shaft.
6. 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.
7. Remove the name plate.

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8. With the 1/2” wrench remove the “positive” flex
lead from the polarity switch. See wiring diagram. Label lead and connection point for
reassembly.

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F-46

13. Using the 1/2” wrench remove the choke lead
from the polarity switch. See wiring diagram.
Label lead and connection point for reassembly.
14. With the 1/2” wrench remove the X1 secondary lead from the polarity switch. See
wiring diagram. Label lead and connection
point for reassembly.
15. With the 7/16” wrench remove the two nuts
and washers that hold the polarity switch to
the front panel.
16. Carefully rotate the polarity switch assembly to
gain access to the micro-switch.
17. 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.
18. Carefully remove the polarity switch assembly
from the machine.

9. 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.
10. 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.
11. Using the 1/2” wrench remove the flat copper
lead from the polarity switch. This lead connects to the high frequency transformer coil
and the by-pass board. See wiring
diagram. Label lead and connection point for
reassembly.
12. 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 diagram. Label lead and connection point for
reassembly.
PRECISION TIG® 225

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F-47

TROUBLESHOOTING AND REPAIR
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.
2. Solder leads #311 and #312 to the micro switch.

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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.
6. Assemble the flat copper leads to the polarity
switch. Make certain they are connected to the
proper terminals and the nuts are tightened.

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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 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.
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.

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12. Assemble the polarity switch handle in place
with the Phillips head screw and check for correct switch operation.
13. Using the Allen type wrench replace the output
control knob.
14. Replace the case wrap-around cover.

PRECISION TIG® 225

F-47

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F-48

NOTES

PRECISION TIG® 225

F-48

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F-49

TROUBLESHOOTING AND REPAIR
HIGH VOLTAGE TRANSFORMER
REMOVAL AND REPLACEMENT PROCEDURE
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.

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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

F-49

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F-50

TROUBLESHOOTING AND REPAIR

F-50

HIGH VOLTAGE TRANSFORMER
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.11 – SECONDARY LEADS AT HIGH FREQUENCY STARTER BOARD

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TRANSFORMER
SECONDARY
LEADS
REMOVAL PROCEDURE
1. Remove input power to the TIG 225 machine.
2. Using the 3/8” nutdriver remove the case wraparound cover.

7. With phillips head screwdriver loosen the two
rear mounting screws.
8. Carefully slide the transformer forward and
remove from the TIG 225 machine.

4. Disconnect the in-line splice quick connect from
one primary lead to lead #231A. Cut any necessary cable ties.
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3. With the needle nose pliers remove the two
secondary leads from the quick-connects on
the high frequency arc starter board assembly.
See Figure F.11.

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.

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 necessary cable ties.
6. Using the phillips head screwdriver remove the
PRECISION TIG® 225

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F-51

TROUBLESHOOTING AND REPAIR

F-51

HIGH VOLTAGE TRANSFORMER
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.12 – HIGH VOLTAGE TRANSFORMER MOUNTING INSULATORS

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SLOTTED REAR
MOUNTING INSULATORS

NOTE: On some machines the
mounting screw configuration may be
different.

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FRONT MOUNTING
INSULATORS

REPLACEMENT PROCEDURE
1. Carefully position the new high voltage transformer in place in the two rear mounting insulators. See Figure F.12.
2. Install the front mounting insulators and mounting screw.
3. Using the phillips head screwdriver tighten all
four mounting screws making certain the insulators are positioned correctly.

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4. Reconnect the two primary leads.
5. Reconnect the two secondary leads to the high
frequency arc starter board assembly.
6. Replace any previously removed cable ties.
7. Replace the case wrap-around cover.

PRECISION TIG® 225

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F-52

NOTES

PRECISION TIG® 225

F-52

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F-53

TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE
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.

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Return to Section TOC
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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 TIG® 225

F-53

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F-54

TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (continued)
REPLACEMENT PROCEDURE

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 transformer
leads. Label leads for reassembly. See wiring
diagram.

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.

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4. Assemble the choke lead to the polarity switch.
4. Unsolder leads W201 and W204 from the main
transformer leads. Label leads for reassembly.
See wiring diagram.
5. Unsolder leads R209 and U210 from the main
transformer leads. Label leads for reassembly.
See wiring diagram.
6. Using the 1/2” wrench remove the shunt
assembly from the choke lead.

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7. With the 3/8” wrench remove the H1, H2 or H3
lead from the input power switch. See wiring
diagram. Label the leads and connection points
for reassembly. Cut any necessary cable ties.
8. Remove plug J3 from the control board and
push through the interior divider panel.
9. 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 secondary lead from the polarity switch. See
wiring diagram. Label lead and connection
point for reassembly.

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 transformer 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 and leads B231
and B232 to the main transformer leads. See
wiring diagram. Insulate connections.
11. Replace any previously removed cable ties.
Clear leads and check for “shorts” or
“grounds”.
12. Perform the SCR Bridge
Replacement Procedure.

12. Carefully hoist the transformer/ choke assembly clear of the base. Clear all leads.
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11. With the 1/2” wrench remove the four nuts and
lock washers from the transformer mounting
bolts at the base of the machine.

PRECISION TIG® 225

Assembly

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F-55

NOTES
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.

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INPUT IDLE AMPS
Input Volts/Hertz

Maximum Idle Amps

208/60
230/60

2.70 Amps
3.00 Amps

OPEN CIRCUIT VOLTAGES
Stick Mode OCV

AC 70 - 75VAC
DC 55 - 66VDC

TIG Mode OCV

AC 70 - 80VAC
DC 60 - 66VDC

MAXIMUM ACCEPTABLE OUTPUT VOLTAGE AT MINIMUM OUTPUT SETTINGS

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DC TIG Mode

5 Amps @ 12 Volts

MINIMUM ACCEPTABLE OUTPUT VOLTAGE AT MAXIMUM OUTPUT SETTINGS
DC TIG Mode

225 Amps @ 29 Volts

RECOMMENDED METERS FOR MACHINE OUTPUT TESTS
VOLTMETER: AC and DC True RMS Meter - Fluke 8922A or equivalent
AMMETER:
Columbia Type AX AC or DC Tong Ammeter

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IMPORTANT: IF OTHER TYPE METERS ARE USED RESULTS MAY NOT BE ACCURATE.

PRECISION TIG® 225

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F-56

NOTES

PRECISION TIG® 225

F-56

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G-1

TABLE OF CONTENTS - DIAGRAM SECTION

G-1

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1

Wiring Diagram (G5646) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Entire Machine Schematic (G5647) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Control PC Board Schematic #1 (G5640) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Control PC Board Schematic #2 (G5640) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5

Control PC Board Assembly #1 (G5641) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7
Control PC Board Assembly #2 (G5641) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8
ByPass PC Board Schematic (S22530) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9
ByPass PC Board Assembly (L10121) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-10

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Control PC Board Schematic #3 (G5640) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6

PRECISION TIG® 225

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G-2

ELECTRICAL DIAGRAMS

WIRING DIAGRAM - COMPLETE MACHINE - ALL CODES (G5646)

VOLTAGE RECONNECTION
SEE RATING PLATE FOR SPECIFIC VOLTAGES
230 or 400-415 or 575 VOLT CONNECTION
(AS SHOWN & AS SHIPPED FROM FACTORY)
H1 and H3 (HIGH) TO POWER SWITCH.
H2 NOT CONNECTED; INSULATE.

115VAC
RECEPTACLE
(BACK VIEW)

208 or 380 or 460 VOLT CONNECTION
H1 and H2 (LOW) TO POWER SWITCH.
H3 NOT CONNECTED; INSULATE.

380V AND ABOVE
G

CONNECT GREEN LEAD TO GROUND PER
NATIONAL AND LOCAL ELECTRICAL CODE
CONNECT BLACK AND WHITE LEADS
TO SUPPLY CIRCUIT

231B

C1 AND C2 MUST ALWAYS BE CONNECTED
ACROSS TRANSFORMER PRIMARIES

B
(L1)

231A
231

W
(L2)
232

233

CB1

208V/230V ONLY

232A

TO GROUND PER
NATIONAL ELECTRIC
CODE

H3
H2

B
(L1)

313

POWER
SWITCH

314

AUTO
BALANCE
LED

FRONT
240 GANG

REAR GANG

A
E
C

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POS

284

AC
BALANCE
CONTROL

MICRO-SWITCH
NO
NC 312A

312

311A

311

DC
B

S2A

PULSE
CONTROL
PULSE
FREQ
LED

(REAR VIEW,
SHOWN IN AC POSITION)
285

A
C
B
D
E

1
2
3
4
5
6

G3
218

220
G2

217

H3 (HIGH)
H2 (LOW)

C4
STICK LED

DIGITAL
DISPLAY

115VAC

THERMAL
Y
LED

1
2

W 221
R 222

SCR1
G1

X3
18VAC
X4
X5
18VAC
X6
X1
78VAC
X2

260 231A

218

218A
X8

232

FAN

115VAC
115VAC
X7

231

SCR3

216
216A

X2
G4

POSTFLOW
CONTROL

SCR2

SCR4

SHUNT
OUTPUT
CONTROL

CONTROL PC BOARD

1
2
3
4

W 221
R 222

POS

GAS VALVE
235

SV1

WORK

L3
239

C1,C2
C3
C4
C5,C6
CB1

238
SPARK
GAP

284A

284B

T3
ELECTRODE

R2
285A

R1
285B

BYPASS/
STABILIZER
PC BOARD
285

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217

ARC
STARTER
AS'BLY

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220A

H1
201
TRIGGER
204
209
POWER
210

220A 218A

220
G4
G3
G2
G1

237

S2
POLARITY
SWITCH

231B

R3
236A

MODE
SWITCH

TIG LED

P7
4 3 2 1
J7

POLARITY SWITCH MICRO SWITCH
AC
A-C, D-E, B-F
OPEN
DC+ B-D, C-E, A-F, G-H
CLOSED
DC- B-D, A-E, C-F, G-H
CLOSED

R4
236

8 76 5 43 21

216

236

REMOTE
RECEPTACLE

235

240
216A
245
244
209
210
312
311
201
204
314
313

232A

1211 10 9 8 7 6 5 4 3 2 1

260

4 32 1

)

10K A-B
AT MINIMUM
OPTIONAL
REMOTE
AMPTROL TM

245 244

CHOKE

A
B
C
D
E

A
B
C
D
E
F

(

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INPUT PLUG (208V/230V ONLY)
W
(L2)

( )

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284

D1
L1
L2,L3
L4,L5
R1,R2
R3
R4,R5
S1
S2
S2A
S4
SCR1,2,3,4
SV1
T1
T2
T3

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
OUTPUT INDUCTOR (CHOKE)
HIGH FREQUENCY INDUCTORS
RF TOROID CHOKES
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

LEAD COLORING CODE:
B-BLACK
G-GREEN

R-RED
W-WHITE

COMPONENT VALUE
UNITS:
RESISTORS:
OHMS/WATTS
CAPACITORS:
MFD/VOLTS

CONNECTOR PIN NUMBERS:
1 2 3

EXAMPLE: THIS IS PIN 7
OF CONNECTOR J4

14
LATCH
VIEW OF CONNECTOR ON PC BOARD
ELECTRICAL SYMBOLS PER E1537.
8

G5646

CLEVELAND , OHIO

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
PRECISION TIG® 225

284

BYPASS/STABILIZER
PCB

5J5

LOCAL

6J5

TOROID

OPTIONAL AMPTROL REMOTE
CONTROL AND ARC START SWITCH

HI-FREQBYPASSCONNECTION
FROM BOTTOM LEFT
MOUNTINGHOLE TOSHEET
METAL

J1 2 PIN

3J5

2J5

+15V

4 PIN(WHITE)
PROGRAMMING
CONNECTOR

1J5

+24V

TRIGGER
INTERFACE

-15V

HI-FREQ BYPASS
CONNECTION

TRIGGER
TO MICRO
PROCESSOR

MICRO-PROCESSOR
X1

OUTPUT CONTROL

POSTFLOW

NEXT TO METER
TWO THERMAL LEDs TO
LIGHT THROUGH
BACK-LIT THERMAL
SYMBOL
+5V

SOFTWARE
VERSION LABEL

FREQUENCY
6 PIN

MICRO
START

+15V
+5V
+5Vref
-15V

POWER SUPPLY

SCR3

SCR4

+15V
(GREEN)

MODE

C4
15/250 5.5 OHMS
TYP.

115V

115VAC

236B

.22/400V
231B
232A

20A (208V/230V)
CB1
6A (380V & ABOVE)

DO NOT REVERSE LEADS
209 &210, USED FOR SCR
PHASE TIMING

209

Rear Panel
Right Side

235
232

18VAC
CONTROL BOARD SUPPLY

210

3J3

8 PIN

201

5000V
F

(115VAC)

12.5 OHM TYP.
12.5 OHM TYP.

.0015/12KV

HIGH FREQ.
TRANSFORMER

260

FAN

SHUNT

OUTPUT INDUCTOR

WORK

285

Gang F

Rear gang H
Gang E

MICRO SWITCH

ELECTRODE

FAN RUNS FOR 5 S AT POWER-UP
STOPS AT IDLE 8 MINUTES
AFTER WELDING.
TYP. RPM:
1600 RPM 60Hz
1340 RPM 50Hz

Gang C

gang B
MOUNTING HOLE

AC
DC+
DC-

115VAC
X8

POLARITY SWITCH
A-C, D-E, B-F
B-D, C-E, A-F, G-H
B-D, A-E, C-F, G-H

SCHEMATIC G5640ASSEMBLY G5641-

312

GANG LOCATIONS ARE
VIEWED FROM REAR OF
SWITCH

MICROSWITCH
OPEN
CLOSED
CLOSED

SCR BRIDGE AND POLARITY SWITCH CONNECTION DETAIL

Right rear side of Main
Transformer

LEADCOLORCODE:
B-BLACKORGRAY
G-GREEN
O-ORANGE
R-REDORPINK
U-BLUE
W-WHITE
Y-YELLOW

Between SCR Bridge halves
behind choke.

COMPONENT VALUEUNITS:
CAPACITOR: MFD/VOLTS

RESISTOR: OHMS/WATTS

CONNECTORPINNUMBERS:
EX. 12 PIN CONNECTOR

LABELS:

COMMON

FRAMEGROUND

CONTROL PC BOARD

UNUSED TERMINAL
311

Rear gang G

4 PIN

CONTROL PCB MAIN COMPONENT & DIANOSTIC LED LAYOUT
(VIEWED FROM COMPONENT SIDE)

Gang A

240

FARTHEST RIGHT SCR
(VIEWED FROM
FRONT)
7GA. FLEX LEAD

Gang D

232

435 OHMS TYP.

SCR4

Mounted to front side
of hi-freq box on
right side of machine
near front.

Center front

115VAC

Right front side of
Main Transformer

SPARK
GAP .020

239

BOTTOM
COPPER
BAR

6 GA. FLEX LEADS

231

12 OHMS TYP.

FARTHEST LEFT
SCR (VIEWED
FROM FRONT)

Right front

SV1

AUX. WINDINGS OF
MAIN TRANSFORMER T1

14.5 KOHMS
TYP.

GAS
SOLENOID

18VAC
TRIGGER CIRCUIT

204

HI-FREQ CIRCUIT

231A

233

238

Right side of machine,
front of gas solenoid,
attached to Base

12 PIN

BALANCE

TROUBLE SHOOTING LED'S PRESENT ONLY ON
PCB REVISION B OR LATER

8J3

4J3

GAS FAN
HF
GREEN LED'S

7J3

260

237

SCR1
SCR2

PHASE
DETECTOR

232A

FAN (115VAC)

ARCSTARTERASSEMBLY

HIGH VOLTAGE
TRANSFORMER

SCR
HEATSINK

Front Panel Top

COMPONENT LOCATION DESCRIPTIONS ARE AS VIEWED
FROM FRONT OF MACHINE UNLESS STATED
OTHERWISE

EARTHGROUND

PROPRIETARY &

1 2

LATCH

VIEWOF CONNECTORON PC BOARD

DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

THE INFORMATION ON THIS
PRINTIS FOR REFERENCE
ONLY. COMPONENTS AND
CIRCUITRY MAY BE DIFFERENT
FROMAN ACTUAL MACHINE.

DESIGN INFORMATION

REFERENCE:

ENGINEER:

SCALE:

DRAWN BY:

APPROVED:

Jbarto

RSamodell
Approve

G4588

NONE

EQUIPMENT TYPE:
SUBJECT:

MATERIAL
DISPOSITION:

Precision Tig 225
MACHINE SCHEMATIC

APPROVAL
DATE: 06/20/2006

PROJECT
NUMBER:

CRM38254

1
1 OF ___
PAGE ___

DOCUMENT
NUMBER:

G5647

DOCUMENT
REVISION:

SOLIDEDGE

REM_POT

DET_REM

REM_SENSE

EN-170

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+5V

4 RED LED'S

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10K

Left front

RF
CHOKES

LED 6
THERMAL
(YELLOW)

NEXT TO METER

NEXT TO PULSE
FREQUENCY POT.
OFF IN STICK, BLINKS AT
FREQUENCY RATE

TO MICRO PROCESSOR
AND SCR GATING
PHASE

115VAC IN

236
235

200/100

285B

100/100

HI-FREQ OFF IN STICK
START ONLY IN DC TIG
CONTINUOUS IN AC TIG

ALUMINUM BAR

)

LED 5
FREQUENCY
(GREEN)

TO MICRO
PROCESSSOR

HI-FREQ (115VAC)

GAS (115VAC)

3J4

2J4

NEXT TO MODE SWITCH

NEXT TO BALANCE POT.
OFF IN STICK AND DC TIG

RECEPTACLE

4J4
1J4

LED 3
TIG
(GREEN)

LED 4
AUT0BALANCE
(GREEN)

Inside hi-freq box on
right side of machine
near front

In Front of main
transformer,
Attached to Base

Left side of Machine
near front

LED 2
THERMAL
(YELLOW)

100/100

HOLDINGRESISTORS

115V CIRCUIT
TRIAC & OPTO-TRIAC
DRIVER

TRIGGER

285A

W 222
R 222

284A
284B

LED INTERFACE

NEXT TO MODE SWITCH

AUTO LOCAL/REMOTE
STICK MODE: ALWAYS LOCAL
TIG MODE: REMOTE IFPLUGGED
LOCAL IFUNPLUGGED

PHASE

MICROPROCESSOR

+5V

LED 1
STICK
(RED)

AUTO
LOCAL/
REMOTE
CONTROL

TO0 COPPER BAR

(SCHEMATIC S22530)
(PCB AS'BLY L10121-1)

+15V

10K

INPUT PLUG

Inside hi-freq box on
right side of machine
near front

(

285

( )

POSTFLOW

C1 AND C2 MUST ALWAYS BE CONNECTED
ACROSS TRANSFORMER PRIMARIES

SEE CONNECTION DETAIL

Front Panel Center

+5Vref

30 S

S2
POLARITY SWITCH

4J6

208 or 380 or 460 VOLT CONNECTION
H1 and H2 (LOW) TO POWER SWITCH.
H3 NOT CONNECTED; INSULATE.

SCR3

+5Vref

+
DC

10K

Gang F

CBW=CONNECTED
BYSWITCH
THESE CONNECTIONS
ARE MASE BY POLARITY
SWITCH, THEY ARE NOT
PHYSICAL LEADS

3J6

DC-

CBW

Gang E

PROGRAMMINGCONNECTOR
FORSOFTWAREUPGRADE

2J6

DC+

216
216A

XRES

CHOKE TSTAT
(NORMALLY CLOSED
OPEN AT 135C TYP.)

CBW

Gang H

CBW

N.C.

MICRO SWITCH CLOSED IN DC
OPEN IN AC

313

DISABLE OUTPUT &HI-FREQ
IF THERMOSTAT OPEN

CBW

230 or 400-415 or 575 VOLT CONNECTION
(AS SHOWN & AS SHIPPED FROM FACTORY)
H1 and H3 (HIGH) TO POWER SWITCH.
H2 NOT CONNECTED; INSULATE.

POS

312

+
DC
DC-

CBW

218
218A

1J6

SCLK

CLOSED
IN DC

314

VOLTAGE RECONNECTION

DATA

312

THERMOSTAT INPUT

1J3

+5Vref

+24V

10K

2J3

DC-

311

MICRO SWITCH INPUT

6J3

Gang A

SEE RATING PLATE FOR SPECIFIC VOLTAGES

Gang B

Gang G

SCR2

INTERFACE

5J3

DC+
DC-

INTERFACE

THERMOSTAT

240

Front Panel Left side

Gang D
Gang C

RECONNECT ISDONEAT
POWERSWITCH

Right side of Machine
above Choke Coil.

Lower left side of
Polarity Switch

LOW

Right Side of SCR Bridge
Rectifier. Top of Machine
behind Choke.

Attached to Power Switch

.0047/ 250VAC

POWER SWITCH

217

0.1 HZ
OFF

DETERMINE IF HI-FREQ IS
CONTINUOUS OR START
ONLY, MIN. CURRENT, AND
BALANCE CONTROL

80 VAC

HIGH

SCR1

PULSE FREQUENCY

AC/DC

Hi = Local

+5Vref

20 HZ

CURRENT FEEDBACK

Remote control

TWISTED PAIRS

SCR2

SHUNT
400A/200mV

OUTPUT
INDUCTOR

REM_POT

REM_SENSE

From Auto Loc/Rem

284

BALANCE

MAX. CLEANING
AUTO

Polling signal

R 222(-)
W 221(+)

IN-LINECONNECTORJ7

On top of Main
Transformer

B
DET_REM

Inside sleeving at top left side of
Main Rectifier

W 221
R 222

SHUNT (+)

SHUNT (-)

218A

15 - 20 OHM
GATE-CATHODE
RESISTANCE TYP.

SCR3

MAIN SCR
RECTIFIER

FREEWHEELINGDIODE SCR1
G1

G1
217
218

SCR4

BYPASS ASSEMBLY
C1

Center of machine

MAIN
TRANSFORMER

220
220A

PULSE FREQUENCY IS
DISABLEDINSTICK

MAX. PENETRATION

BACKGROUND AC INPUT

+24V +5Vref

A1
+5Vref

1J1
2J1

BACKGROUND ( + )

TOROID

BACKGROUND RESISTORS

G4
G3
G2

Top rear
SEE CONNECTION DETAIL

POS

BALANCECONTROL IS
DISABLEDINSTICKAND
DCTIG

5 - 230A
ACand DC

Iarc

OUTPUT CONTROL
(ENCODER)

-15V

OUTPUT REGULATOR

SETPOINT

216A

CBW

+5Vref

METER, ENCODER, SWITCH, LEDs,
AND ALL POTENTIOMETERS ARE
MOUNTED ON PC BOARD

PHASE_FIRE

12/100 EACH

216A
245
244
240

BACKGROUND ( - )

G4
G3
G2
220

220A

216
4
3
2

231

Return to Master TOC

+15V

BACKGROUND AC INPUT

11J3
10J3
9J3
12J3

(DISABLED IN STICK)

TOGGLE BETWEEN TIG &
STICK.
HI-FREQ, GAS, BALANCE
CONTROL, PULSE
FREQUENCY, &
MICRO-START CIRCUIT
ARE DISABLED IN STICK

Rear of machine attached to
base, below fan

PHASE

MICRO-START
CIRCUIT

SCR1 GATE
G1
SCR2 GATE
G2
SCR3 GATE
G3
SCR4 GATE
G4
SCR3,SCR2 CATHODE 218
SCR1 CATHODE
217
SCR4 CATHODE
216
SCR1,SCR4 ANODE 220

5J2
6J2
3J2
8J2
2J2
1J2
4J2
7J2

SCR
GATING & SNUBBER

+15V

+5Vref

MODE

65V INDC
75V INAC

FIRE_SCR

METER
INTERFACE

+15V

TYPICAL OCV

+5V

3 DIGIT
METER
(DISP1)

+24V

+5V

POS

OUTPUT CONTROL &
MODE SETTINGS ARE
MEMORIZED AT POWER
- DOWN AND RECALLED
ATPOWER - UP

+15V

CBW

POWER-UPSEQUENCE

DISPLAY PRESET AT IDLE
ACTUAL AMP WHEN WELDING
NO HOLD FUNCTION

CBW

CHANGEDETAIL: RELEASEDFROM XA.02

ENGINEERING CONTROLLED
MANUFACTURER: No

CBW

Return to Master TOC

SCHEMATIC - COMPLETE MACHINE - ALL CODES (G5647)

METERANDMODEDISPLAY THEPREVIOUSOUTPUT
CONTROL ANDMODESETTINGS. FANRUNS FOR5
SECONDS. IF MODE IS TIG, GAS FLOWS FORA TIME
SET BY THEPOSTFLOWKNOB. OUTPUT ISHOT IF
MODE ISSTICK. INTIG MODEOUTPUT ISCOLDUNTIL
TRIGGERISCLOSED

Return to Section TOC

G-3

ELECTRICAL DIAGRAMS
G5647

Return to Section TOC

G-3

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PRECISION TIG® 225

Return to Master TOC

ELECTRICAL DIAGRAMS

G-4

SCHEMATIC - CONTROL PC BOARD #1 (G5640)

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-4

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PRECISION TIG® 225

Return to Master TOC

ELECTRICAL DIAGRAMS

G-5

SCHEMATIC - CONTROL PC BOARD #2 (G5640)

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-5

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PRECISION TIG® 225

Return to Master TOC

ELECTRICAL DIAGRAMS

G-6

SCHEMATIC - CONTROL PC BOARD #3 (G5640)

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-6

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PRECISION TIG® 225

CHANGE DETAIL: NEW

ENGINEERING CONTROLLED
MANUFACTURER: Yes

R4 5

MOV 3

MOV 2

MOV 1

R2 9

R2 8
R4 4

C13

R15

R14

R13

R9 1
R104

D2 7

D2 6

D2 5

D2 4

C6 1

C6 0

C6 5

D23

MOV 8

MOV 7

MOV 6

C73

.20

R157

R163

R164

R165

R168

R169

R175

R176

R179

R180

C99
C101

N.K.

R19 3

C106
R19 1

D39

N.K.

C96

R19 2

D37

J4
R160

R159

R18 6

C105

R156

R158

R18 5

R152

R17 0

R16 2

R15 1
R155

C108

R18 9

D38

R142

R18 8

D36

DZ10

Q18

C104

R2 00

C9 8
R16 7

L ED9

D35

R18 4

R17 4

L ED17
R18 3

C103

R18 2

Q17

Q16

R14 1

R19 0

DZ8

D32

R15 0

R14 9

C9 2

OCI 5

L ED16

R17 3

L ED15

R17 2

C100

OCI 4

R17 7

OCI 3

L ED10

OCI 2

R16 1

C70

C86

R14 8

C9 1

R14 7

R14 6

R14 5

C9 0

R14 4

R14 3

C8 9

R13 6

TRI 4

TRI 3

C94

C95

R17 8

C9 7

C8 8

OCI1

TRI 2

TRI 1
C7 8

R13 5

L1
L4

D18

C54

R110

R93

C48

R9 0

R7 8

D14

R92

C47

R103

C2 6

R5 8

R5 7

R5 6

C2 5

R4 3

R2 7

R2 6
R4 2

R2 01

D10

D15

8.80

COMPONENT SIDE

N.K.

C69

C7 2

C7 1

C8 7

D13

R105

X10

D2 2

MOV5

C46

C51

D2 1

MOV4

D12

D17

D20

X12

C6 4

C6 3

R117

C6 2

X11

R118

R12 5

TP5

R12

C6
C18
C2 4

R77

C5 7

R107

R106

C5 3
C5 9

R115

Q12

R74

R76

R114

C5 6

R102

R101

R100

R9 9

R9 8

R9 7
C5 2

R73

L ED7

DZ4
R8 5

C4 4

R8 9

R8 8

R8 7

C4 5

R8 6

R199

R9 6

D16

R72

R5 5

C3 2

R217

R7 5

R2 08

C113

R54

DZ3

Q8
D19

R109

R12 7

LED14

R13 4

C102

R218

C4 1

R11

DZ2

R5 3

R8 4

Q10

R14 0

R18 1

LED12

R6 9

R7 0

R2 5

C16

Q1
Q5

R2 03

R2 16

R5 1

C3 4

C111

R18

C2 3
C2 9
R5 0

R19 4
R6 8

R16 6

R17 1

R36

R41

C4 3

R8 3

C4 0

C2 1

R2 15

C112

R64

R20

C107

R18 7

R219

TP7

R13 9

C9 3

Q15

D3 4
0

R19 5

C3 3

R6 7

R6 6

R6 5
R8 1

R8 2

C5 5

D3 0

D2 9
R13 3

Q14

LED13

R40

R47

C50

R12 4

R12 3

R12 6
C7 7

R12 2

C6 7

R13 8

R13 2

R13 1

C8 5

C7 6

R13 0
R13 7

C8 3

DZ7

DZ6

D3 3

R12 1

C6 6

R119

R12 0

R2 02

L ED8
R12 9

C8 4

R12 8

X14

D28

R220

C20

R213

R214

TP6

R2 04

R6 3

C3 9
C4 2
Q13

DZ9
.20

C31

R207

Q11

R113

R112

R111

R19 8

R19 6

C7 5
C8 2

R8 0

C3 8

R7 1
R2 09

R206

R108

C5 8
R19 7

R15 3

R15 4

Return to Master TOC

C7 9

C8 0

C8 1

C7 4

D31

R52

LED11

R35

R46

R205

DZ5

R116

D40

R19

PT185/ 2 2 5
CONTROL

TP1 TP2

R4 9

R4 8

TP4

R95

C49

X13

9.00

REVISION CONTROL
G5 6 4 1 - 2C0

N.K.

PART NO. IDENTIFICATION
CODE
TEST PER E4238-C
COAT WITH E1844 AND E3668 (2 COATS)
SCHEMATIC REFERENCE: G5640-2C0

MAKE DETAIL
MANUFACTUR PER E1911-RoHS
BUY BLANK COMPLETE
(2 BOARDS PER PANEL)

4 LAYER BOARD BLANK PANEL
SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION.

NOTE:

MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ddietz
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER:
MATERIAL TOLERANCE (" t ") TO AGREE
Trang Nguyen
WITH PUBLISHED STANDARDS.
APPROVED:
DO NOT SCALE THIS DRAWING

SCALE:

EQUIPMENT TYPE:

UNITS:

MATERIAL
DISPOSITION:

1:1.25

IF PRINTED
@ A1 SIZE

INCH

SUBJECT:

PRECISION TIG 185/225
CONTROL PC BOARD ASSEMBLY
APPROVAL
DATE:

2/15/2008

PROJECT
NUMBER:

CRM36266

REFERENCE:

G4551-1

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 provided 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
machine.

2
1 OF ___
PAGE ___

DOCUMENT
NUMBER:

G5641-2

SOLID EDGE

DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

EN-170

Return to Master TOC

R2 10

R7 9

TP3
R94

N.G.

D41

C3 5

C3 7

C3 6

D11

Return to Master TOC

Return to Section TOC

N.B.

C19

R3 4

C17

R3 7
R2 11

C3 0

R2 12

R6 1

R6 0

C2 8

C2 7

R5 9

C110

R3 9

R3 8

R6 2

C2 2

C109

R10

C15

C14

C12
R3 3

R3 2

R3 1

R3 0

G5 6 4 1- 2

R17

R16

R2 4

C11

R2 3

R2 2

C10

DZ1

5.80

6.00

C68

Return to Section TOC

N.K.

5.00

R2 1

Return to Master TOC

PC BOARD ASSEMBLY - CONTROL #1 (G5641)

5.10

Return to Section TOC

G-7

ELECTRICAL DIAGRAMS
G5641-2

Return to Section TOC

G-7

DOCUMENT
REVISION:

Insight

PRECISION TIG® 225

ENGINEERING CONTROLLED
MANUFACTURER: Yes

Return to Master TOC

Return to Section TOC

X XXX
X S1
X
X XXX

N.C.,N.D.

X
X
X
X

N.C.,N.J.

N.C.

DISP1

LED1

LED3

XXXXXX
X R1
X
X
X
X
X
X
X
X
X
XXXXX

Return to Master TOC

XXXXXX
R2
X
X
X
X
X
X
X
X
X
X
XXXXX

LED5

N.C., N.D., N.H. (3 PLACES)

OPPOSITE COMPONENT SIDE

N.B.
N.C.
N.D.

N.E.
N.F.
N.G.
N.H.
N.J.
N.K.
N.L.

N.L.

XXXXXX
R3
X
X
X
X
X
X
X
X
X
X
XXXXX

N.C.

N.A.

N.C.

XXXXXXX
X
X
X
X
X A1
X
XXXXX

LED2

LED6

NOTES:

QTY
1
3
3
AS REQ
3
1
AS REQ
AS REQ

PART NUMBER
G5641-C
CF000003
E106A-13
E1868
S18104-3
S26585-4
E2861
E2519-1

DESCRIPTION
PC BOARD BLANK
6-32 X .375 ROUND HEAD MACHINE SCREW
# 6 LOCK WASHER
THERMO JOINT COMPOUND
HEAT SINK,ALUMINUM,EXTRUDED,FOR 1 TO-220
PSOC SOFTWARE
SEALANT
SEALANT

THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY, SEE E2454 BEFORE
HANDLING.
PROGRAM X1 WITH ITEM 6.
KEEP FREE OF ENCAPSULATION MATERIAL.
SEAL COMPONENT BY APPLYING ITEM 7 AS SHOWN SO THAT ENCAPSULATION MATERIAL
DOES NOT GET INSIDE COMPONENT.
KEEP FREE OF ENCAPSULATION MATERIAL (.50 DIA. MIN.) ON BOTH SIDES OF BOARD.
KEEP MOUNTING HOLES FREE OF ENCAPSULATION MATERIAL (5 PLACES).
COVER MOLEX WITH TAPE.
HAND TIGHT MOUNTING WASHER AND MOUNTING NUT TO POTENTIOMETER BUSHING.
WHEN ASSEMBLING DISPLAY, SPACE DISPLAY OFF THE BOARD .125+/- .010 MEASURED
FROM BOTTOM OF DISPLAY TO PC BOARD SURFACE.
SQUEEZE COMPONENTS TOGETHER BEFORE ENCAPSULATION.
SEAL COMPONENT BASE WITH ITEM 8.

N.C.

N.E.

REFERENCES
A1
C1, C3, C29, C39, C41,
C42, C43, C58, C60, C78,
C84, C89, C90, C91, C92,
C94, C95, C103, C104,
C109, C110
C2, C10, C35, C111
C4, C23, C38
C5, C20, C45
C6, C7, C9, C12, C17,
C18, C24, C30, C31, C32,
C34, C44, C53, C59
C8, C13, C25, C26
C11, C14, C19, C21, C22,
C33, C48, C50, C51, C52,
C55, C56, C62, C64, C66,
C68, C74, C75, C76, C79,
C80, C81, C82, C83, C85,
C93, C98, C100, C105,
C107, C108, C112
C15, C63
C16, C40, C113
C27, C36, C37
C28
C46, C49
C47
C54, C69, C70, C73, C86,
C96, C99, C101, C106
C57, C61, C65
C67, C77
C71, C72, C87, C88, C102
C97
D1, D2, D3, D5, D7, D8,
D21, D22
D4, D6, D16, D18, D19,
D20, D28, D31, D32, D35,
D40, D41
D9, D10, D11, D12, D13,
D14, D15, D17, D23, D29,
D30, D33, D34, D36, D37,
D38, D39
D24, D25, D26, D27
DISP1
DZ1, DZ8, DZ10
DZ2, DZ3
DZ4
DZ5, DZ6
DZ7, DZ9
J1
J2
J3
J4
J5
J6
L1, L2, L3, L4, L5
LED1
LED2, LED6
LED3, LED4, LED5
LED7, LED8, LED9,
LED10, LED15, LED16,
LED17
LED11, LED12, LED13,
LED14
MOV1
MOV2, MOV3, MOV4,
MOV5
MOV6, MOV7, MOV8

QTY
1

PART NUMBER
M17789-4

DESCRIPTION
ENCODER,INCREMENTAL,2-BIT,PEC12

S25020-2SMT

CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%,X7R,S0805

4
3
3

S25020-9SMT
S25024-2SMT
S25020-12SMT

CAPACITOR,SMD,CERAMIC,47pF,50V,5%,COG,S0805
CAPACITOR,SMD,TANTALUM,1.0MF,35V,10%,S3528
CAPACITOR,SMD,CERAMIC,100pF,100V,5%,COG,S0805

S20500-17

CAPACITOR,PPMF,0.1MF,630V,5%,BOX

S25020-10SMT

CAPACITOR,SMD,CERAMIC,4700pF,50V,10%,XR7,S0805

S25020-3SMT

CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X7R,S0805

2
3
3
1
2
1

S25020-4SMT
S25020-14SMT
S25020-7SMT
S25020-24SMT
S13490-199
S13490-179

CAPACITOR,SMD,CERAMIC,820pF,50V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,330pF,100V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,0.22MF,50V,20%,X7R,S1812
CAPACITOR,SMD,CERAMIC,1.0MF,25V,10% ,X7R,S1206
CAPACITOR,ALEL,220,25V,20%,LOW-ESR
CAPACITOR,ALEL,1000,35V,20%

3
2
5
1

S13490-197
S25020-5SMT
T11577-58K
S13490-181

CAPACITOR,ALEL,82,35V,20%,LOW-ESR
CAPACITOR,SMD,CERAMIC,2700pF,50V,5%,X7R,S0805
CAPACITOR,CD,.0047,3000V,20%
CAPACITOR,ALEL,22,63V,20%

T11577-52K

S25040-1SMT

CAPACITOR,CD,.0047/.005,1400V,20%

DIODE,SMD,1A,400V,FAST RECOVERY,DO-214BA

S25040-5SMT

DIODE,SMD,DUAL,0.200A,70V,UFR

S25040-2SMT

DIODE,SMD,1A,400V,DO-214BA/AC

4
1
3
2
1
2
2
1
1
1
1
1
1
5
1
2
3

S25040-10SMT
S17395-11
S25046-4SMT
S25046-3SMT
S25046-1SMT
S25045-1SMT
S25044-3SMT
S24020-2G
S24020-8
S24020-12
S24020-4
S24020-6
S18248-4
T12218-9
T13657-2
T13657-14
T13657-3

DIODE,SMD,3A,400V,D0-214AB
LED,DISPLAY,7-SEGMENT,CC,3-DIGIT
ZENER DIODE,SMD,0.5W,12V,5%,SOD-123
ZENER DIODE,SMD,0.5W,18V, 5%,SOD123
ZENER DIODE,SMD,0.5W,5.1V, 5%,SOD123
ZENER DIODE,SMD,225mW,12V,5%,SOT-23
ZENER DIODE,SMD,3W,12V,5%, SMB
CONNECTOR,MOLEX,MINI,PCB,2-PIN,GOLD
CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,12-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,4-PIN
CHOKE,RF,390UH,5%, 225MA,CONFORMAL
LED,T-1,3/4,RED,HLMP-3003
LED,T-1,3/4,AMBER,HIGH-INTENSITY
LED,T-1,3/4,GREEN,HLMP-3502

S25080-1SMT

LED,SMD,RED,CLEAR,S1206

T13640-25

MOV,130VRMS,90J,20MM

7
1

S25080-2SMT
T13640-16
T13640-18

LED,SMD,GREEN,CLEAR,S1206
MOV,150VRMS,80J,20MM

MOV,320VRMS,150J,20MM

CAPACITORS= MFD/ VOLTS
RESISTORS = OHMS

N.A.

OCI1
OCI2, OCI3, OCI4, OCI5
Q1, Q6
Q2, Q3, Q5, Q7, Q9, Q10,
Q12, Q13, Q15, Q16,
Q17, Q18
Q4, Q8, Q11, Q14
R1, R2, R3
R4, R49, R50, R68, R69,
R72, R107, R122, R132,
R162, R184, R200
R5
R6
R7, R9, R111, R112,
R113, R135, R143, R145,
R147, R149, R172, R173,
R174, R178, R191, R196,
R197, R198
R8, R34, R203
R10, R11, R52, R53, R90,
R91, R103, R104
R12, R13, R14, R15, R26,
R27, R28, R29, R42, R43,
R44, R45, R55, R56, R57,
R58
R16, R17, R30, R31, R32,
R51, R60, R61, R92,
R167, R194, R195, R208,
R212, R215
R18
R19, R64, R157, R160,
R165, R170, R217, R218,
R219, R220
R20, R36, R41, R54
R21
R22
R23, R79
R24
R25, R75
R33, R38
R35, R84, R108, R109,
R139, R166
R37, R85, R106
R39, R81, R82, R98,
R128, R131, R177, R182,
R185, R187, R188, R210,
R211
R40, R46, R47, R73, R74,
R76, R77, R86, R96, R97,
R141, R142, R179, R180
R48, R199, R209, R213,
R214
R59, R136
R62
R63, R120
R65, R66, R94, R95,
R130, R137
R67
R70, R117, R119, R121,
R202, R204
R71
R78
R80, R83, R216
R87, R88, R89, R99,
R100, R101, R102, R205,
R206, R207
R93
R105, R110
R114
R115
R116, R153, R154
R118
R123, R133
R124, R125, R127, R171,
R181, R189
R126, R138
R129
R134
R140
R144, R146, R148, R150,
R186, R190, R192, R193
R151, R152, R155, R156,
R158, R159, R163, R164,
R168, R169, R175, R176
R161
R183
R201
S1
T1, T2
TRI1, TRI2, TRI3, TRI4
X1
X2
X3, X4, X14
X5
X6
X7
X8
X9
X10
X11
X12
X13

1
4
2

S15000-34SMT
S15000-16
S25051-11SMT

IC,SMD,OPTOCOUPLER,HMA124
OPTOCOUPLER,TRIAC,DRIVER,ZVC,3083
TRANSISTOR,SMD,NMF,DPAK,TO-252,48A,100V(SS)

4
3

S25050-2SMT
T10812-116

TRANSISTOR,SMD,PNP,SOT23,0.5A, 40V,MMBT4403LT1
POT,SINGLE-TURN,0.25W,10K,10%

12
1
1

S25050-1SMT

TRANSISTOR,SMD,NPN,0.5A,40V,SOT-23,MMBT4401LT1

S25000-1002SMT RESISTOR,SMD,METAL FILM,1/10W,10.0K,1%,S0805

S25000-1301SMT RESISTOR,SMD,METAL FILM,1/10W,1.30K,1%,S0805
S25000-1500SMT RESISTOR,SMD,METAL FILM,1/10W,150OHMS,1%,S0805

S25001-1001SMT RESISTOR,SMD,1K,1/4W,1206,1%,TR

S25000-6812SMT RESISTOR,SMD,METAL FILM,1/10W,68.1K,1%,S0805

S25003-1210SMT RESISTOR,SMD,1W,121OHMS,1%

S25000-1001SMT RESISTOR,SMD,METAL FILM,1/10W,1.00K,1%,S0805

S25000-5622SMT RESISTOR,SMD,METAL FILM,1/10W,56.2K,1%,S0805

4
1
1
2
1
2
2

S25003-15R0SMT
S25000-7681SMT
S25000-4752SMT
S25000-2213SMT
S25001-2210SMT
S25006-10R0SMT
S25008-1002SMT

S25004-1R00SMT RESISTOR,SMD,1W,1.00OHMS,1%

S25001-47R5SMT RESISTOR,SMD,47.5OHMS,1/4W,1206,1%,TR

RESISTOR,SMD,1W,15.0OHMS,1%
RESISTOR,SMD,METAL FILM,1/10W,7.68K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,47.5K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,221K,1%,S0805
RESISTOR,SMD,221OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/2W,10OHMS,1%,S2010
RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.5%,S0805

S25001-1000SMT RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR

S25000-3322SMT RESISTOR,SMD,METAL FILM,1/10W,33.2K,1%,S0805

S25000-4751SMT RESISTOR,SMD,METAL FILM,1/10W,4.75K,1%,S0805

S25001-4751SMT RESISTOR,SMD,4.75K,1/4W,1206,1%,TR

S25000-2210SMT RESISTOR,SMD,METAL FILM,1/10W,221OHMS,1%,S0805

S25008-4751SMT RESISTOR,SMD,PREC,MF,1/10W,4.75K,0.5%,S0805

2
1
2
1

1
1
3

10
1
2
1
1
3
1
2
6

2
1
1
1

12
1
1
1
1
2
4
1
1
3
1
1
1
1
1
1
1
1
1

S25000-4750SMT RESISTOR,SMD,METAL FILM,1/10W,475OHMS,1%,S0805
S25000-1000SMT RESISTOR,SMD,METAL FILM,1/10W,100OHMS,1%,S0805
S25000-8251SMT RESISTOR,SMD,METAL FILM,1/10W,8.25K,1%,S0805
S25000-1003SMT RESISTOR,SMD,METAL FILM,1/10W,100K,1%,S0805

S25000-3321SMT RESISTOR,SMD,METAL FILM,1/10W,3.32K,1%,S0805

S25000-1004SMT RESISTOR,SMD,METAL FILM,1/10W,1.00M,1%,S0805
S25001-1002SMT RESISTOR,SMD,10K,1/4W,1206,1%,TR
S25000-1212SMT RESISTOR,SMD,METAL FILM,1/10W,12.1K,1%,S0805

S25000-47R5SMT RESISTOR,SMD,METAL FILM,1/10W,47.5OHMS,1%,S0805
S25000-2671SMT
S25003-47R5SMT
S25000-6811SMT
S25000-2212SMT
S25003-2002SMT
S25001-4752SMT
S25000-2211SMT

RESISTOR,SMD,METAL FILM,1/10W,2.67K,1%,S0805
RESISTOR,SMD,1W,47.5OHMS,1%
RESISTOR,SMD,METAL FILM,1/10W,6.81K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,22.1K,1%,S0805
RESISTOR,SMD,1W,20.0K,1%
RESISTOR,SMD,47.5K,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,2.21K,1%,S0805

S25001-1213SMT
S25000-2001SMT
S25000-6813SMT
S25000-3323SMT

RESISTOR,SMD,121K,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,2.00K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,681K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,332K,1%,S0805

S25003-2000SMT RESISTOR,SMD,1W,200OHMS,1%

S25001-2670SMT RESISTOR,SMD,267OHMS,1/4W,1206,1%,TR
S25001-1821SMT RESISTOR,SMD,1.82K,1/4W,1206,1%,TR
S25001-7500SMT
S25000-1502SMT
S25001-2211SMT
T13381-16
T12737-2
S15161-27
S25073-12SMT
S15128-27SMT
S15128-28SMT
S15128-6
S15128-10SMT
M15102-4SMT
S15128-5SMT
S25072-2SMT
S15018-21SMT
S17900-24SMT
S25065-3SMT
S15018-11SMT

RESISTOR,SMD,750OHMS,1/4W,1206,1%,TR
RESISTOR,SMD,METAL FILM,1/10W,15.0K,1%,S0805
RESISTOR,SMD,2.21K,1/4W,1206,1%,TR
SWITCH,PUSHBUTTON,SPST
TRANSFORMER,PULSE,3-WINDING,1:1:1
TRIAC,TO220,8A,800V
IC,SMD,CMOS,PSOC,8-BIT,CY8C27643,TFN49(SS)
IC,OP-AMP,SINGLE,PRECISION,LT1097S8
IC,OP-AMP,SMT,QUAD,HIGH-PERF,33074ADT
IC,VOLT REG,FIXED,3-T,(+),1A,15V,TO220
IC,SMD,VOLTAGE REF,ADJ, PRECISION,431I,SOIC-8
IC,SMD,ARRAY,DRIVER,PERIPHERAL,NPN,DARLINGTON
IC,VOLT REG,SMD,FIXED,3-T,(+),1A,5V
IC,SMD,ACT,BUFFER,OCTAL,3-STATE,TSSOP-20(SS)
IC,SMD,CMOS,DRIVER,MOSFET,4451, SOIC-8(SS)
IC,SMD,CMOS,GATE,NAND,2-INPUT,QUAD,SCHM(SS)
IC,SMD,CMOS,INVERTER,SCHMITT,HEX,VHC14(SS)
IC,SMD,CMOS,SWITCH,ANALOG,QUAD,201(SS)

ALL COMPONENTS AND MATERIALS USED INTHIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

EN-170

Return to Master TOC

ITEM (USED WITH)*`
1
2 (TRI1, TRI3, X5)*
3 (TRI1, TRI3, X5)*
4 (TRI1, TRI3, X5)*
5 (TRI1, TRI3, X5)*
6
7
8

REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW

LED4

Return to Section TOC

CHANGE DETAIL: NEW

NOTE:

SCALE:

EQUIPMENT TYPE:

UNITS:

MATERIAL
DISPOSITION:

1:1.25

IF PRINTED
@ A1 SIZE

INCH

SUBJECT:

PRECISION TIG 185/225
CONTROL PC BOARD ASSEMBLY
APPROVAL
DATE:

2/15/2008

PROJECT
NUMBER:

CRM36266

REFERENCE:

G4551-1

2
2 OF ___
PAGE ___

DOCUMENT
NUMBER:

G5641-2

SOLID EDGE

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PC BOARD ASSEMBLY - CONTROL #2 (G5641)

N.F.

Return to Section TOC

G-8

ELECTRICAL DIAGRAMS
G5641-2

Return to Section TOC

G-8

DOCUMENT
REVISION:

Insight

PRECISION TIG® 225

SCHEMATIC - BYPASS PRINTED CIRCUIT BOARD (S22530)
ENGINEERING CONTROLLED
MANUFACTURER: No

CHANGE DETAIL: NEW

ARC STABILIZER CAPACITOR

Return to Master TOC

Return to Section TOC

C1
.05
600V

CONNECTION MADE THROUGH
HOLE WITH SOLDER PAD
C2
.05
600V

C3
.05
600V

C4
.05
600V

TP1
320V
160J

TP2
320V
160J

C5
.05
600V

C6
.05
600V

C7
.05
600V

C8
.05
600V

Graphic

GND

Return to Master TOC

GND CONNECTION MADE THROUGH SOLDER PAD
AND SCREW TO STEEL STANDOFF ON MACHINE

DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION

ON 2 PLACE DECIMALS IS ± .02

ON 3 PLACE DECIMALS IS ± .002

DRAWN BY:

DO NOT SCALE THIS DRAWING

APPROVED:

ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.

EN-164

Return to Master TOC

Return to Section TOC

15
250V

CONNECTION MADE THROUGH
HOLE WITH SOLDER PAD

Graphic

Return to Section TOC

ARC STABILIZER RESISTOR

ENGINEER:

FEI

REFERENCE:

S22530
SCALE:
NONE

EQUIPMENT TYPE:
SUBJECT:

MATERIAL
DISPOSITION:

APPROVAL
DATE:

BYPASS/STABILIZER BOARD
SCHEMATIC
08/26/2002

PROJECT
NUMBER:

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

CRM34563

1
1 OF ___
PAGE ___

DOCUMENT
NUMBER:

S22530-1B0

DOCUMENT
REVISION:

STRP

SOLID EDGE

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G-9

ELECTRICAL DIAGRAMS

S22530-1B0

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G-9

PRECISION TIG® 225

Return to Master TOC

G-10

ELECTRICAL DIAGRAMS

PC BOARD ASSEMBLY - BYPASS (L10121)
L10121-3

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G-10
ENGINEERING CONTROLLED
MANUFACTURER: No

CHANGE DETAIL: REVISED P.C. BOARD BLANK INFORMATION

REFERENCES
C1, C2, C3, C4, C5, C6, C7, C8

QTY
8

R1
TP1, TP2

P.C. BOARD BLANK INFORMATION

BUY COMPLETE AS L10121-D (2 LAYER BOARD PER E3281
WITH LEAD FREE HASL SURFACE FINISH).
MAKES 12 BOARDS PER PANEL.

1
2

SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION

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REQ'D

.16 OZ

PART NO.

SEE BLANK INFO.
E2861

IDENTIFICATION

P.C. BOARD BLANK
SEALANT

N.F., N.G.
1.00

4.50 ±.04

3.80±.04

(.438)

N.C.,
N.D.

(3.450)

BYPASS/STABILIZER

XXX XXXXXXXXXXXXX

L10121-3

(.338)

TP2

XXXXXXXXXXX

XXX
XXX
TP1

N.H.

XXXXXXXXXXX
C2

Return to Master TOC

XXXXXXXXXXX

(1.900)

XXXXXXXXXXXXXXXXXXXXXXXXXXXXX

XXXXXXXXXXXXX

XXXXXXXXXXXXXXXXXXXXXXXXXXXXX

(3.462)

Return to Section TOC

CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRYS

ITEM
1

Return to Section TOC

PART NUMBER DESCRIPTION
T11577-58K
CAPACITOR,CD,.0047,3000V,20%
CAPACITOR,POLYPROPYLENE METALLIZED
S13490-155
FILM,PPMF,15MF,250VAC,10%
T14648-25
RESISTOR,WW,5W,10,5%,SQ
T13640-18
MOV,320VRMS,150J,20MM

MANUFACTURED AS:

NOTES:

N.C. SQUEEZE TOGETHER ITEMS C1-C4, TP1 AND
C5-C9, TP2 BEFORE APPLYING SEALANT.

L10121-3D0

N.D. APPLY SEALANT AS SHOWN.

IDENTIFICATION CODE

N.F. KEEP THIS AREA FREE OF ENCAPSULATION, TOP AND
BOTTOM OF BOARD.

(.350)

N.G. TIN ALL EXPOSED COPPER WITH SOLDER IN THIS AREA,
BOTH SIDES OF BOARD.

MAKE PER E1911-ROHS

ENCAPSULATE WITH E1844,
2 COATS.
TEST PER E3553-B

N.H. NO ICICLES OR SOLDER BLOBS ARE PERMITTED
WITHIN 0.5" 0 (BOTH SIDES).

SCHEMATIC REFERENCE: S22530-3D0

(4.250)

FOR PARTS ORDERS ONLY:
INCLUDE S22772PRINT

NOTE:

MANUFACTURING TOLERANCE PER E2056 CONTROL:
CLEVELAND
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
fivory
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER:
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
APPROVED:
-

DO NOT SCALE THIS DRAWING

SCALE:
1:1

IF PRINTED
@ A2 SIZE

UNITS:

INCH

SW TIG 175 & 275
BYPASS/STABILIZER P.C. BOARD ASSEMBLY

EQUIPMENT TYPE:
SUBJECT:

MATERIAL
DISPOSITION:

APPROVAL
9-7-2007
DATE:

PROJECT
NUMBER:

CRM34432

REFERENCE:

L10121-1

1
1 OF ___
PAGE ___

DOCUMENT
NUMBER:

L10121-3

SOLID EDGE

EN-168

Return to Master TOC

Return to Section TOC

ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.

DOCUMENT
REVISION:

Insight

PRECISION TIG® 225

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Lincoln Electric Precision Tig Svm186 A Users Manual

SVM186-A to the manual 3f515961-cb22-4d7c-af7c-21c47f215bfc

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