SVM186-A
October, 2008
PRECISION TIG® 225
For use with machine code numbers:
11317, 11318, 11319
(11320 Ready-Pak)
(11321 Ready-Pak w/Cart)
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.888.935-3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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SAFETY
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.
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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases.When welding, keep
• AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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.
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.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-
cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
3.g. Never dip the electrode in water for cooling.
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.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
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.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
Aug ‘06
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
process used and properly operating
regulators designed for the gas and
the
welding
sparks
from
starting
sparks
a
fire.
hot
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
Remember
that welding
and
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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
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.
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.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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).
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.
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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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.
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.h. Also see item 1.c.
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.
6.j. Do not use a welding power source for pipe thawing.
Jan ‘07
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SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ
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 suiv-
antes:
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.
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.
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 met-
allique 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 defonc-
tionnement.
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.
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.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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.
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 rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
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.
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.
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 debranch-
er à l’interrupteur à la boite de fusibles.
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, pan-
talons sans revers, et chaussures montantes.
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 com-
plete 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 equip-
ment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
L10093
3-1-96H
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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
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommen-
dations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of 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 equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
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 con-
nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capaci-
tance, selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
1
tions.
_________________________
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
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
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
A-1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2,A-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Select Suitable Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Environmental Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
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
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
Stick Electrode Cable and Work Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
PRECISION TIG® 225
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INSTALLATION
TECHNICAL SPECIFICATIONS - PRECISION TIG® 225 (K2533-1AND K2535-1,-2)
INPUT - SINGLE PHASE ONLY
Standard Voltage
Power Factor
Input Current at Rated Output
Idle Current
3.0A/2.7A Max.
42A / 39A Effective
208/230/1/60
0.62 Min.
and 94A / 85A Maximum
OUTPUT RANGE
Maximum Open
Circuit Voltage
(STICK AND TIG)
AC OCV: 75
Output Current
Range
Type of Output
CC (Constant Current)
AC/DC
5-230 Amps (AC)
5-230 Amps (DC)
DC OCV: 66
RATED OUTPUT
Process Duty Cycle**
GTAW
Weld Current*
Weld Voltage (NEMA)
10% Duty Cycle
20% Duty Cycle
100% Duty Cycle
225A AC/DC
180A AC/DC
15.7 V AC/DC
15.2 V AC/DC
14.1 V AC/DC
14.0 V AC/DC
90A AC/DC (BAL.)
80A AC (AUTO-BAL.)
SMAW
10% Duty Cycle
20% Duty Cycle
100% Duty Cycle
225A AC/DC
180A AC/DC
90A 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 Limits1
2 input supply
Using provided input cable for protected
100%
90%
80%
70%
AC/DC Stick & Bal.TIG
60%
50%
40%
30%
20%
10%
0%
with Max. Aux. load or
Auto-Bal. TIG w/o Aux.
AC Auto-Bal. TIG with
Max. Aux. Load
50 70 90 110 130 150 170 190 210 230
Output Amps
1 Output Limits allow for continuous max. rated load on 115vac auxiliary receptacle.
2 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
A-3
TECHNICAL SPECIFICATIONS -ICNASNTAADLIALNA(TKI2O53N3-2), INTERNATIONAL K2534-1)
K2533-2 INPUT (at Rated Output)
Voltage/Phase/Freq.
Current
Idle Current
Power Factor
460/575/1/60
18 A/15 A Effective
42 A/33 A Max.
1.3 A/1.0 A Max.
0.62 Min.
K2534-1 INPUT (at Rated Output)
Voltage/Phase/Freq.
Current
Power Factor
0.62 Min.
Idle Current
380/400-415/1/50/60
N80
21 A/20 A Effective
50 A/48 A Max.
1.5 A/1.4 A Max.
OUTPUT RANGE
Output Type
Max. OCV.
Weld Current
CC (Constant Current)
AC or DC
75 V (AC)
66 V (DC)
5-230 A (AC)
5-230 A (DC)
RATED OUTPUT
Process Duty Cycle**
Weld Current*
Weld Voltage (NEMA)
SMAW
15%
225 A AC/DC
180 A AC/DC
90 A AC/DC
29.0 V
27.2 V
23.4 V
20%
100%
GTAW
10%
225 A AC/DC
180 A AC/DC
15.7 V
15.2 V
14.1 V
14.0 v
20%
100%
90 A AC/DC (Bal.)
80 A AC (Auto-Bal.)
* Inputs and ratings include a 6 amp rated load on the 115vac receptacle.
** Based on a 10 minute cycle.
PHYSICAL DIMENSIONS (2)
MODEL
HEIGHT
WIDTH
DEPTH
WEIGHT
Machine Only
(K2533-1,-2)
(K2534-1)
20.71 in.
526 mm
14.48 in.
368 mm
Approx. 192 lbs.
87.1 kgs
25.62 in.
751 mm
Ready-Pak
(K2535-1)
20.71 in.
526 mm
14.48 in.
368 mm
Approx. 212lbs..
96.2 kgs.
25.62 in.
651 mm
Ready-PakW/Cart
(K2535-2)
31.24 in.
794 mm
19.81 in.
503 mm
Approx. 258lbs.
117.0 kgs.
38.01 in.
966 mm
(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
A-4
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 instruc-
tions 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.
SAFETY PRECAUTIONS
Read entire installation section before starting
installation.
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
WARNING
Do not attempt to lift the power
source with an undercarriage
attached.
• 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.
----------------------------------------------------------------------------
The undercarriage is designed for hand moving only;
mechanized movement can lead to personal injury
and/or damage to the PRECISION TIG® 225.
SELECT SUITABLE LOCATION
MOUNTING
TILTING
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.
Each machine must be placed on a secure, level sur-
face, either directly or on a recommended undercar-
riage. The machine may topple over if this procedure is
not followed.
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 mainte-
nance problems.
STACKING
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
A-5
INSTALLATION
The ground should be securely made and the ground-
ing cable should be as short as possible using cable of
the same size as the work cable, or larger. Grounding
to the building frame electrical conduit or along pipe
system can result in re-radiation, effectively making
these members radiating antennas.
MACHINE GROUNDING AND HIGH FRE-
QUENCY 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.
6. Keep covers and all screws securely in place.
7. Electrical conductors within 50 ft (15.2m) of the welder
should be enclosed in grounded rigid metallic conduit
or equivalent shielding, wherever possible. Flexible
metallic conduit is generally not suitable.
This welder must be grounded! See your local and
national electrical codes for proper grounding meth-
ods.
The high frequency generator, being similar to a radio
transmitter, may cause radio, TV and electronic equip-
ment interference problems. These problems may be the
result of radiated interference. Proper grounding methods
can reduce or eliminate radiated interference.
8. When the welder is enclosed in a metal building,the
metal building should be connected to several good
earth driven electrical grounds (as in 5 (b) above)
around the periphery of the building.
Failure to observe these recommended installation proce-
dures can cause radio or TV and electronic equipment
interference problems and result in unsatisfactory welding
performance resulting from lost high frequency power.
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.
INPUT AND GROUNDING CONNECTIONS
4. Interference from re-radiation of “pickup” by unground-
ed metallic objects.
Only a qualified electrician should connect the PRECI-
SION TIG® 225. Installation should be made in accor-
dance with the appropriate National Electrical Code, all
local codes and the information in this manual.
Keeping these contributing factors in mind, installing
equipment per the following instructions should minimize
problems.
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.
1. Keep the welder power supply lines as short as possi-
ble and enclose as much of them as possible in rigid
metallic conduit or equivalent shielding for a distance of
50 feet (15.2m). There should be good electrical con-
tact between this conduit and the welder case ground.
Both ends of the conduit should be connected to a dri-
ven ground and the entire length should be continuous.
2. Keep the work and electrode leads as short as possi-
ble and as close together as possible. Lengths should
not exceed 25 ft (7.6m). Tape the leads together when
practical.
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 begin-
ning of this section. Fuse the input circuit with the recom-
mended super lag fuses or delay type1 circuit breakers.
Using fuses or circuit breakers smaller than recommend-
ed may result in “nuisance” shut-offs from welder inrush
currents even if not welding at high currents.
3. Be sure the torch and work cable rubber coverings are
free of cuts and cracks that allow high frequency leak-
age.
4. Keep the torch in good repair and all connections tight
to reduce high frequency leakage.
5. The work 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.
1
Also 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.
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.
PRECISION TIG® 225
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A-6
A-6
INSTALLATION
INPUT RECONNECT PROCEDURE
INPUT LEADS
L1 & L2
On multiple input voltage welders, be sure the machine
is connected per the following instructions for the volt-
age being supplied to the welder.
LEAD H1
(DO NOT
REMOVE)
CAUTION
Failure to follow these instructions can cause
immediate failure of components within the welder
and void machineʼs warranty.
FOR LOWEST RATED VOLTAGE
: H2 CONNECTED
FOR HIGHEST RATED VOLTAGE
: H3 CONNECTED
-----------------------------------------------------------------------
Multiple voltage models are shipped connected for
the highest voltage. To change this connection
refer to the following instructions.
BACK VIEW OF LIINE SWITCH
FIGURE A.1 Reconnect Leads
WARNING
ELECTRIC SHOCK can kill.
OUTPUT CONNECTIONS
• Turn the input power OFF at the dis-
connect switch or fuse box before
working on this equipment.
------------------------------------------------------------------------
For the lowest rated voltage connection (Refer to figure A.1):
1. Remove the sheet metal left side cover.
ELECTRODE/GAS
OUTLET
2. Disconnect lead H3 from the power switch and insu-
late with the insulation from the H2 lead.
RECEPTACLE
(TWIST-MATE)
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.
CONNECTIONS FOR TIG (GTAW) WELDING
2. Disconnect lead H2 from the power switch and insu-
late with the insulation from the H3 lead.
TIG TORCH CONNECTION
3. Connect lead H3 to the line switch where H2 was
connected.
Refer to Included Equipment in the Operation
Section of this manual for TIG welding equipment
which is included with the PRECISION TIG® 225.
4. Tighten connections.
5. Replace sheet metal cover and all screws.
PRECISION TIG® 225
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A-7
A-7
INSTALLATION
The available Under-Storage Cart features a low plat-
form that simplifies loading and unloading of gas cylin-
ders.
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
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.
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.
------------------------------------------------------------------------
WORK CABLE CONNECTION
WARNING
A work cable with attached work clamp is factory con-
nected to the PRECISION TIG® 225. To minimize high
frequency interference, refer to Input and Ground
and High Frequency Interference Protection section
of this manual for the proper procedure on grounding
the work clamp and work piece.
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 con-
trols.
SHIELDING GAS CONNECTION
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.
CONNECTIONS FOR STICK (SMAW)
WELDING
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
“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
A-8
NOTES
PRECISION TIG® 225
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B-1
B-1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Graphic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
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
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
Recommended Electrode Amperage Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
PRECISION TIG® 225
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B-2
B-2
OPERATION
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
SAFETY PRECAUTIONS
Read and understand this entire section before operat-
ing the machine.
INPUT POWER
WARNING
ELECTRIC SHOCK
can kill.
POSITIVE OUTPUT
NEGATIVE OUTPUT
•
Do not touch electrically live parts
or electrode with skin or wet cloth-
ing.
•
Insulate yourself from work and
ground.
• Always wear dry insulating gloves.
DIRECT CURRENT
•
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.
PROTECTIVE
GROUND
--------------------------------------------------------------------------------
FUMES AND GASES
can be dangerous.
WARNING OR
CAUTION
• 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.
DO NOT SWITCH
WHILE WELDING
------------------------------------------------------------------------
WELDING SPARKS can cause fire or
explosion
SINGLE PHASE
• Keep flammable material away.
• Do not weld on containers that
have held combustibles.
TRANSFORMER AC AND
RECTIFIER DC POWER
SOURCE
------------------------------------------------------------------------
ARC RAYS can burn.
• Wear eye, ear and body
protection.
OFF
------------------------------------------------------------------------
Observe additional Safety Guidelines detailed in
the beginning of this manual.
ON
------------------------------------------------------------------------
PRECISION TIG® 225
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B-3
B-3
OPERATION
PROCESS LIMITATIONS
PRODUCT DESCRIPTION
The PRECISION TIG® machines are not recommended for
arc gouging due to its limited output capacity, and are also
not recommended for pipe thawing.
The PRECISION TIG® 225 is a member of our field
acclaimed PRECISION TIG® family of industrial arc welding
power sources. Premium features include:
RECOMMENDED EQUIPMENT/INTERFACE
(See Installed Options in Accessories Section for
more details)
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.
The PRECISION TIG® 225 will be available as a basic
Machine (Only) and in two Factory-Configured Welding
Packages:
4. Built-in high frequency stabilization for DC TIG starting
and continuous AC TIG welding.
1. Machine(Only) (K2345-1)
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.
2. Ready-Pak (K2347-1)
3. Ready-Pak w/Cart (K2347-2)
Basic module will also be available with Domestic, Canadian
and International input voltages for user configuration, with
optional accessories.
Select Machine
208/230/1/60 Machine with NEMA 6-50P
Plug Cable and Receptacle (K2533-1)
460/575/1/60 Machine only with cable (K2533-2)
380/400/415/1/50/60 Machine only
with cable (K2534-1)
The PRECISION TIG® 225 also provides advanced features
such as:
• Digital Meter
• Presettable control, adjustable Auto Balance™
• Fan As Needed (F.A.N.)
Torch Starter Kit
(Select one)
Air Cooled System:
TIG-Mate
Water Cooled System:
TIG-Mate 20
• Timers for fixed Preflow and variable Postflow shielding
gas.
Torch Starter Kit*
Not Applicable
Torch Starter Kit*
115V 50/60Hz
Water Cooler
Cool-Arc 40*
• 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.
Under-Storage
Cart (Optional )
Optional Remote
Trigger Device
(Select one)
K2348-(*)
Arc Start Switch*
Foot Amptrol*
Start Pedal Foot Amptrol*
Hand Amptrol*
*For “Part Numbers” or “K Numbers” see Accessories Section.
EQUIPMENT LIMITATIONS
Four models are available for 60Hz. with Domestic and
Canadian input voltages, as well as an International model
with 50/60Hz voltages.
The PRECISION TIG® machines are protected from over loads
beyond the output ratings and duty cycles, per the Specifications
in the Installation Section, with Thermostat protection of the out-
put power coils and rectifiers.
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 (K2534-
1) models are rated 6 amps, while the 208/230/1/60 models
(K2533-1 and K2535-1/-2) are rated 20 amps (for use with
Lincoln’s 115v SP and Power MIG models).
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.
RECOMMENDED PROCESSES AND EQUIP-
MENT
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.
RECOMMENDED PROCESSES
WELDING CAPABILITY(Duty Cycle)
The PRECISION TIG® 225 is recommended for the TIG
(GTAW) and Stick (SMAW) welding processes within its out-
put capacity range of 5 amps DC or AC to 225 amps AC/DC.
It is compatible with most Magnum TIG accessories, as well
as many industry standard items, such as TIG torches
(adapted for Twist-Mate™), hoses, and water coolers.
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
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
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
1. POWER SWITCH
13
9
5
2. POLARITY SWITCH
3. MODE SWITCH
4. AC BALANCE CONTROL
3
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
4
12. WORK CABLE
13. REMOVABLE LIFT EYEBOLT
6
7
8
1
2
11
12
10
• 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.
CONTROL FUNCTIONALITY
1. POWER SWITCH – Input line switch turns input
power ON or OFF, as indicated by the on or off sta-
tus of the front panel digital display (See Item 6, also
see the following page for Power-Up Sequence).
5. MAXIMUM OUTPUT CONTROL – Presets the out-
put welding current over the rated output range of
the machine:
2. POLARITY SWITCH – The rotary power switch has
3-positions for DC+, AC and DC- selections for the
electrode output stud welding polarity.
• With a Remote Current Control (Amptrol) connect-
ed to the Remote Receptacle (See item 10), this
knob sets the Maximum output current level set
table with the remote Amptrol.
CAUTION
• Do not switch the polarity switch
while welding or damage may result
to the machine.
• For Pulse TIG (See Item 8) this knob sets the
Peak Pulse level, with the Remote Amptrol (if
used).
6. DIGITAL METER – A 3 digit LED meter is used to
display the preset output current level before weld-
ing, and actual output level while welding:
• A lit display indicates input power is turned on.
(See Item 1).
------------------------------------------------------------------------
3. MODE SWITCH – The push button switch allows
selection of the two machine welding modes as indi-
cated by colored mode lights:
• STICK mode – Top position Red light.
• TIG mode – Bottom position Green light.
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.
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:
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.
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B-5
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:
POWER-UP SEQUENCE
When the PRECISION TIG® 225 Power switch is ini-
tially turned On , the following will be observed:
(Refer to this Section Controls and Settings Figure
B.1)
• 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%.
• 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.
A Green light "blinks" with each Peak Pulse to indi-
cate the Pulse TIG Control setting before and dur-
ing welding.
9. THERMAL SHUTDOWN LIGHT This Yellow LED
panel light turns on if the machine output is shut-
down because internal overheating has occurred,
and turns off when cooled to reset.
10. REMOTE RECEPTACLE – Provides for connec-
tion of remote control and/or arc start switch only in
TIG Mode: (There is no remote output control
capability when stick welding).
• Plugging a remote current control (Amptrol) into
this receptacle automatically switches the output
control from the panel Max Output Control (See
Item 5) to the remote control.
• The connected remote control will then control the
output current between the Min. range of the
machine and the setting of the panel Max Output
Control.
• Switching Mode Switch (See Item 3) to Stick will
automatically disable the connected remote con-
trol and switch the output control back to the Max
Output panel control.
11. ELECTRODE/GAS OUTPUT RECEPTACLE -
This quick connect Twist-Mate™ receptacle pro-
vides electrical connection to the electrode holder
and cable for Stick welding and a combined electri-
cal and gas connection for the TIG torch when TIG
welding.
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
the Installation section of this manual for the prop-
er procedure on grounding the work clamp and
work piece to minimize high frequency interfer-
ence.
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B-6
B-6
OPERATION
CASE REAR COMPONENTS
FIGURE B.2
4
3
5
1
2
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 right-
hand thread female fitting for connection of input gas
supply.
3. COOLING AIR VENTS – Air is drawn in through the
upper vents and exhausted out through the lower
vents. The louver baffle steers exhaust air down and
prevents it from re-entering the upper vents.
4. MACHINE RATING PLATE
5. RECEPTACLE AND CIRCUIT BREAKER-115vac
auxiliary NEMA 6-20R .
PRECISION TIG® 225
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B-7
B-7
OPERATION
OPERATING STEPS
WELDING IN TIG MODE
1. Connect the TIG torch and cable Twist-Mate™ quick
connect plug to the Electrode/Gas output recepta-
cle. This receptacle also contains an integral gas
connection for the torch. Connect the work clamp to
the work piece.
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.
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.
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 con-
tinue for the time set by the Post Flow Time
control. When the polarity switch is set to DC,
the TIG Arc Starter will turn on and off auto-
matically to start and stabilize the arc. In AC the
TIG Arc Starter will turn on with the output and
remain on continuously until the remote control
is released.
PULSE TIG CONTROL
Use this knob to set the frequency or the number of
pulses per second(pps), from 0.1pps to 20pps.
• This setting adjusts heat output and bead shape for
travel speed. Thinner plate that is welded with faster
travel speed will require higher frequency than thick-
er plate with slower travel speed. 2-3pps is a typical
starting point.
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B-8
B-8
BENEFITS OF THE PRECISION TIG® 225 DESIGN
OPERATION
REMOTE CONTROL OPERATION
A Foot Amptrol is included with the PRECISION TIG®
225 Ready-Pak models and available for other models
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 por-
tion may also cause the electrode to overheat at high
currents causing “tungsten spitting”. The negative por-
tion of the AC wave offers no cleaning action but con-
centrates more heat on the work.
Both the Hand and Foot Amptrol work in a similar man-
ner. For simplicity, the following explanation will refer
only to “Amptrols”, meaning both Foot and Hand mod-
els. The term “minimum” refers to a foot pedal in the
“up” position, as it would be with no foot pressure, or a
Hand Amptrol in the relaxed position, with no thumb
pressure.
The AC waveform of the PRECISION TIG® 225 opti-
mizes cleaning and heating of the work. The result is
the capability to weld through the complete range in AC
TIG or DC- TIG requiring only one electrode, a 3/32”
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 elimi-
nate accidental high current damage to the work piece
and/or tungsten, and provides a fine control of the cur-
rent. When the welder is in the stick mode a remote
control has no effect and is not used.
It is important to note that, in some cases, the tungsten
will not start an arc at the minimum current because
the tungsten may be too large or cold. To start an arc
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” tung-
sten may be used on DC- to weld over the full range of
the machine.
To start the arc, the operator may have to turn the cur-
rent control up and depress the Amptrol approximately
1/4 of the way down. Depressing the Amptrol to its min-
imum position may not start the arc. Also if the current
control is set too low, the arc may not start. In most
cases, a large or cold tungsten will not readily establish
an arc at low currents. This is normal. In Direct Current
mode the PRECISION TIG® 225 will start a 3/32”, 2%
thoriated tungsten electrode at 15 amperes provided
the electrode tip is properly grounded and not contam-
inated.
PRECISION TIG® 225
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B-9
B-9
OPERATION
WELDING IN STICK MODE
5. Turn the power switch to “ON”.
6. Adjust the Current Control to the desired amps.
7. Strike an arc and weld.
1. Put the electrode holder and cable quick connect
plug into the electrode output receptacle. Turn clock-
wise until tight. Connect the work clamp to the work
piece.
NOTE: When the TIG/STICK switch is set to “STICK”
the output is always on when the power switch
is on. A remote control has no effect on the
welding current and the gas flow and high fre-
quency TIG arc starter are disabled.
2. Set the TIG/STICK switch to “STICK”.
3. Set the Polarity Switch to the weld mode desired for
the type of electrode being used (most commonly
DC+).
4. Place the electrode in the electrode holder.
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
DC+
3/32"
40 - 70
40 - 80
70 - 95
75 - 95
85 - 110
40 - 80
40 - 70
1/8"
5/32"
Fleetweld 5P, Fleetweld 5P+ E6010
75 - 130
55 - 110
100 - 135
100 - 145
110 - 160
75 - 110
60 - 100
90 - 175
105 - 135
145 - 180
135 - 200
130 - 200
95 - 150
90 - 140
Fleetweld 180
Fleetweld 37
E6011
E6013
E7014
E7018
DC+
DC+
Fleetweld 47
DC-
Excalibur
DC+
Blue Max Stainless
Red Baron Stainless
DC+
DC+
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
GTAW Process
Electrode Polarity
DC-
AC
Approximate Argon
Gas Flow Rate
C.F.H. (l/min.)
Sharpened
Balled
Electrode Tip Preparation
EWZr
Electrode Type
EWTh-1, EWTh-2
EWCe-2, EWLa-1
EWG
EWTh-1, EWCe-2
EWTh-2, EWLa-1
EWG
EWP
Stainless
Steel
(2-4) 3-8 (2-4)
Tungsten Size (in.)
Aluminum
.010
.020
.040
1/16
3/32
1/8
Up to 15 A.
Up to 15 A.
Up to 80 A.
Up to 150 A.
Up to MAX. A.
X
Up to 10 A.
Up to 15 A.
Up to 15 A.
Up to 20 A.
Up to 60 A.
Up to 130 A.
Up to MAX. A.
X
3-8
5-10
5-10
5-10
(3-5) 5-10 (3-5)
(3-5) 5-10 (3-5)
(3-5) 9-13 (4-6)
Up to 40 A.
Up to 100 A.
Up to 160 A.
Up to MAX. A.
13-17 (6-8) 11-15 (5-7)
15-23 (7-11) 11-15 (5-7)
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure..................................EWP........green
+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
TRI-MIX OF ELEMENTS.............EWG.........gray
Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.
PRECISION TIG® 225
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B-10
B-10
NOTES
PRECISION TIG® 225
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C-1
C-1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Standard Equipment Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Factory Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3
Field Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
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C-2
C-2
ACCESSORIES
2. PRECISION TIG® 225 Ready-Pak w/Cart (K2535-
STANDARD EQUIPMENT PACKAGES
2)
The PRECISION TIG® 225 will be available in two
Factory-Configured Welding Packages:
• 208/230/1/60 Machine (K2533-1)
• 9 ft.(2.7m) Input Cable with NEMA 6-50P Plug*
• NEMA 6-50R Receptacle
1. PRECISION TIG® 225 Ready-Pak (K2535-1)
• 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)
• 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*
• Under-Storage Cart (K2348-1)
• TIG Slide Rule ( WC332)*
* Included with K2533-1 Machine Only model.
• GTAW Book (JFLF-834)*
• Lift Eyebolt*
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)
Water Cooled System
Air Cooled System
Optional
Torch Starter Kit
(Select one)
K2267-1 TIG-Mate 20 Torch Starter Kit
K1813-1 115V 50/60Hz Cool-Arc 40
K2266-1 TIG-Mate Torch Starter
Not Applicable
Water Cooler
Not Applicable
K1813-1 115V 50/60Hz Cool-Arc 40
Optional Under-
Storage Cart
K2348-1
K814 Arc Start Switch
Optional Remote
Trigger Device
(Select one)
K870 Foot Amptrol
K963-3 Hand Amptrol
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C-3
C-3
ACCESSORIES
2. PRECISION TIG® 225 Ready-Pak w/Cart (K2535-
FACTORY INSTALLED OPTIONS
2)
The PRECISION TIG® 225 will be available in two
Factory-Configured Welding Packages:
• 208/230/1/60 Machine (K2533-1)
• 9 ft.(2.7m) Input Cable with NEMA 6-50P Plug*
• NEMA 6-50R Receptacle
1. PRECISION TIG® 225 Ready-Pak (K2535-1)
• 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
• 208/230/1/60 Machine (K2533-1)
• 9 ft. (2.7m) Input Cable with NEMA 6-50P Plug*
• NEMA 6-50R Receptacle
- 3/32 Collet (10N24)
• 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 Body (10N32)
- #7 Alumina Nozzle (10N47)
• Foot Amptrol (K870)
- 3/32 Collet (10N24)
• TIG Slide Rule (WC332)*
• GTAW Book (JFLF-834)*
• Lift Eyebolt*
- 3/32 Collet Body (10N32)
- #7 Alumina Nozzle (10N47)
• Foot Amptrol (K870)
• Under-Storage Cart (K2348-1)
• TIG Slide Rule ( WC332)*
• GTAW Book (JFLF-834)*
* Included with K2533-1 Machine Only model.
• Lift Eyebolt*
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)
380/400-415/1/50-60 Machine only with Cable (K2534-1)
Water Cooled System
Air Cooled System
Optional
Torch Starter Kit
(Select one)
K2267-1 TIG-Mate 20 Torch Starter Kit
Includes:
K2266-1 TIG-Mate Torch Starter
Kit Includes:
• 200A PTW-20 12.5 ft.(3.81m) Torch
• KP510 Parts Kit
• 150A PTA-17 12.5 ft.(3.81m) Torch.
• KP508 Parts Kit.
• Regulator & Hose
• Regulator & Hose.
• K1622-4 Twist Mate Torch Adapter
• Water Hose & Hose Coupler
• Work Cable & Clamp (Not required for
PRECISION TIG® 225)
• K1622-1 Twist Mate Torch Adapter.
• Work Cable & Clamp (Not required for PRECI-
SION TIG® 225)
K1813-1 115V 50/60Hz Cool-Arc 40
Not Applicable
Water Cooler
Optional Under-
Storage Cart
K2348-1
K814 Arc Start Switch
Optional Remote
Trigger Device
(Select one)
K870 Foot Amptrol
K963-3 Hand Amptrol
PRECISION TIG® 225
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C-4
C-4
ACCESSORIES
• Magnum “Pro-Torch™ TIG Torch” assemblies and
FIELD INSTALLED OPTIONS
Accessories.
Requires Twist-Mate™ Adapter:
K1622-1 for PTA-9/-17
The following Options/Accessories are available for the
PRECISION TIG® 225:
K1622-3 for PTA-26
K1622-4 for PTW water cooled torch
• 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)
• 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.
• K870 Foot Amptrol
Single pedal foot activation of arc start switch and
output control, with 25 ft.(7.6m) plug cable.
• K963-3 Hand Amptrol
Fastens to torch for convenient thumb activation of
arc start switch and output control, with 25 ft.(7.6m)
plug cable:
• K814 Arc Start Switch
Needed for TIG welding without an Amptrol. Includes
25 ft.(7.6m) plug cable, and attaches to torch for con-
venient finger control.
• TIG-Mate Torch Starter Kits:
Includes Torch with Twist-Mate adapter and acces-
sories listed below:
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
D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Spark Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Fan Motor or Fan Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
PRECISION TIG® 225
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D-2
D-2
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
Use extreme caution when working with a high fre-
quency circuit. The high voltages developed can
be lethal. Turn the input power off using the dis-
connect switch or fuse box before working inside
machine. This is particularly important when work-
ing on the secondary circuit of the high voltage
transformer (T3) because the output voltage is
dangerously high.
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should per-
form this maintenance.
• Turn the input power OFF at the dis-
connect switch or fuse box before
working on this equipment.
-----------------------------------------------------------------------
Refer to figure D.1. Note in highly dirty environments
where there is an abundance of conductive contami-
nant's, use a low pressure air stream or a firm piece of
paper to clean the spark gap. Do not disturb the facto-
ry setting.
• Do not touch electrically hot parts.
------------------------------------------------------------------------
To check the spark gap:
WARNING
- 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.
To avoid receiving a high frequency shock, keep
the TIG torch and cables in good condition.
------------------------------------------------------------------------
- Check the spark gap with a feeler gauge.
If adjustment is needed:
ROUTINE AND PERIODIC MAINTENANCE
- 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.
1. Disconnect power supply lines to machine before
performing periodic maintenance.
If the gap is correct:
2. Periodically clean the inside of the machine with a
low pressure air system. Be sure to clean the fol-
lowing components thoroughly.
• Main Transformer
- Replace the wraparound.
8. Inspect gas hose and inlet fitting for cracks or leaks.
9. Replace any unreadable labels or decal's.
• Electrode/Gas Output Receptacle
• Polarity Switch
• Rectifier Assembly
10. Verify that the machine and welding circuit is prop-
erly grounded.
• Arc Starter/Spark Gap Assembly
• PC Boards
FIGURE D.1 SPARK GAP
• Fan Blades
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 cool-
ing.
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.
6. The fan motor has sealed ball bearings which
require no maintenance.
7. SPARK GAP ADJUSTMENT
The spark gap .020(.5mm) is set at the factory to a
gap of 0.015 inches (0.4mm) See Figure D.1. This
setting is adequate for most applications. Where less
high frequency is desired, the setting can be reduced
to 0.015 inches (0.4mm).
.30ł
FIGURE D.2
PRECISION TIG® 225
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E-1
E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
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
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
MAIN
HI-FREQUENCY
TRANSFORMER
TRANSFORMER
INPUT
POWER
SWITCH
BYPASS
ASBLY
C
H
O
K
E
H1
AC
SCR
BRIDGE
DC+
X1
X2
H2
H3
HIGH VOLTAGE
SHUNT
TRANSFORMER
CIRCUIT
DC-
AC
F
E
E
D
B
A
C
K
115VAC
18VAC
18VAC
115VAC
CONTROL
BOARD
POWER
"ON"
115 VAC
FAN
DIGITAL
DISPLAY
Receptacle
Circuit Breaker
Protected
MODE
SWITCH
REMOTE
RECEPTACLE
THERMO-
THERMAL
LIGHT
GAS
VALVE
OUTPUT
STATS
CONTROL
AC
BALANCE
AUTO
BALANCE
LED
PULSE
FREQ.
LED
STICK
TIG
POSTFLOW
CONTROL
PULSE
LED
LED
CONTROL
CONTROL
PRECISION TIG® 225
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 - General Description & Input Power Circuit
BY-PASS
BOARD
WORK
POLARITY
SWITCH
ELECTRODE
MAIN
HI-FREQUENCY
TRANSFORMER
TRANSFORMER
INPUT
POWER
SWITCH
BYPASS
ASBLY
C
H
O
K
E
H1
AC
SCR
BRIDGE
DC+
X1
X2
H2
H3
HIGH VOLTAGE
SHUNT
TRANSFORMER
CIRCUIT
DC-
AC
F
E
E
D
B
A
C
K
115VAC
18VAC
18VAC
115VAC
CONTROL
BOARD
POWER
"ON"
115 VAC
FAN
DIGITAL
DISPLAY
Receptacle
Circuit Breaker
Protected
MODE
SWITCH
REMOTE
RECEPTACLE
THERMO-
THERMAL
LIGHT
GAS
VALVE
OUTPUT
STATS
CONTROL
AC
BALANCE
AUTO
BALANCE
LED
PULSE
FREQ.
LED
STICK
TIG
POSTFLOW
CONTROL
PULSE
LED
LED
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 high-
The main transformer changes the high voltage, low
current input power to a low voltage, high current out-
put which is available at the main secondary winding
(X1 and X2). In addition three auxiliary windings are
incorporated in the main transformer. The 115VAC
winding supplies power to the fan motor, the 115 VAC
receptacle, and also, through the control board, pow-
ers the gas solenoid valve and the high voltage trans-
former. The 18VAC winding provides power to the trig-
ger circuitry. The other 18VAC winding is rectified and
regulated to a 15VDC supply which operates the cir-
cuitry on the control board.
er Maximum (225 amps) output control range.
4. Built-in high frequency stabilization for DC TIG
starting and continuous AC TIG welding.
5. AC/DC Stick (SMAW capability.)
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
PRECISION TIG® 225
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E-3
E-3
THEORY OF OPERATION
FIGURE E.2 - Output Rectification & Feedback Control
BY-PASS
BOARD
WORK
POLARITY
SWITCH
ELECTRODE
MAIN
HI-FREQUENCY
TRANSFORMER
TRANSFORMER
INPUT
POWER
SWITCH
BYPASS
ASBLY
C
H
O
K
E
H1
AC
SCR
BRIDGE
DC+
X1
X2
H2
H3
HIGH VOLTAGE
SHUNT
TRANSFORMER
CIRCUIT
DC-
AC
F
E
E
D
B
A
C
K
115VAC
18VAC
18VAC
115VAC
CONTROL
BOARD
POWER
"ON"
115 VAC
FAN
DIGITAL
DISPLAY
Receptacle
Circuit Breaker
Protected
MODE
SWITCH
REMOTE
RECEPTACLE
THERMO-
THERMAL
LIGHT
GAS
VALVE
OUTPUT
STATS
CONTROL
AC
BALANCE
AUTO
BALANCE
LED
PULSE
FREQ.
LED
STICK
TIG
POSTFLOW
CONTROL
PULSE
LED
LED
CONTROL
CONTROL
OUTPUT RECTIFICATION AND
FEEDBACK CONTROL
The AC output from the main transformer secondary is
rectified and controlled through the SCR bridge.
Output current is sensed at the shunt as a low voltage
signal and fed back to the control board. The control
board compares the commands of the mode switch,
output control, AC balance control, pulse control, post-
flow control, or remote control with the feedback infor-
mation. The appropriate SCR gate firing signals are
created by the control board and sent to the SCR
bridge. The control board controls the firing of the
SCRs, which control the output of the machine. See
SCR Operation. The control board monitors the ther-
mostats, and also controls the gas solenoid valve, ther-
mal light, auto balance LED, pulse frequency LED, TIG
LED, stick LED, and the digital display.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
PRECISION TIG® 225
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E-4
E-4
THEORY OF OPERATION
FIGURE E.2 - High Voltage/High Frequency Circuit.
BY-PASS
BOARD
WORK
POLARITY
SWITCH
ELECTRODE
MAIN
HI-FREQUENCY
TRANSFORMER
TRANSFORMER
INPUT
POWER
SWITCH
BYPASS
ASBLY
C
H
O
K
E
H1
AC
SCR
BRIDGE
DC+
X1
X2
H2
H3
HIGH VOLTAGE
SHUNT
TRANSFORMER
CIRCUIT
DC-
AC
F
E
E
D
B
A
C
K
115VAC
18VAC
18VAC
115VAC
CONTROL
BOARD
POWER
"ON"
115 VAC
FAN
DIGITAL
DISPLAY
Receptacle
Circuit Breaker
Protected
MODE
SWITCH
REMOTE
RECEPTACLE
THERMO-
THERMAL
GAS
OUTPUT
HIGH VOLTAGE / HIGH FREQUENCY
CIRCUIT
The control board passes the 115VAC voltage to the
primary of the high voltage transformer. The secondary
of the high voltage transformer is coupled to a spark
gap generator and also to the high frequency trans-
former. The high frequency transformer transfers the
high frequency “spark” to the electrode terminal which
is coupled to the TIG torch.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
PRECISION TIG® 225
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E-5
E-5
THEORY OF OPERATION
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
ELECTRODE
G
G
DC
PRIMARY
1Ø
G
G
WORK
FIGURE E.5 DC Welding Current Generation.
PRECISION TIG® 225
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E-6
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 con-
nected to one of the AC connections on the SCR bridge. The electrode terminal is connected to the other AC
side of the bridge. The choke is now electrically across the negative and positive SCR bridge connections. With
the ability of the choke to store energy and the SCRs to turn on at the appropriate times, an AC square wave is
developed and applied to the output terminals.
CHOKE
G
G
ELECTRODE
DC
G
G
PRIMARY
1Ø
WORK
FIGURE E.6 AC Square Wave Welding Current Generation.
PRECISION TIG® 225
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E-7
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 pass-
es current only during positive half cycles of the AC
supply. The positive half cycle is the portion of the
sine wave in which the anode of the SCR is more
positive than the cathode.
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 con-
trolled by the Gate.
An SCR is fired by a short burst of current into the gate.
This gate pulse must be more positive than the cath-
ode voltage. Since there is a standard PN junction
INPUT
CATHODE
OUTPUT
NOTE: AS THE GATE
PULSE IS APPLIED
LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.
ANODE
GATE
GATE
FIGURE E.7 SCR Operation
PRECISION TIG® 225
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E-8
E-8
THEORY OF OPERATION
Once the machine cools sufficiently the thermostats
are self-resetting. If the thermostat shutdown is caused
by excessive output or duty cycle and the fan is oper-
ating normally, the 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.
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 com-
ponents. Both thermal protection and current overload
are included. Fan as needed (F.A.N.) Fan runs for 5
seconds at power-up and stops at idle 8 minutes after
welding.
OVERLOAD PROTECTION
THERMAL PROTECTION
The machine is electronically protected from producing
excessively high output currents. The output is limited
to 200 amps.
OVER TEMPERATURE LIGHT-
If the welder
overheats due to blocked air flow, high ambient air
temperature, or exceeded duty cycle, an internal ther-
mostat will open disabling the welding output and this
yellow light will illuminate. The cooling fans will contin-
ue to run to cool the unit during this time. The light will
go out when the unit cools and the thermostat resets.
Once the light goes out, the machine will again
become available to weld.
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
F-1
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
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
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
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
Retest after Repair......................................................................................................................................F-55
PRECISION TIG® 225
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F-2
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.
---------------------------------------------------------------------------------------------------------------------------
Step 3. RECOMMENDED
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
COURSE OF ACTION
The last column labeled “Recommended
Course of Action” lists the most likely com-
ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com-
ponent is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos-
sible symptoms that the machine may exhib-
it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob-
lems, wire feeding problems, and welding
problems.
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.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
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-3
F-3
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield-
ing bag.
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.
- 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 prop-
er failure analysis.
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
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.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board
to assure that the PC board is properly
connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
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:
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.
PC board can be damaged by static electricity.
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.
- Remove your body’s static
charge before opening the static-
shielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
grounded part of the
ATTENTION
Static-Sensitive
Devices
equipment frame.
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.
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
Handle only at
Static-Safe
Workstations
- 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
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
1. Make sure that the input power
switch is in the "ON" position
and the machine is plugged in.
Machine is dead. No output - No
fan - No 115 VAC at receptacle.
1. Check the input power switch
and associated wires for loose
or faulty connections.
2. Perform the T1 Transformer
2. Check the input voltage at the
machine. Input voltage must
match the rating plate and volt-
age connection. Refer to
Reconnect Procedure in the
Installation section of this manu-
al.
Test.
3. Blown or missing fuses in the
input line.
4. CB-1 circuit breaker open.
1. Check for loose or faulty con-
nections on the heavy current
carrying leads. (polarity switch,
output choke output terminals
etc.)
1. Check for proper input voltages
per nameplate and voltage
reconnect configuration.
The fan runs normally. No output
from the machine in either Stick or
TIG modes.
2. Check to make sure the polarity
switch is in the proper position
and functioning correctly.
2. Perform the T1 Transformer
Test.
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
Observe Safety Guidelines detailed in the beginning of this manual.
F-5
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
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. One of the thermostats may be
faulty. Check or replace. See
wiring diagram.
1. The welding application may
have exceeded the recommend-
ed duty cycle. Allow the unit to
run until the fan cools the unit
and the yellow light goes out.
2. Check for loose or faulty wires
on the thermostats and associ-
ated circuitry. See wiring dia-
gram.
2. The air louvers may be blocked.
Remove air obstruction and
allow unit to cool.
1. Check the continuity (zero
ohms) of the leads between the
remote receptacle and plug J5
on the control board. See
wiring diagram.
1. Make certain the machine is in
the TIG mode.
The machine does not respond (no
gas flow, no high frequency and no
open circuit voltage) when the arc
start switch or Amptrol is activated
- fan is working normally.
2. The Amptrol may be defective.
Check for continuity(zero ohms)
between pins "D" and "E" on
cable connector when the
2. Perform the T1 Transformer
Test.
Amptrol is depressed.
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
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
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.
1. The thermostat(s) may be
faulty. Check or replace.
Machine regularly over heats - ther-
mostat opens. Yellow light on front
panel glows. The fan runs but the
machine has no output.
2. The control board may be
faulty.
1. Check the Stick/TIG switch(S3)
and associated leads. See
wiring diagram.
The machine does not have output
in the Stick mode. The machine
operates correctly in the TIG mode.
The machine does not have output
in the Stick mode. The machine
operates correctly in the TIG mode.
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
Observe Safety Guidelines detailed in the beginning of this manual.
F-7
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
1. If welding in the TIG mode the
remote control device may be
defective.
Machine welds at a very low out-
put regardless of the current con-
trol setting.
1. Check the polarity switch and
associated leads.
2. Check the interior connections
of the heavy current carrying
leads.
2. Make certain the input line volt-
age is correct for the machine
reconnect configuration.
3. Perform the SCR Bridge Test.
3. Check the welding cables and or
torch for loose or faulty connec-
tions.
4. Perform the T1 Transformer
Test.
5. Check the current control for
proper operation. Normal
resistance is 10k ohms. See
wiring diagram.
6. The control board may be
faulty.
1. Perform the SCR Bridge Test.
1. If welding in the TIG mode the
remote control device may be
defective.
The machine welds at a very high
output regardless of the current
control setting.
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
Observe Safety Guidelines detailed in the beginning of this manual.
F-8
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
Machine output is intermittently
lost. Gas flow and high frequency
are also interrupted.
1. Check for loose or faulty con-
nection on the leads between
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 cer-
tain that they are grounded
properly.
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
faulty.
2. Make sure the Amptrol is operat-
ing properly.
3. Check to make sure that the
input voltage is correct for the
machine reconnect configura-
tion. Refer to Reconnect
Procedure in the Installation
section of this manual.
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
Observe Safety Guidelines detailed in the beginning of this manual.
F-9
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
1. The tungsten electrode may be
too large in diameter for the cur-
rent setting.
The arc "flutters" when TIG weld-
ing.
1. Check the polarity switch for
proper operation and loose or
faulty lead connections. See
wiring diagram.
2. The tungsten tip may not be
"sharp" enough.
2. Perform the SCR Bridge Test.
3. Check for loose or faulty con-
nections at the shunt. ( leads
#221 and #222 ).
3. The gas shielding may be insuf-
ficient. Increase the gas flow
and or reduce the tungsten
4. Check components R3 and C4
in the high voltage transformer
primary circuit. Replace if nec-
essary. See wiring diagram.
stickout beyond the gas cup.
4. Check for contaminated gas or
leaks in the gas line, torch, or
connections.
5. The control board may be
faulty. Replace.
5. If a helium blend is used as a
shielding gas then reduce the
percentage of helium.
1. Check the micro switch S2A on
the polarity switch. It may be
stuck closed. See wiring dia-
gram.
1. Make sure the gas and proce-
dure are correct for the process
being used.
The arc "pulsates" when AC TIG
welding.
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
Observe Safety Guidelines detailed in the beginning of this manual.
F-10
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
Black areas along weld bead.
1. This may be a welding proce-
dure problem.
1. Clean any oily or organic conta-
mination from the work piece.
Contact The Lincoln Electric
Service Department, 1-888-935-
3877.
2. Tungsten electrode may be con-
taminated. Replace or sharpen.
3. Check for contaminated gas or
leaks in the gas line, torch, or
associated connections.
4. The gas shielding may be insuf-
ficient. 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.
1. Check for loose or faulty con-
nections at the torch and/or
welding cables.
Weak high frequency - machine
has normal welding.
2. The gas shielding may be insuf-
ficient. Increase gas flow:
reduce tungsten stickout beyond
the gas cup.
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
this manual.
3. If spark is weak at the spark
gap, check or replace the high
frequency circuit.
(Examples: T3, L3, L4).
4. The work and electrode cables
may be in poor condition allow-
ing the high frequency to "leak
off". Use good quality cables
with a high natural rubber con-
tent, such as Lincoln Stable Arc
Cable. Cables should be as
short as possible.
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
Observe Safety Guidelines detailed in the beginning of this manual.
F-11
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
High frequency "spark" is present
at tungsten electrode, but operator
is unable to establish a welding
arc. Machine has normal open cir-
cuit voltage. Refer to Technical
Specifications in the Installation
Chapter.
1. This may be a welding proce-
dure problem.
1. The torch may be faulty. Check
or replace.
Contact The Lincoln Electric
Service Department 1-888-935-
3877.
2. The current control may be set
too low.
3. The tungsten electrode may be
contaminated. Replace or
sharpen.
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.
F-12
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
No high frequency. Machine is in
the TIG mode and has normal out-
put.
1. Check the high voltage trans-
former (T3). The normal resis-
tance of the secondary winding
of the high voltage transformer
is 12.5k ohms.
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.
WARNING
2. Check spark gap operation and
setting. Normal is (0.020").
Refer to Maintenance section
of this manual.
ELECTRIC SHOCK CAN
KILL. When 115VAC is
applied to the primary of T3. A
very high voltage is developed on
the secondary winding. For
assistance call the Lincoln Electric
Service Department 1-888-935-
3877.
----------------------------------------------
2. Check the values of R3, and
C4.
3. Perform the T1 Transformer
Test.
4. The control board may be
faulty. Replace.
1. Possible gas supply problems.
1. The gas supply is either empty
or not turned on.
No gas flow when Amptrol is acti-
vated in the TIG mode. Machine
has normal output - fan runs.
A "click" can be heard indicating
that the gas solenoid valve is oper-
ating.
Consult your local welder/gas dis-
tributor.
2. The flow regulator may be set
too low.
3. Check the gas hose for kinks or
blockages.
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
Observe Safety Guidelines detailed in the beginning of this manual.
F-13
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
When AC TIG welding, the arc is
erratic and there is a loss of
"cleaning" of the work piece.
1. Check components R3 and C4
in the high voltage transformer
primary circuit.
1. The tungsten electrode may be
too small for the process. Use
a larger diameter tungsten or a
pure tungsten.
2. Perform the SCR Bridge Test.
2. If a helium blend is used as a
shielding gas, then reduce the
percentage of helium.
1. This may be a welding proce-
dure problem.
1. The welding current is too high
for the electrode type and or
size. See Table B.1 in the
Operation Section.
The end of the tungsten electrode
melts away.
Contact The Lincoln Electric
Service Department 1-888-935-
3877.
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
Observe Safety Guidelines detailed in the beginning of this manual.
F-14
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
Stick electrode "Blasts Off" when
arc is struck.
1. Perform the SCR Bridge Test.
1. Weld current may be set too
high for electrode size. Reduce
current control setting, or use a
larger diameter electrode.
2. The control board may be
faulty. Replace.
1. The weld current may be set too
low. Increase the current control
setting or use a smaller diameter
electrode.
The stick electrode "sticks" in the
puddle.
Variable or sluggish welding arc
when welding in the Stick mode.
1. Check work and electrode
cables for loose or poor connec-
tions.
1. Check the polarity switch for
excessive wear or faulty connec-
tions.
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.
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
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will disable the high frequency circuit. The technician will then be able to
take voltage measurements without the possibility of high frequency damage to his test
equipment.
MATERIALS NEEDED
3/8” Nutdriver
5/64” Allen type wrench
.020” feeler gauge
WARNING
HIGH VOLTAGE IS STILL PRESENT IN THE HIGH FREQUENCY CIRCUIT.
----------------------------------------------------------------------------------------------------------------------
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F-16
F-16
TROUBLESHOOTING AND REPAIR
HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE (continued)
FIGURE F.1 – SPARK GAP ASSEMBLY
.020 Spark Gap
LEFT SIDE OF MACHINE
PROCEDURE
1. Remove input power to the TIG 225 machine.
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.
2. Using the 3/8” nutdriver remove the right side
panel.
3. Locate the Spark Gap Assembly at the right
side of the machine. See Figure F.1.
4. With the 5/64” Allen type wrench loosen the set
screw holding the upper electrode in place.
5. Increase the distance between the electrodes
to at least 3/8” by sliding one electrode away
from the other electrode. Secure the one elec-
trode in this position.
6. This should disable the high frequency circuit.
Visually check to make sure high frequency
sparking is NOT present before connecting
any test equipment to the TIG 225 machine.
PRECISION TIG® 225
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F-17
F-17
TROUBLESHOOTING AND REPAIR
T1 TRANSFORMER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the correct voltage is being applied to the primary of the
T1 transformer and also if the correct voltages are being induced on the secondary wind-
ings of the transformer.
MATERIALS NEEDED
Volt/Ohm Meter
PRECISION TIG® 225 Wiring Diagrams
3/8” nutdriver
PRECISION TIG® 225
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F-18
F-18
TROUBLESHOOTING AND REPAIR
T1 TRANSFORMER TEST (continued)
FIGURE F.2 – Plugs J3 & J4 on Control Board
PRECISION TIG 225 CONTROL BOARD
PIN 7 (LEAD #210)
PIN 8 (LEAD #209)
PIN 3 (LEAD #204)
PIN 4 (LEAD #201)
PIN 3 (LEAD #232)
PIN 2 (LEAD #260)
PROCEDURE
1. Remove main supply power to the machine.
2. Using the 3/8” nutdriver remove the case wrap-
around cover.
3. Locate plugs J3 and J4 on the
control board. See Figure F.2.
4. Carefully apply the correct input power making
certain the reconnect configuration at the input
switch is correct for the input voltage applied.
Turn the TIG 225 ON.
5. Using the voltmeter carefully test for the correct
transformer secondary voltages per Table F.1.
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F-19
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 sec-
ondary voltages are incorrect the T1 trans-
former 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.
TABLE F.1 T1 TRANSFORMER VOLTAGE
TEST POINTS
ACCEPTABLE VOLTAGES
SECONDARY VOLTAGES
SECONDARY WINDINGS
PLUG J3 PIN 8 (LEAD #210)
TO
18VAC
18VAC
PLUG J3 PIN 7 (LEAD #209)
PLUG J3 PIN 4 (LEAD #201)
TO
PLUG J3 PIN 3 (LEAD #204)
PLUG J4 PIN 2 (LEAD #260)
TO
CHECK DURING FIRST 5 SECONDS OF POWER UP
115VAC
PLUG J4 PIN 3 (LEAD #232)
X1 TO X2
PRIMARY WINDINGS
H1 TO H2
80 VAC
PRIMARY VOLTAGES
208VAC
H1 TO H3
230VAC
NOTE: If the input voltages vary the secondary voltages will vary accordingly.
PRECISION TIG® 225
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F-20
F-20
NOTES
PRECISION TIG® 225
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F-21
F-21
TROUBLESHOOTING AND REPAIR
STATIC SCR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure is a quick check to determine if an SCR is shorted or “leaky”. See
machine waveform section for normal and abnormal SCR waveforms.
MATERIALS NEEDED
Volt/Ohm Meter (Analog)
PRECISION TIG® 225 Wiring Diagrams
3/8” nutdriver
SCR Heat Sink Assembly Drawing
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F-22
F-22
TROUBLESHOOTING AND REPAIR
STATIC SCR TEST (continued)
FIGURE F.3 – Plug J2 Location on Control Board
PLUG J2 REMOVED
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.
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F-23
F-23
TROUBLESHOOTING AND REPAIR
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.4 – SCR TEST POINTS
SCR2 CATHODE
SCR3 CATHODE
SCR4 ANODE
SCR1 ANODE
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.
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F-24
F-24
NOTES
PRECISION TIG® 225
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F-25
F-25
TROUBLESHOOTING AND REPAIR
ACTIVE SCR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the device is able to be gated “ON” and conduct current
from anode to cathode.
MATERIALS NEEDED
An SCR tester as outlined in this procedure.
PRECISION TIG® 225 Wiring Diagrams
3/8” nutdriver
PRECISION TIG® 225
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F-26
F-26
TROUBLESHOOTING AND REPAIR
ACTIVE SCR TEST (continued)
FIGURE F.5 – ACTIVE SCR TEST SETUP
SW1
R2
V
R1
SW2
6volt
A
G
Lantern
Battery
SCR
C
under
test
R1= 4 ohms /10 watts
R2= 3 ohms/ 10 watts
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.
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.
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F-27
F-27
TROUBLESHOOTING AND REPAIR
ACTIVE SCR TEST (continued)
FIGURE F.6 – SCR GATE LOCATIONS
SCR2 CATHODE
SCR3 CATHODE
SCR1 ANODE
SCR4 ANODE
SCR1 CATHODE/SCR2 ANODE
SCR3 ANODE/SCR4 CATHODE
PLUG J7
3
4
SCR3
SCR4
SCR1
1
SCR2
2
S24018-4 (INSERTION SIDE)
SCR GATE LEADS/TEST POINTS
zero. If the voltage is higher than zero, the SCR
is shorted.
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.
10. Replace SCR Bridge Assembly if any SCRs
do not pass the test in Step #3. See SCR
Bridge
Assembly
Removal
and
Replacement.
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.
11. Replace plug J2 into the control board.
12. Replace the case wrap-around cover.
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).
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
F-28
NOTES
PRECISION TIG® 225
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F-29
F-29
TROUBLESHOOTING AND REPAIR
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
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 rep-
resents 2 milliseconds in time.
Note: Scope probes connected at
machine output terminals: (+) probe to
electrode, (–) probe to work.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
PRECISION TIG® 225
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F-30
F-30
TROUBLESHOOTING AND REPAIR
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 volt-
age waveform generated from a prop-
erly operating machine. Note that
each vertical division represents 50
volts and that each horizontal division
represents 2 milliseconds in time.
Note: Scope probes connected at
machine output terminals: (+) probe to
electrode, (–) probe to work.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
PRECISION TIG® 225
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F-31
F-31
TROUBLESHOOTING AND REPAIR
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
This is the typical AC output voltage
waveform generated from a properly
operating machine. Note that each
vertical division represents 50 volts
and that each horizontal division rep-
resents 2 milliseconds in time.
Note: Scope probes connected at
machine output terminals: (+) probe to
electrode, (–) probe to work.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
PRECISION TIG® 225
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F-32
F-32
TROUBLESHOOTING AND REPAIR
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
2ms
This is the typical DC (+) output volt-
age waveform generated from a prop-
erly operating machine. Note that
each vertical division represents 50
volts and that each horizontal division
represents 2 milliseconds in time.
Note: Scope probes connected at
machine output studs: (+) probe to
electrode, (–) probe to work.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
PRECISION TIG® 225
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F-33
F-33
TROUBLESHOOTING AND REPAIR
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 wave-
form generated from a properly operating
machine. Note that each vertical division
represents 10 volts and that each horizontal
division represents 2 milliseconds in time.
The machine was loaded with a resistance
grid bank. The grid load meters read 180
amps and 16VDC
Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (–)
probe to work.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
PRECISION TIG® 225
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F-34
F-34
TROUBLESHOOTING AND REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
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
MACHINE LOADED TO 180 AMPS AT 16VDC.
This is the typical DC (+) output voltage wave-
form generated from a properly operating
machine. Note that each vertical division repre-
sents 10 volts and that each horizontal division
represents 2 milliseconds in time. The machine
was loaded with a resistance grid bank. The grid
load meters read 180 amps and 16VDC
Note: Scope probes connected at machine out-
put terminals: (+) probe to electrode, (–) probe to
work.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
PRECISION TIG® 225
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F-35
F-35
TROUBLESHOOTING AND REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
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
MACHINE LOADED TO 180 AMPS AT
26VDC.
This is the typical AC output voltage wave-
form generated from a properly operating
machine. Note that each vertical division
represents 10 volts and that each horizontal
division represents 2 milliseconds in time.
The machine was loaded with a resistance
grid bank. The grid load meters read 180
amps and 26VDC
Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (–)
probe to work.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
PRECISION TIG® 225
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F-36
F-36
TROUBLESHOOTING AND REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
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
2ms
MACHINE LOADED TO 180 AMPS AT
26VDC.
This is the typical AC output voltage waveform
generated from a properly operating machine.
Note that each vertical division represents 10
volts and that each horizontal division repre-
sents 2 milliseconds in time. The machine
was loaded with a resistance grid bank. The
grid load meters read 180 amps and 26VDC
Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (–)
probe to work.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
PRECISION TIG® 225
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F-37
F-37
TROUBLESHOOTING AND REPAIR
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 discon-
nected to simulate an open or non-
functioning output SCR. Note that
each vertical division represents 50
volts and that each horizontal division
represents 2 milliseconds in time.
Note: Scope probes connected at
machine output terminals: (+) probe to
electrode, (–) probe to work.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
PRECISION TIG® 225
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F-38
F-38
NOTES
PRECISION TIG® 225
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F-39
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the SCR assembly.
MATERIALS NEEDED
5/16” 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
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F-40
F-40
TROUBLESHOOTING AND REPAIR
SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.7 – CASE BACK MOUNTING SCREWS
REAR PANEL
MOUNTING
SCREWS
away to allow access to the SCR Bridge
Assembly. Support the case back so as not to
stress the fan motor leads. It is not necessary
to disconnect the fan motor leads.
PROCEDURE
1. Remove input power to the TIG 225 machine.
2. Using the 3/8” nutdriver remove the case wrap-
around cover.
8. Using the 5/16” nutdriver remove the two
screws holding the front panel assembly to the
base. See Figure F.8.
3. With the slot head screwdriver loosen the input
cable strain relief to allow movement of case
back.
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
F-41
TROUBLESHOOTING AND REPAIR
SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.8 – FRONT PANEL MOUNTING SCREWS
FRONT PANEL
MOUNTING
SCREWS
13. With the 7/16” wrench remove the shunt from
the SCR bridge left side negative heat sink.
PROCEDURE (continued)
9. Remove plug J2 from the control board. (See
Figure F.9.) Also remove plug and lead harness
from internal divider panel.
14. Using the 7/16” wrench remove the polarity
switch lead from the right side AC SCR heat
sink.
10. Carefully slide the internal divider panel away
a few inches to allow access to the SCR
bridge assembly.
15. Using the 7/16” wrench remove the positive
lead from the right side positive heat sink.
11. Using the 7/16” wrench disconnect the diode
pigtail connection from the polarity switch lead.
See Figure F.10. Cut any necessary cable
ties and remove insulating sleeving.
Note placement of sleeving and cable ties for
reassembly.
12. Using the 7/16” wrench remove the X2 sec-
ondary transformer lead from the left side AC
SCR heat sink.
PRECISION TIG® 225
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F-42
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
FIGURE F.10 DIODE PIGTAIL CONNECTION TO POLARITY SWITCH LEAD.
DIODE
PIGTAIL
CONNECTION
PRECISION TIG® 225
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F-43
F-43
TROUBLESHOOTING AND REPAIR
SCR BRIDGE ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (continued)
16. With the 3/8” wrench remove the four mount-
ing screws holding the SCR bridge assembly
to the main transformer frame. Note insulator
placement.
17. Carefully remove the SCR bridge assembly
from the TIG 225 cutting any necessary cable
ties.
REPLACEMENT PROCEDURE
1. Carefully place the new SCR bridge assembly
in position in the TIG 225.
11. Position and install the case back and secure
with the screws previously removed.
12. Install the gas hose onto the solenoid valve.
13. Tighten the input cable strain relief.
14. Assemble the case wrap-around cover.
2. Using the 3/8” wrench install the four mounting
screws taking special care that the insulators
are in the correct positions.
USE DOW CORNING 340 HEAT SINK COM-
POUND ON ALL ALUMINUM CONNECTIONS
3. Assemble the positive lead to the right side pos-
itive heat sink.
4. Assemble the lead from the polarity switch to
the right side AC heat sink. Note: Also connect
lead #216
5. Assemble the shunt to the SCR bridge left side
negative heat sink.
6. Assemble the X2 secondary transformer lead to
the left side AC SCR heat sink. Note: Also con-
nect lead #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.
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
F-44
NOTES
PRECISION TIG® 225
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F-45
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the 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
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F-46
F-46
TROUBLESHOOTING AND REPAIR
POLARITY SWITCH
REMOVAL AND REPLACEMENT PROCEDURE (continued)
REMOVAL PROCEDURE
1. Remove the input power to the TIG 225
13. Using the 1/2” wrench remove the choke lead
machine.
from the polarity switch. See wiring diagram.
Label lead and connection point for reassem-
bly.
2. Using the 3/8” nutdriver remove the case wrap-
around cover.
14. With the 1/2” wrench remove the X1 sec-
ondary lead from the polarity switch. See
wiring diagram. Label lead and connection
point for reassembly.
3. Using the 3/32” Allen type wrench remove the
output control knob.
4. Using the Phillips head screwdriver remove the
screw from the polarity switch handle.
15. With the 7/16” wrench remove the two nuts
and washers that hold the polarity switch to
the front panel.
5. With the 2 slot head screwdrivers carefully pry
the polarity switch handle from the shaft.
16. Carefully rotate the polarity switch assembly to
gain access to the micro-switch.
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.
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.
7. Remove the name plate.
8. With the 1/2” wrench remove the “positive” flex
lead from the polarity switch. See wiring dia-
gram. Label lead and connection point for
reassembly.
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 con-
nects 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 dia-
gram. Label lead and connection point for
reassembly.
PRECISION TIG® 225
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F-47
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.
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.
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.
12. Assemble the polarity switch handle in place
with the Phillips head screw and check for cor-
rect switch operation.
13. Using the Allen type wrench replace the output
control knob.
14. Replace the case wrap-around cover.
PRECISION TIG® 225
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F-48
F-48
NOTES
PRECISION TIG® 225
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F-49
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the high voltage
transformer.
MATERIALS NEEDED
3/8” Nutdriver
Phillips head screwdriver
Needle nose pliers
Wire cutters
PRECISION TIG® 225
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F-50
F-50
TROUBLESHOOTING AND REPAIR
HIGH VOLTAGE TRANSFORMER
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.11 – SECONDARY LEADS AT HIGH FREQUENCY STARTER BOARD
TRANSFORMER
SECONDARY
LEADS
front mounting screws from the base of the high
voltage transformer. Take note of insulator
placement for reassembly. NOTE: On some
machines the mounting screw configuration
may be different.
REMOVAL PROCEDURE
1. Remove input power to the TIG 225 machine.
2. Using the 3/8” nutdriver remove the case wrap-
around cover.
7. With phillips head screwdriver loosen the two
rear mounting screws.
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.
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 nec-
essary cable ties.
5. Remove the lead splice from the other primary
lead that is connected to lead #236 and the C4
capacitor. See wiring diagram. Cut any neces-
sary cable ties.
6. Using the phillips head screwdriver remove the
PRECISION TIG® 225
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F-51
F-51
TROUBLESHOOTING AND REPAIR
HIGH VOLTAGE TRANSFORMER
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.12 – HIGH VOLTAGE TRANSFORMER MOUNTING INSULATORS
SLOTTED REAR
MOUNTING INSULATORS
NOTE: On some machines the
mounting screw configuration may be
different.
FRONT MOUNTING
REPLACEMENT PROCEDURE
1. Carefully position the new high voltage trans-
former in place in the two rear mounting insula-
tors. See Figure F.12.
2. Install the front mounting insulators and mount-
ing screw.
3. Using the phillips head screwdriver tighten all
four mounting screws making certain the insu-
lators are positioned correctly.
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
F-52
NOTES
PRECISION TIG® 225
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F-53
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the main transformer
and choke assembly.
MATERIALS NEEDED
3/8” Nutdriver
1/2” Wrench
Wire cutters
PRECISION TIG® 225
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F-54
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.
1. Position the new transformer/choke assembly
onto the base and mounting bolts.
2. Perform the SCR Bridge Assembly Removal
Procedure.
2. Assemble the four nuts and washers to the
mounting bolts on the base of the machine.
3. Unsolder the two 115VAC leads and leads
B231 and B232 from the main transformer
leads. Label leads for reassembly. See wiring
diagram.
3. Assemble the X1 secondary lead to the polarity
switch.
4. Assemble the choke lead to the polarity switch.
5. Install the J3 plug into the control board.
4. Unsolder leads W201 and W204 from the main
transformer leads. Label leads for reassembly.
See wiring diagram.
6. Assemble the H1, H2 or H3 lead onto the input
power switch. Insulate and secure the unused
lead (H2 or H3).
5. Unsolder leads R209 and U210 from the main
transformer leads. Label leads for reassembly.
See wiring diagram.
7. Assemble the shunt assembly to the choke
lead.
6. Using the 1/2” wrench remove the shunt
assembly from the choke lead.
8. Solder leads R209 and U210 to the main trans-
former leads. See wiring diagram. Insulate
connections.
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.
9. Solder leads W201 and W204 to the main
transformer leads.
Insulate connections.
See wiring diagram.
8. Remove plug J3 from the control board and
push through the interior divider panel.
10. Solder the two 115VAC leads and leads B231
and B232 to the main transformer leads. See
wiring diagram. Insulate connections.
9. Using the 1/2” wrench remove the choke lead
from the polarity switch. See wiring diagram.
Label lead and connection point for reassembly.
11. Replace any previously removed cable ties.
Clear leads and check for “shorts” or
“grounds”.
10. With the 1/2” wrench remove the X1 sec-
ondary lead from the polarity switch. See
wiring diagram. Label lead and connection
point for reassembly.
12. Perform the SCR Bridge Assembly
Replacement Procedure.
11. With the 1/2” wrench remove the four nuts and
lock washers from the transformer mounting
bolts at the base of the machine.
12. Carefully hoist the transformer/ choke assem-
bly clear of the base. Clear all leads.
PRECISION TIG® 225
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F-55
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.
INPUT IDLE AMPS
Input Volts/Hertz
Maximum Idle Amps
208/60
230/60
2.70 Amps
3.00 Amps
OPEN CIRCUIT VOLTAGES
AC 70 - 75VAC
DC 55 - 66VDC
Stick Mode OCV
TIG Mode OCV
AC 70 - 80VAC
DC 60 - 66VDC
MAXIMUM ACCEPTABLE OUTPUT VOLTAGE -
AT MINIMUM OUTPUT SETTINGS
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
IMPORTANT: IF OTHER TYPE METERS ARE USED RESULTS MAY NOT BE ACCURATE.
PRECISION TIG® 225
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F-56
F-56
NOTES
PRECISION TIG® 225
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G-1
G-1
TABLE OF CONTENTS - DIAGRAM SECTION
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 Schematic #3 (G5640) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6
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
PRECISION TIG® 225
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G-2
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 SHO
W
N & AS SHIPPED FROM FACTORY
)
H1 and H3 (HIGH) TO PO
W
ER S ITCH.
W
H2 NOT CONNECTED; INSULATE.
115VAC
RECEPTACLE
C5
(BACK VIEW)
208 or 380 or 460 VOLT CONNECTION
C6
380V AND ABOVE
H1 and H2 (LO
H3 NOT CONNECTED; INSULATE.
W) TO POWER SWITCH.
G
CONNECT GREEN LE
NATIONA ND LOCAL ELECTRIC
CONNECT BL CK ND WHITE LE
TO SUPPLY CIRCUI
A
D TO GROUND PE
L CODE
DS
R
231B
L
A
A
B
(L1
231A
231
A
A
T
A
C1 AND C2 MUST AL AYS BE CONNECTED
ACROSS TRANSFORMER PRIMARIES
W
)
W
(L2
)
232
233
C2
C1
CB1
TO GROUND PER
NATIONAL ELECTR DE
208V/230V ONLY
232A
CIOC
INPUT
PLUG (208V/230V ONLY)
W
(L2
H3
H2
)
)
B
(L1
H1
S1
POWER
SWITCH
313
314
G
S4
CHOKE
245
244
A
B
C
D
E
A
B
C
D
E
F
L5
R4
R5
10K A-B
AT MINIMUM
236
P7
J7
OPTIONAL
REMOTE
4
3
1
12
11 10
9
8
5
4
3
2
8
6
3
1
2
7
6
1
7
5
4
2
4
3
2
1
REMOTE
RECEPTACL
AMPTROLTM
E
231B
220A
218A
220
R3
C4
J2
J4
J3
236A
237
H3 (HIGH
H2 (LOW)
)
220A
AUTO
M
ODE
BALA
N
CE
G
SWITCH
S
CR
1
LED
H1
G1
G2
201
TRIGGER
X3
18VAC
X4
G
R
POLARITY SWITCH
MICRO SWITCH
217
AC
AC
A-C, D-E
,
,
B-F
A-F
OPEN
260
231A
F
RONT
GANG
TIG LED
AC
BALA
CONTRO
STICK LED
S
CR
2
DC+ B-D, C-E
,
G-H
CLOSED
CLOSED
204
N
CE
L
240
C
DC- B-D, A-E, C-F, G-H
209
X5
218
REAR GANG
MICRO-SWITC
H
POWER
210
18VAC
X6
D
AC
218A
NO
NC
)
(
H
232
231
X8
+
A
312A
311A
312
311
X1
78VAC
X2
FAN
E
G
F
115VAC
X7
DIGITAL
DISPLAY
115VAC
PULSE
115VAC
S2
A
DC
CONTRO
L
G3
G4
PULSE
REQ
LED
S
CR
3
B
G
216
216A
F
T2
T1
1
2
W 221
R 222
X2
J1
THER
LED
MAL
L4
S2
POLARITY
Y
POS
POSTFLO
CONTRO
W
L
(
REAR VIEW,
SHOWN IN AC POSITION
S
CR4
A
C
B
1
2
3
4
5
6
SHUN
T
SWITCH
)
OUTPUT
CONTRO
)
_
(
J5
L
1
2
3
4
D
E
284
285
D1
J6
W 221
R 222
POS
CONTROL PC BOARD
L1
DC
GAS VALVE
235
SV1
WORK
L2
238
L3
C1,C2
C3
C4
C5,C6
CB1
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
239
SPARK
GAP
ARC
STARTER
S'BLY
A
C3
T3
D1
L1
284A
284B
COMPONEN
T
VALUE
L2,L3
L4,L5
R1,R2
R3
R4,R5
S1
ELECTRODE
R1
285B
R2
LEAD COLORIN
G
CODE:
UNITS:
RESISTORS:
OHMS/WATTS
CAPACITORS:
MFD/VOLTS
HOLDING RESISTORS, 100/100W
PHASE SHIFT RESISTOR, 200/100W
MICRO START RESISTORS, 12/100W
INPUT POWER SWITCH
B-BLACK
R-RED
285A
G-GREEN
CONNECTO
1 2 3
W-WHITE
BYPASS/
STABILIZER
PC BOARD
R
PIN NUMBERS:
EXAMPLE: THIS IS PI
OF CONNECTO J4
S2
POLARITY SWITCH
N
7
285
S2A
S4
MICROSWITCH ON POLARITY SWITCH
MAIN CHOKE THERMOSTAT
R
7
284
SCR1,2,3,4 MAIN POWER SCR'S
SV1
T1
T2
GAS SOLENOID VALVE, 115VAC
MAIN TRANSFORMER
HIGH VOLTAGE TRANSFORMER
HIGH FREQUENCY TRANSFORMER
14
LATC
8
J4
H
R
VIEW OF CONNECTO
ELECTRICAL SYMBOLS PER E1537.
O
N
PC
BOARD
T3
R
G5646
A
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
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G-3
G-3
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - ALL CODES (G5647)
4 7 5 6 G
CHANG
E
D
ETAIL:
ELEASEDF
R
R
OM XA.02
E
NGI
N
EERING CONTROLLE
D
Top rear
SE CONNECTIO DETAIL
C
enter
o
f machine
Attached to Power Switch
216A
MANUFACTURER: No
E
N
DISPLAY PRESET AT IDLE
BYPASS ASSEMBL
Y
+15V
+5V
+24V
SCR1 GATE
G1
216
4
3
2
5J2
6J2
3J2
8J2
2J2
1J2
4J2
7J2
ACT
U
AL AMP WHEN WELDING
C1
SCR2 GATE
G2
G3
G4
G3
G2
220
G4
G3
G2
NO HO
L
D FUNCTIO
N
M
AIN
SCR3 GATE
SCR4 GATE
SCR3,SCR2 CATHODE
SCR1 CATHODE
SCR4 CATHODE
SCR1,SCR4 ANODE
15 - 20 OHM
GATE- ATHODE
ESISTAN E TYP.
SCR4
SCR3
TRANSFORMER
C
G4
R
ear of machine attached to
FIRE_SCR
.0047/250VA
C
3 DIGIT
METER
T1
R
C
SCR
218
217
216
220
base, below fan
M
AI
N
S
CR
H3
GATING & SN
U
BBER
HIGH
POWER SWITC
S1
H
+
-
RECTIFIE
R
(DI P1)
S
220A
R4
C2
D1
+5V
OUTPUT CONTROL &
MODE SETTINGS ARE
MEMORIZED AT POWER
L1
W
12/100
R5
EACH
FR
E
E
WHEELI
N
GDIODE
SCR1
H2
LOW
SCR2
X2
G1
1
G1
PHASE
+15V
217
-
DOWN AND RECALLED
METER
INTE FACE
BA
C
KGROUN
D
RESISTORS
80 VAC
X1
218
R
ATPOWER
-
UP
218A
BACKGROUND AC INPUT
BACKGROUND ( - )
BACKGROUND ( + )
11J3
10J3
9J3
216A
POWER-
U
P
SEQUENCE
DI PL
H1
MICRO-START
CIRCUIT
R 222(-)
W 221(+
L2
SHUNT
400A/200mV
B
BG
IN-LI
N
E
CONNECT
O
RJ7
245
244
240
R
ight Side of
ectifier Top o
behind Choke.
S
C
R
Bridge
)
MET ANDMOD
E
R
E
S
A
YT
H
E
PREVIOU
RUNSF
ATIM
OT IF
OL NTIL
S
O
UT
P
UT
Inside sleeving top lef
a
t
t
side
of
R
.
f
Machine
+5Vre
f
G
RECONNECT I
S
DON
EAT
CONT OL ANDMOD
SECONDS. IF MODEISTIG, GASFLOWSF
ET YT POSTFL KNOB. UT UT I
MO EI STI K. INTIG MOD UT UT I
TRIGGERI CLOSED
R
E
S
ETTINGS. F
A
N
O
R5
Main Rectifier
BACKGROUND AC INPUT
(DISABLED I
N
STI
CK)
AC
12J3
POWE WITCH
R
S
O
R
E
+15V
S
B
H
E
OW
O
P
S
H
DC
Front Panel Lef
t
side
+15V
-15V
R
ight side o
f
Machine
D
S
C
E
O
P
S
C
DU
OUTPUT
above Choke Coil.
S1
L1
S
INDUCTOR
TOROI
D
VOLTAGE RECONNECTION
Gang
D
MODE
SHUNT (+)
SHUNT (-)
PHASE_FIRE
Iarc
ET
1J1
2J1
W 221
R 222
TOGGLE BETWEEN IG&
T
SEE RATING PLAT
230 or 400 415 or 575 VOLT CONNECTIO
AS SHOWN & AS S IPPED FROM FACTORY)
1 and (HIGH) TO POWER
NOT CONNECTE ; INSULA
460 VOLT CONNECTIO
LOW) TO POWER
; INSULA
AYS BE CONNECTE
E
FOR SPECIFIC VOLTAGES
Gang
Gang
C
TWISTED PAIRS
TYPI
65V I
75V I
C
ALOCV
DC
AC
S
TICK.
Gang
B
OUTPUT
REGULATOR
HI-FREQ, GAS, BALANCE
CONTROL, PULSE
FREQUENCY, &
G
CURREN FEEDBACK
T
-
N
N
240
+
+
N
S
P
OINT
DC
DC
DC
MICRO-STAR CIRCUIT
T
AC
+
+5Vref
On top
o
f
Main
er
AC
(
H
-
-
ARE DISABLED IN STICK
DC
Transfor
m
Gang
A
CBW
CBW
CBW
H
H
H
3
S
WITCH.
CBW=CONNECTED
BYSWITCH
A
Gang
H
THESE CONNECTIONS
ASE BY POLARIT
2
D
T
E.
C
DETERMINE IFHI-FREQ IS
CONTINUOUS OR START
Lo
wer lef
t
S
side
of
+5Vre
f
AC
+
24V
ARE
SWITCH,
PHYSICAL LEADS
M
Y
AC
Polarity
w
itch
OUTPUT CONTRO
L
B
-
THEY ARE NOT
+
-
DC
DC
DC
ONLY, IN. CURRENT, AND
M
DC
208 or 380 o
r
H
N
MET
AN
MO
E
R, ENCODER,
ALL OT NTIOMETER
NT BOARD
SWIT
C
H, L
EDs,
N
CODER)
BALANCE CONTROL
CBW
CBW
D
P
ED
E
S
ARE
311
312
311
5J3
6J3
A1
5
-
(E230A
H
H
1 and
3
2
(
S
WITCH.
TE.
DET_REM
P
olling signal
Hi Lo al
emote con
U
ON
PC
A
C/DC
INTERFACE
MICRO SWITCH INPUT
ACand DC
REM_SENSE
=
c
NOT CONNECTE
D
CLOSED
IN DC
Gang F
Gang
E
S2
REM_POT
R
trol
N.C.
POLARI
TY
SWITCH
+5Vref
FromAuto Loc/Rem
Front Panel Center
SEE CONNECTION DETAIL
C1 AND C
2
MUST AL
W
D
314
313
2J3
1J3
312
TH
E
RMOSTAT
THERMOSTAT INPUT
INTERFACE
ACROSS TRANSFORMER PRIMARIES
MICRO SWITC
H
CLOSED IN DC
MAX. PENET ATION
R
DISABLE OUTPU
T
&HI-FREQ
CW
OPEN IN A
C
285
284
IFTHERMOSTA
T
OPEN
B
ALANC
DISABL
CTI
E
CONT
R
OLI
S
BALANCE
MAX. CLEANING
UT
R1
Inside hi-freq box on
right side of machine
E
DI STI
N
C
K
AND
+5Vre
f
+24
V
C
HOKE TSTAT
MALLY CLOSE
OPEN AT 135C TYP.)
10K
D
G
near fron
t
(
NOR
D
A
O
+5Vref
BYPASS/STABILIZER
PC
D
AT
CL
XRES
A
1J6
TO0 COPPER BAR
B
S
K
PROGRAMMI
N
G
CONNECTOR
UPGRADE
W
222
2J6
3J6
4J6
20 HZ
(SCHEMATIC S22530
)
CW
10K
FO OFTWAR
R
S
E
(P B AS'BLY L10121-1
C
)
R 222
P
UL
S
EFREQUENCYI
S
PULSE FREQUENCY
R2
DISABL
E
DI STICK
N
+5Vre
f
ALUMINUM BAR
0.1 HZ
O
FF
284A
285A
100/100
R2
+5Vref
284B
+15V
HOLDIN
G
RESISTOR
S
30 S
POSTFLOW
1S
SCR
HEATSINK
CW
10K
285B
Inside hi-freq box on
right side of machine
R3
In Front of main
R1
transformer,
PHASE
TRIGGER
115V CIRCUIT
MICRO
-
near fron
t
Attached to Base
100/100
TRIAC & OPTO-TRIA
C
P
RO ESSOR
C
R
ight side of machine,
gas solenoid,
attached to Base
FARTHEST RIGH
(VIEWED RO
FRONT)
T
SCR
FARTHEST
SCR (VIEWED
FROM RONT
L
EFT
HI-FREQ OFF INSTICK
STAR ONLY IN DC IG
CONTINUOUS IN AC IG
DRIVER
F
M
fron
t
of
B
OTTOM
T
T
+5V
7GA.
F
LEX LEAD
COPPER
BAR
F
)
T
Lef
t
side
o
f
Machine
near fron
t
H
IG
H
VO
L
TAG
E
ARC
ST
A
RT
E
R
ASSEMBL
Y
T
RANSFO
ER
T2 RM
6 GA.
DC
FLEX LEADS
200/100
R3
LED INTE
R
FACE
238
HI-FREQ (115VAC)
GAS (115VAC)
115VAC IN
4J4
1J4
236
235
232A
260
L2
Mounted to fron
t
side
C3
of hi-freq box on
237
LED 1
LED 3
TIG
right side of machine
near front.
236B
3J4
2J4
S
STICK
(RED)
1
2.5 OHM TYP.
C4
15/250
12KV
.0015/
Gang
A
(G
REEN)
FAN (115VAC)
Gang
D
5.5 OHMS
TYP.
115V
1
4.5 KOHMS
SPARK
GAP 020
HIGH FREQ.
NEX
T
TO
MODE SWITCH
NEX
T
TO MODE SWITCH
T3
115VAC
TYP.
OUTPUT INDUCTOR
285
.
1
2.5 OHM TYP.
L3
TRANSFORMER
C5
TO ICRO PROCESSOR
M
240
5000V
F
C6
.22/400V
231B
AND SCR GATING
PHASE
LED 6
THE MAL
(YELLOW)
NEX ETER
TWO HERMAL LEDs
LIGH
LED 2
LED 5
Gang
F
LED 4
Center front
Rear gang
H
R
THERMAL
FREQUENCY
A
UT0BALANCE
UNUSED TERMINA
311
L
W
ORK
(YELLOW)
NEX ETER
HI-FREQ CIRCUIT
(G EEN)
R
231A
Rear gang
G
(GREEN)
Gang
E
T
TO
M
239
T
TO
M
NEX TO PULSE
T
NEXT
TO BALANCE POT.
T
TO
FREQUENCY POT
.
MICRO SWITC
H
OFF INSTICK AND DC
T
IG
233
OFF INSTICK, BLINKS AT
FREQUENCY RATE
T
THROUGH
232A
B1
PHASE
ET CTOR
X1
BACK-LITTHERMAL
ELECTRODE
D
E
2
0A (2
0
8V/2
3
0V)
312
SYMBOL
C
G
AS
R
R
ear Panel
ight Side
Gang
C
gang
B
6A (3 0V & ABOVE)
8
SOLENOID
(115VAC)
+5V
Right front
GANG LO
VIEWED F
C
R
ATION
OM REA
S
ARE
OF
+5V
DO NOT REVERSE LEADS
209&210, USED OR SCR
PHASE IMING
TO
M
ICRO
R
+24V
F
PROCESSSOR
SWITCH
SV
1
MOUNTING HOLE
231
235
232
T
+15V
+5V
2019
7J3
8J3
232
X5
TRIGGER
8VAC
TRIGGE
R
A
UTO
LO AL/
EMOTE
CONTRO
POWER SUPPLY
CONTRO
Y
L BOARD SUXP6PL
T1
MICR
O
S
WITC
H
+
15
V
P
OL
A
RIT
Y
S
WITC
H
INTE FACE
R
TO
M
ICRO
+5Vre
f
C
210
435 OHMS TYP.
PROCESSOR
-15V
OPEN
AC
A-C, D-E, B-F
R
X7
-15V
L
CLOSED
CLOSED
B-D, C-E, A-F, G-H
B-D, A-E, C-F, G-H
DC+
AUTO LOCAL/REMOTE
STICK MODE ALWAYS LOCAL
TIG MODE REMOTE FPLUGGED
LOCAL FUNPLUGGED
DC-
T1
115VAC
:
FAN RUNS FOR 5 S AT POWER-UP
115VA
C
12 OHMS TYP.
:
I
STOPS AT IDLE 8 MINUTES
SCR1
SCR3
X8
X3
2018VAC
I
4J3
3J3
J1
2 PIN
AFTER WELDING.
1
FAN
SCR BRIDGE AND POLARIT
Y
SWITCH CONNECTION DETAIL
TRIGGER CIRCUIXT 4
J2
RF
204
TYP. RPM:
260
RECEPTACLE
CHOKES
SCR2
SCR4
1600
1340
R
PM 60Hz
PM 50Hz
Left front
Right rea
r
side o
f
Main
R
8 PIN
Transfor
m
er
+15V
C
OMPONENT
CAPACIT R: MFD/
RESIST R: HMS/
CONNECT PI UMBERS:
EX. 12 PIN CONNECTO
V
AL
U
E
U
NITS:
OLT
ATT
AUX
.
WINDINGS OF
MAIN TRANSFORMER T1
LEA
D
C
OL
O
RCODE:
4PIN( HITE)
W
U
N
A
B
C
D
E
F
1J5
(GREEN)
PROGRAMMI
NG
Betw
een S
C
R
Bridge halves
B-BLAC
K
O
R
GRAY
O
O
V
W
S
S
R
ight fron
t
side
of
MIC
R
O-PROCESSOR
MODE
CONNECTOR
behind choke
.
10K
Main Transformer
G-GREEN
O-ORANGE
R-RE PINK
U-BLUE
W- HIT
Y- ELLOW
LABELS:
3J5
2J5
X1
O
J6
R
B
J3
D
OR
OR
NN
O
UTPUT CONT OL
R
SOFTWAR
E
LOCAL
5J5
6J5
R
W
E
VERSION LABE
L
Y
2
1
6
W
12 PIN
BALANCE
FREQUENCY
COMMON
J4
7
12
POSTFLOW
FRAM
E
GROUND
GROUND
LATCH
TOROI
WITCH
BYPAS
D
MICRO
START
J5
6 PIN
4 PIN
GA
S
AC
FA
N
HF
TM
EARTH
VIEWOF CONNECTORON PC BOARD
OPTIONAL
CONTROL
AMPTROL REMOTE
GREEN LED'S
AND
ARC
S
TART
S
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MA
Y
NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
CONTROL PCB MAIN COMPONENT & DIANOSTIC LED LAYOUT
(VIEWED FROM COMPONENT SI E)
TROUBLE SHOOTI G LED' PRESENT ONLY O
REVISIO B OR LATER
COMPONENT LO
C
ATIO
N
D
ES
MACHI
OTHERWISE
C
RIPTIO
NS ARE AS VIEWED
HI-FRE
FROM
MO NTI
METAL
Q
S
CONNECTION
D
DESIG
N
I
NFORMATION
Jbarto
RAWN BY:
REFERENCE:
H
I-FREQ BYPASS
T
HE INFORMA
PRIN IS OR RE
ONLY. MPONEN
CIRCUI RY MA BE DIFFERENT
RO AN AC UAL ACHINE.
T
IO
N
ON
ERENC
AND
T
HIS
EQUIP
M
ENT TYPE:
CONT
R
OL PC BOARD
SCHEMATIC G5640-
ASSEMBLY G5641-
PAGE _1__ OF _1__
DOCUMENT
UM NT
Precision Tig 225
B
OTTOM LEFT
FROM RONT
F
OF
N
E UNLESS STATED
N
S
N
T
F
F
E
Front Panel Top
D
G4588
CONNECTION
DO
C
E
U
N
G
H
OLET
O
SHEET
PCB
N
C
O
T
S
SUBJECT:
MACHINE SCHEMATIC
N
BER:
REVISION:
UM G5647
ENG
INEER:
R
Samodell
SCA
L
E:
T
Y
MATERIAL
APPROVAL
PROJECT
F
M
T
M
CRM38254
A
NA
APPROVED
:
Approve
NONE
06/20/2006
DISPOSITION:
DATE:
NUMBER:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PRECISION TIG® 225
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD #1 (G5640)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PRECISION TIG® 225
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD #2 (G5640)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PRECISION TIG® 225
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD #3 (G5640)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PRECISION TIG® 225
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - CONTROL #1 (G5641)
2 - 4 1 5 6 G
E
NGI
NEERING CONTROLLE
D
CHANGE
DETAIL:
NEW
MANUFACTURER:
Yes
1
N.K.
5.00
6.00
5.80
5.10
D2
LED11
LED13
R220
R219
R
10
J 1
C7
R19
R20
D3
T1
T2
X2
P
T185/ 225
CONTROL
Q2
D4
R3
5
R36
C20
R41
R40
D40
R4
6
X3
R47
D5
R54
D8
MOV4
MOV5
TP4
LED12
LED14
R218
R217
TP1
TP2
D6
X4
R52
C3
1
R64
N.K.
D12
D9
D13
R7
3
6
R7
4
7
D41
R72
D10
Q7
R7
R7
N.B.
D15
D16
TP3
R92
R93
C47
R199
Q10
C48
C46
R94
R95
R205
R206
X1
C50
R213
X6
N.G.
C5
1
C49
R105
X7
R207
C54
Q11
Q13
R110
X9
Q12
D20
X
10
DZ5
D23
R214
X12
X11
R116
TP5
C68
C69
TP7
X13
X14
C70
C73
C86
D28
TRI2
TRI 4
D31
TRI 1
TRI 3
DZ6
N.K.
R141
R142
R152
R156
R159
R164
R169
R176
R180
D3
2
OCI
1
Q14
Q15
R151
R155
R158
R163
R168
R175
R179
C94
R160
C96
C99
C95
R157
R165
Q16
R161
OCI 2
OCI 3
OCI 4
OCI 5
D35
C101
Q17
DZ10
N.K.
C106
D36
D38
D37
D39
.20
TP6
0
.20
8.80
9.00
0
2
3
4
5
REVISION CONTROL
G
5
6
4
1
-
2
C
0
N.K.
PART NO. IDENTIFICATION
CODE
COMPONENT SIDE
TEST PER E4238-C
COAT WITH E1844 AND E3668 (2 COATS)
SCHEMATIC REFERENCE: G5640-2C0
MAKE DETAI L
MANUFACTUR PER E1911-RoHS
BUY BLANK COMPLETE
(2 BOARDS PER PANEL)
4LAYER BOARD BLANK PANEL
SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION.
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
M
ANUFACTURING TO
L
ERANCE
P
ER E2056
CONTROL: CLEVELAND
SCA
L
E:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIP
M
ENT TYPE:
1
2
PRECISI
O
N TIG 185/225
PAGE ___ OF ___
ON
ON
ON
2
3
PLAC
E
D
ECIMAL
S
I
S
.02 in.
(
0.5 mm)
1:1.2
5
DRAWN BY:
ENGINEER:
APPROVED:
d
di
etz
PLACE
D
E
CIMALS IS
.
00
A
2
i
n.
(
0.
0
5
mm)
DOCUMEN
T
DOCUMEN
T
IF PRIN
T
ED
A
LL ANGL
E
S
I
S
.5 OF
DE
GREE
SUBJECT:
REVISION:
NUMBER:
CONT OL PC BOA
R
R
D ASSE
M
G4551-
BLY
@ A
T
1
SIZ
E
MATERI
WITH
A
L
TO
L
ERANC
E
("
"
)
TO
A
GREE
TrangNguye
n
t
UNIINSC: H
LISHED
ANDARD
REFERENCE:
DO NOPTUBSCAL
E
STTHIS DRS.AWING
1
MATERIAL
APPROVA
DA E:
L
PROJEC
T
G5641-
2
UF
DISPOSITION:
2/15/2008
A
CRM36266
-
T
NUMBER:
Insight
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
PRECISION TIG® 225
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - CONTROL #2 (G5641)
2 - 4 1 5 6 G
OCI1
1
4
2
S15000-34SMT
S15000-16
IC,SMD,OPTOCOUPLER,HMA124
CHANGE
D
ETAIL:
NEW
E
NGI
NEERING CONTROLLED
ITEM (USED WITH)*`
QTY PART NUMBER DESCRIPTION
MANUFACTURER:
Yes
OCI2, OCI3, OCI4, OCI5
Q1, Q6
OPTOCOUPLER,TRIAC,DRIVER,ZVC,3083
TRANSISTOR,SMD,NMF,DPAK,TO-252,48A,100V(SS)
1
1
3
3
G5641-C
CF000003
E106A-13
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
S25051-11SMT
2 (TRI1, TRI3, X5)*
Q2, Q3, Q5, Q7, Q9, Q10,
Q12, Q13, Q15, Q16,
Q17, Q18
Q4, Q8, Q11, Q14
R1, R2, R3
3 (TRI1, TRI3, X5)*
12
S25050-1SMT
TRANSISTOR,SMD,NPN,0.5A,40V,SOT-23,MMBT4401LT1
4 (TRI1, TRI3, X5)*
AS REQ E1868
5 (TRI1, TRI3, X5)*
3
1
S18104-3
S26585-4
4
3
S25050-2SMT
T10812-116
TRANSISTOR,SMD,PNP,SOT23,0.5A, 40V,MMBT4403LT1
POT,SINGLE-TURN,0.25W,10K,10%
6
7
8
AS REQ E2861
R4, R49, R50, R68, R69,
R72, R107, R122, R132,
R162, R184, R200
R5
AS REQ E2519-1
12
S25000-1002SMT RESISTOR,SMD,METAL FILM,1/10W,10.0K,1%,S0805
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
1
1
S25000-1301SMT RESISTOR,SMD,METAL FILM,1/10W,1.30K,1%,S0805
S25000-1500SMT RESISTOR,SMD,METAL FILM,1/10W,150OHMS,1%,S0805
REFERENCES QTY PART NUMBER DESCRIPTION
R6
A1
1
M17789-4
ENCODER,INCREMENTAL,2-BIT,PEC12
R7, R9, R111, R112,
R113, R135, R143, R145,
R147, R149, R172, R173,
R174, R178, R191, R196,
R197, R198
C1, C3, C29, C39, C41,
C42, C43, C58, C60, C78,
C84, C89, C90, C91, C92,
C94, C95, C103, C104,
C109, C110
18
S25001-1001SMT RESISTOR,SMD,1K,1/4W,1206,1%,TR
21
S25020-2SMT
CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%,X7R,S0805
N.C.
N.L.
N.C.,N.J.
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
3
8
S25000-6812SMT RESISTOR,SMD,METAL FILM,1/10W,68.1K,1%,S0805
S25004-1R00SMT RESISTOR,SMD,1W,1.00OHMS,1%
N.F.
N.C.,N.D.
N.C.
C2, C10, C35, C111
C4, C23, C38
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
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
16
S25003-1210SMT RESISTOR,SMD,1W,121OHMS,1%
14
4
S25020-10SMT
S20500-17
CAPACITOR,SMD,CERAMIC,4700pF,50V,10%,XR7,S0805
CAPACITOR,PPMF,0.1MF,630V,5%,BOX
R16, R17, R30, R31, R32,
R51, R60, R61, R92,
R167, R194, R195, R208,
R212, R215
15
S25000-1001SMT RESISTOR,SMD,METAL FILM,1/10W,1.00K,1%,S0805
32
S25020-3SMT
CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X7R,S0805
R18
1
S25000-5622SMT RESISTOR,SMD,METAL FILM,1/10W,56.2K,1%,S0805
S25001-47R5SMT RESISTOR,SMD,47.5OHMS,1/4W,1206,1%,TR
R19, R64, R157, R160,
R165, R170, R217, R218,
R219, R220
10
2
3
3
1
2
1
S25020-4SMT
S25020-14SMT
S25020-7SMT
S25020-24SMT
S13490-199
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
R20, R36, R41, R54
R21
4
1
1
2
1
2
2
S25003-15R0SMT RESISTOR,SMD,1W,15.0OHMS,1%
C16, C40, C113
C27, C36, C37
C28
S25000-7681SMT RESISTOR,SMD,METAL FILM,1/10W,7.68K,1%,S0805
S25000-4752SMT RESISTOR,SMD,METAL FILM,1/10W,47.5K,1%,S0805
S25000-2213SMT RESISTOR,SMD,METAL FILM,1/10W,221K,1%,S0805
S25001-2210SMT RESISTOR,SMD,221OHMS,1/4W,1206,1%,TR
S25006-10R0SMT RESISTOR,SMD,METAL FILM,1/2W,10OHMS,1%,S2010
S25008-1002SMT RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.5%,S0805
R22
R23, R79
DISP
1
C46, C49
XXX
R24
L
L
ED
ED
2
6
XXXXX
X
X
X
X
X
X
X
X
X
L
L
ED
1
3
X
X
X
X
C47
S13490-179
CAPACITOR,ALEL,1000,35V,20%
R25, R75
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
X
X
X
R33, R38
9
T11577-52K
CAPACITOR,CD,.0047/.005,1400V,20%
S1
R35, R84, R108, R109,
R139, R166
6
3
S25001-1000SMT RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR
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%
A1
R37, R85, R106
R39, R81, R82, R98,
R128, R131, R177, R182,
R185, R187, R188, R210,
R211
S25000-3322SMT RESISTOR,SMD,METAL FILM,1/10W,33.2K,1%,S0805
XXXXX
XXX
ED
CAPACITOR,ALEL,22,63V,20%
13
S25000-4751SMT RESISTOR,SMD,METAL FILM,1/10W,4.75K,1%,S0805
8
S25040-1SMT
DIODE,SMD,1A,400V,FAST RECOVERY,DO-214BA
DIODE,SMD,DUAL,0.200A,70V,UFR
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
R40, R46, R47, R73, R74,
R76, R77, R86, R96, R97,
R141, R142, R179, R180
R48, R199, R209, R213,
R214
12
S25040-5SMT
14
5
S25001-4751SMT RESISTOR,SMD,4.75K,1/4W,1206,1%,TR
S25000-2210SMT RESISTOR,SMD,METAL FILM,1/10W,221OHMS,1%,S0805
17
S25040-2SMT
DIODE,SMD,1A,400V,DO-214BA/AC
R59, R136
2
1
2
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
R62
D24, D25, D26, D27
DISP1
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
DIODE,SMD,3A,400V,D0-214AB
R63, R120
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
R65, R66, R94, R95,
R130, R137
XXXXXX
6
1
6
S25008-4751SMT RESISTOR,SMD,PREC,MF,1/10W,4.75K,0.5%,S0805
S25000-1003SMT RESISTOR,SMD,METAL FILM,1/10W,100K,1%,S0805
S25000-3321SMT RESISTOR,SMD,METAL FILM,1/10W,3.32K,1%,S0805
XXXXXX
XXXXXX
DZ1, DZ8, DZ10
DZ2, DZ3
R2
R1
R3
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
R67
X
X
X
X
X
X
X
X
DZ4
R70, R117, R119, R121,
R202, R204
DZ5, DZ6
DZ7, DZ9
R71
R78
1
1
3
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
J1
J2
R80, R83, R216
R87, R88, R89, R99,
R100, R101, R102, R205,
R206, R207
J3
S24020-12
S24020-4
L
ED4
X
N.C.
X
X
X
X
X
J4
10
S25000-47R5SMT RESISTOR,SMD,METAL FILM,1/10W,47.5OHMS,1%,S0805
XXXXX
XXXXX
J5
S24020-6
XXXXX
J6
S18248-4
R93
1
2
1
1
3
1
2
S25000-2671SMT RESISTOR,SMD,METAL FILM,1/10W,2.67K,1%,S0805
S25003-47R5SMT RESISTOR,SMD,1W,47.5OHMS,1%
L
ED5
L1, L2, L3, L4, L5
LED1
T12218-9
R105, R110
T13657-2
R114
R115
S25000-6811SMT RESISTOR,SMD,METAL FILM,1/10W,6.81K,1%,S0805
S25000-2212SMT RESISTOR,SMD,METAL FILM,1/10W,22.1K,1%,S0805
S25003-2002SMT RESISTOR,SMD,1W,20.0K,1%
LED2, LED6
T13657-14
LED,T-1,3/4,AMBER,HIGH-INTENSITY
LED,T-1,3/4,GREEN,HLMP-3502
LED3, LED4, LED5
LED7, LED8, LED9,
LED10, LED15, LED16,
LED17
T13657-3
R116, R153, R154
R118
S25001-4752SMT RESISTOR,SMD,47.5K,1/4W,1206,1%,TR
S25000-2211SMT RESISTOR,SMD,METAL FILM,1/10W,2.21K,1%,S0805
N.C.
7
S25080-2SMT
LED,SMD,GREEN,CLEAR,S1206
R123, R133
N.E.
R124, R125, R127, R171,
R181, R189
6
S25003-2000SMT RESISTOR,SMD,1W,200OHMS,1%
LED11, LED12, LED13,
LED14
4
1
4
3
S25080-1SMT
T13640-16
T13640-25
T13640-18
LED,SMD,RED,CLEAR,S1206
MOV,150VRMS,80J,20MM
MOV,130VRMS,90J,20MM
N.C., N.D., N.H. (3 PLACES)
R126, R138
2
1
1
1
S25001-1213SMT RESISTOR,SMD,121K,1/4W,1206,1%,TR
MOV1
R129
S25000-2001SMT RESISTOR,SMD,METAL FILM,1/10W,2.00K,1%,S0805
S25000-6813SMT RESISTOR,SMD,METAL FILM,1/10W,681K,1%,S0805
S25000-3323SMT RESISTOR,SMD,METAL FILM,1/10W,332K,1%,S0805
MOV2, MOV3, MOV4,
MOV5
R134
R140
MOV6, MOV7, MOV8
CAPACITO MOV,320VRMS,150J,20MM
R
S
=
MF
D
/
VOLTS
R144, R146, R148, R150,
R186, R190, R192, R193
R151, R152, R155, R156,
R158, R159, R163, R164,
R168, R169, R175, R176
R161
8
S25001-2670SMT RESISTOR,SMD,267OHMS,1/4W,1206,1%,TR
OPPOSITE COMPONENT SIDE
RESI
S
TO
R
S
=
OHMS
12
S25001-1821SMT RESISTOR,SMD,1.82K,1/4W,1206,1%,TR
1
1
1
1
2
4
1
1
3
1
1
1
1
1
1
1
1
1
S25001-7500SMT RESISTOR,SMD,750OHMS,1/4W,1206,1%,TR
S25000-1502SMT RESISTOR,SMD,METAL FILM,1/10W,15.0K,1%,S0805
S25001-2211SMT RESISTOR,SMD,2.21K,1/4W,1206,1%,TR
R183
R201
S1
T13381-16
SWITCH,PUSHBUTTON,SPST
TRANSFORMER,PULSE,3-WINDING,1:1:1
TRIAC,TO220,8A,800V
T1, T2
T12737-2
TRI1, TRI2, TRI3, TRI4
X1
S15161-27
S25073-12SMT
S15128-27SMT
S15128-28SMT
S15128-6
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)
X2
X3, X4, X14
X5
X6
S15128-10SMT
M15102-4SMT
S15128-5SMT
S25072-2SMT
S15018-21SMT
S17900-24SMT
S25065-3SMT
S15018-11SMT
NOTES:
N.A.
X7
N.A.
THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY, SEE E2454 BEFORE
HANDLING.
X8
X9
N.B.
N.C.
N.D.
PROGRAM X1 WITH ITEM 6.
X10
KEEP FREE OF ENCAPSULATION MATERIAL.
X11
SEAL COMPONENT BY APPLYING ITEM
DOES NOT GETINSIDE COMPONENT.
7
AS SHOWN SO THAT ENCAPSULATION MATERIAL
X12
X13
N.E.
N.F.
N.G.
N.H.
N.J.
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
-
ALL COMPONENTS AND MATERIALS USED
INTHIS
FROM BOTTOM OF DISPLAY TO PC BOARD SURFACE.
SQUEEZE COMPONENTS TOGETHER BEFORE ENCAPSULATION.
SEAL COMPONENT BASE WITH ITEM 8.
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253
N.K.
N.L.
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
M
ANUFACTURING TO
L
ERANCE
P
ER E2056
CONTROL: CLEVELAND
SCA
L
E:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIP
M
ENT TYPE:
2
2
PRECISI
O
N TIG 185/225
PAGE ___ OF ___
ON
ON
ON
2
3
PLAC
E
D
ECIMAL
S
I
S
.02 in.
(
0.5 mm)
1:1.2
5
DRAWN BY:
ENGINEER:
APPROVED:
d
di
etz
PLACE
D
E
CIMALS IS
.
00
A
2
i
n.
(
0.
0
5
mm)
DOCUMEN
T
DOCUMEN
T
IF PRIN
T
ED
A
LL ANGL
E
S
I
S
.5 OF
DE
GREE
SUBJECT:
REVISION:
NUMBER:
CONT OL PC BOA
R
R
D ASSE
M
G4551-
BLY
@ A
T
1
SIZ
E
MATERI
WITH
A
L
TO
L
ERANC
E
("
"
)
TO
A
GREE
TrangNguye
n
t
UNIINSC: H
LISHED
ANDARD
REFERENCE:
DO NOPTUBSCAL
E
STTHIS DRS.AWING
1
MATERIAL
APPROVA
DA E:
L
PROJEC
T
G5641-
2
UF
DISPOSITION:
2/15/2008
A
CRM36266
-
T
NUMBER:
Insight
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
PRECISION TIG® 225
Download from Www.Somanuals.com. All Manuals Search And Download.
G-9
G-9
ELECTRICAL DIAGRAMS
SCHEMATIC - BYPASS PRINTED CIRCUIT BOARD (S22530)
0 1 - B 5 2 3 0 2 S
CHANGE DETAIL:
NEW
ENGINEERIN
G
CONTROL
LED
M
ANUFACTURER:
No
ARC ST
ABILIZER CAPACITOR
ARC STA
B
ILIZER RESISTOR
C9
15
250V
10
R1
5W
CONNECTION MADE THROUGH
HOLE WITH SOLDER AD
CONNECTION MADE THROUGH
P
HOLE WITH SOLDER PAD
C1
C2
C3
C4
C5
C7
C6
Graphic
TP1
C8
.05
TP2
.05
.05
.05
.05
.05
.05
.05
320V
160J
320V
160J
Graphic
600
V
600
V
600
V
600
V
600
V
600
V
600
V
600
V
GND
GND CONNECTION MADE THROUGH SOLDER PAD
AND SCREW TO STEEL STANDOFF ON MACHINE
THIS DOCUMENT CONTAINS PROPRIETARY INFO
R
MATION O
W
NED BY
L
INCOLN GLO
B
AL
,
INC. AN
D
MAY NOT BE
D
UPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO
O
THER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN
P
BYPASS/STABILIZER BOARD
SCHEMATIC
ERMISSION OF LINCOLN GLO
B
AL INC.
,
U
NLESS OTHERWISE SPE
C
IFIED
CE PER E2056
MALS IS .0
TOLERANCE
DESIGN INFO
RAW BY:
ENGINEER
APP OVED:
RMAT
IO
N
REFERENCE:
MANUFACTURING TOLERA
N
EQUIPMENT TYPE:
SUBJECT:
1_
PAGE _1_ OF __
_
ON
ON
2
3
PLACE DEC
I
2
FEI
D
N
S22530
PLACE DECIMALS IS .002
DOCUMENT
REVISION:
DOCUM
E
NT
ON ALL ANGLES IS .5 OF A DEGREE
N
UMBER:
:
MATERIAL TOLERANCE (" ") TO AGREE
t
SCALE
:
WITH
DS.
DO NOPTUSBLCISAHED
L
E TSTHAINSDDARRAWING
MATERIAL
NA
APPROVAL
DATE:
PROJECT
S22530-1B0
A
CRM34563
NUMBER:
R
NONE
08/26/2002
DISPOSITION:
S
TRP
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PRECISION TIG® 225
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G-10
G-10
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - BYPASS (L10121)
3
1 2 1 0 - L
CHANGE DE
T
AIL: REVISED P.C.
BOARD BLANK INFORMATION
ENGINEERING CONTROL
MANUFACTURER: No
LED
REFERENCES
QTY PART NUMBER DESCRIPTION
C1, C2, C3, C4, C5, C6, C7, C8
8
T11577-58K
CAPACITOR,CD,.0047,3000V,20%
CAPACITOR,POLYPROPYLENE METALLIZED
FILM,PPMF,15MF,250VAC,10%
RESISTOR,WW,5W,10,5%,SQ
C9
1
S13490-155
R1
TP1, TP2
1
2
T14648-25
T13640-18
MOV,320VRMS,150J,20MM
P.C
.
BOARD BLANK
I
NFORMATION
C
APACITORS = MFD/VOLTS
BUY
COMPLETE AS L10121-D (2 LAYE
WITH LEA EE ASL SURFAC
AKES 12 BOARDS PER PA
R
B
OARD PE
R
E3281
INDUCTANC = HENRYS
E
D
FR
H
E
FI IS ).
N
H
M
N
EL.
SEE EL
E
CTRONIC FILE FOR DDITIONAL INFORMATION
A
I
TEM REQ'D PART NO.
IDENTIFI
CATION
1
1
SEE BLANK INFO. P.C. BOARD BLANK
3
E2861
SEALANT
.16 OZ
N.F.
,
N.G.
1.00
.04
4.50
3.80 .04
(3.450
(3.462
)
)
XXXXXXXXXXXXX
R1
1
MANUFACTURED AS:
NOTES:
N.C
.
SQ EEZE TOGETHE
U
R
I
TEM
S
C1-C4, TP1
AND
XXXXXXXXXXX
XXXXXXXXXXX
XXX
XXX
(1.900
)
C5-C9, TP2 BEFORE APPLYI
APPLY SEALANT AS SHOWN
.F. KEEP THIS A EA F EE OF ENCAPS
BOTTOM OF BOARD.
.G. TIN ALL E POSED COPPER WITH SOLDER IN T
BOT SI ES OF BOARD.
O ICICLES O SOLDER BLOBS A
WITHIN 0.5" 0 (BOTH SI ES).
N
G SEAL NT.
A
L10121-3D0
N.D
.
.
IDENTIFICATION CODE
N
R
R
ULATIO
N,
TOP
A
ND
N.H.
XXXXXXXXXXX
N
X
HIS A
REA,
XXX
XXXXXXXXXXXXX
M
AKE PER E1911-ROHS
ENCAPSULATE WITH E1844,
COATS.
TES PE
H
D
N.H
.
N
R
RE PERMITTED
(.338
)
(.350)
D
2
0
T
R
E3553-B
0
SCHEMATIC REFERENCE: S22530-3D0
3
(.438
)
(4.250
)
N.C.,
N.D.
A
LL
C
OMPON
E
NTS AND MATERIALS
U
SED IN THIS
ASSEMBLY ARE TO
BE
R
oH OMPLIANT PER
S
C
E4253.
FOR
PARTS ORDERS ONLY:
INCLUDE S22772PRINT
HIS DOCUME
N
T CONTAINS P
R
OPRIETARY INFORMATIO
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
N
D MAY NOT BE
D
UPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:TTO OT
HER PA
SCALE:
1:1
R
TIES O USE
R
D
FOR ANY P RPOSE WITHOUT THE E
U
X
PRESS
W
RITTEN PERMISSIO
N
OF LIN
C
OLN GLOBAL, INC.
MANUFACTURIN
NLESS OTHERWISE SPE
N 2 PLACE DECIMALS IS .02 in. ( 0.5 mm)
G
TOLERANCE PER E2056
CONTROL:
CLEVELAND
U
C
IFIE TOLERA CE:
D
N
EQUIPMENT TYPE
SUBJECT:
:
_1__
1
SW TI
G
175 & 275
PAGE
OF ___
O
DRA
WN BY:
fivory
ON
3
P
LA
C
E
DECIMALS IS .002 0.05 mm)
in.
(
IF PRINTED
DOCUMENT
DOCUMENT
REVIS ON:
O
N ALL ANGLES IS .5 OF A DEGREE
@
A2
S
IZE
NUMBER:
I
BYPASS/STABILIZER P.C. BOARD ASSEMBLY
E
NGINEER:
-
MATERIAL TOLERANCE (
"
") TO AGREE
t
U
NIITNSC: H
DISPOSITION:
REFLER1E0121-1
WITH PUBLISHED
NCE:
DO NOT SCALESTTAHNIDSARDS.
D
RAWING
APPROVAL
DATE:
MATERIAL
PROJECT
NUMBER:
L10121-3
UF
9-7-2007
C
APPROVED:
-
CRM34432
Insigh
t
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level 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.
PRECISION TIG® 225
Download from Www.Somanuals.com. All Manuals Search And Download.
|