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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.
ELECTRICAL DIAGRAMS
G-8
PRECISION TIG® 225
PC BOARD ASSEMBLY - CONTROL #2 (G5641)
EN-170
S
O
L
I
D
E
D
G
E
G564
1-
2
PRE
CISI
O
N TIG 185/2
25
CO
NT
R
OL PC BOA
R
D ASSE
M
BLY
1:1.2
5
G4551-
1
DO NO
T
SC
AL
E
T
HIS DR
A
WING
EQ
UIP
M
ENT
TYPE:
SUBJECT:
SCA
L
E:
UF
CRM36266
2
PAGE ___ OF
___
2
E
NGI
N
EE
RI
NG
CO
NT
RO
LLE
D
MA
NU
FA
CT
URE
R:
Y
es
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBA
L, INC.
AND MA
Y
NOT BE DUPLICATED, COMMUNICATED
TO O
THER PARTIES OR US
ED FOR
AN
Y
PURPOS
E WITHOU
T
THE EXPRES
S WRIT
TEN PERMISSION
OF LINCOLN GLOBAL, INC.
PRO
PRIETARY & C
ONFIDENTIAL:
t
MAT
ERI
A
L TO
L
ER
ANC
E ("
"
) TO A
GR
EE
WITH
PU
B
LI
SH
ED
ST
ANDARD
S.
ON A
LL
AN
GL
E
S I
S ± .5 OF
A D
E
GR
EE
ON
3
PLACE
D
E
CIM
ALS
IS
± .
00
2 i
n.
(
±
0.
0
5
mm)
ON 2
PL
AC
E D
ECIM
AL
S I
S ± .02 in. (
±
0.5 mm)
UNLESS OTHERWISE SPECIFIED TOLERANCE:
M
ANUF
ACTURING TO
L
ER
ANC
E
P
ER
E
2056
N
EW
CHAN
GE
D
ET
AIL:
REFER
ENCE:
MA
T
ERI
AL
DIS
PO
SI
T
ION:
AP
PRO
VA
L
DA
T
E:
PROJ
EC
T
NUMBER:
DOCUMEN
T
NUMBER:
DOCUMEN
T
REV
ISI
ON:
IF PR
IN
T
ED
@ A
1
SIZ
E
UNI
T
S:
IN
CH
2/
15
/
2008
d
di
e
tz
Tran
gNg
uye
n
-
DRAWN BY:
ENGINEER:
CL
EV
EL
AND
APPROVED:
CONTROL:
A
G
5641-2
Insight
NOTES:
N.A.
THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY, SEE E2454 BEFORE
HANDLI NG.
N.B.
PROGRAM X1 WITH ITEM 6
.
N.C.
KEEP FREE OF ENCAPSULATION MATERIAL.
N.D.
SEAL COMPONENT BY APPLYING ITEM
7
AS SHOWN SO THAT ENCAPSULATION MATERIAL
DOES NOT GE
TINSIDE COMPONENT.
N.E.
KEEP FREE OF ENCAPSULATION MATERIAL (.50 DIA. MIN.) ON BOTH SIDES OF BOARD.
N.F.
KEEP MOUNTING HOLES FREE OF ENCAPSULATION MATERIAL (5 PLACES).
N.G.
COVER MOLEX WITH TAPE.
N.H.
HAND TIGHT MOUNTING WASHER AND MOUNTING NUT TO POTENT
IOMETER BUSHING.
N.J.
WHEN ASSEMBLING DISPLAY, SPACE DISPLAY OFF THE BOARD .125+/
-
.010 MEASURED
FROM BOTTOM OF DISPLAY TO PC BOARD SURFACE.
N.K.
SQUEEZE COMPONENTS TOGETHER BEFORE ENCAPSULATION.
N.L.
SEAL COMPONENT BASE WITH ITEM 8.
N.
A.
N.C.
CAPA
CI
TO
R
S
=
MF
D
/
V
OL
TS
RE
SI
S
TO
R
S
=
OHMS
OCI1
1
S15000-34SMT
IC,SMD,OPTOCOUPLER,HMA124
O
CI2, OCI3, OCI4, OCI5 4
S
15000-16
O
PTOCOUPLER,TRIAC,DRIVER,ZVC,3083
Q1, Q6 2
S25051-11SMT
TRANSISTOR,SMD,NMF,DPAK,TO-252,48A,100V(SS)
Q
2, Q3, Q5, Q7, Q9, Q10,
Q12, Q13, Q15, Q16,
Q17, Q18
12
S25050-1SMT
TRANSISTOR,SMD,NPN,0.5A,40V,SOT-23,MMBT4401LT1
Q4, Q8, Q11, Q14 4
S25050-2SMT
TRANSISTOR,SMD,PNP,SOT23,0.5A, 40V,MMBT4403LT1
R1, R2, R3 3
T10812-116
POT,SINGLE-TURN,0.25W,10K,10%
R4, R49, R50, R68, R69,
R72, R107, R122, R132,
R
162, R184, R200
12
S25000-1002SMT
RESISTOR,SMD,METAL FILM,1/10W,10.0K,1%,S0805
R5
1
S25000-1301SMT
RESISTOR,SMD,METAL FILM,1/10W,1.30K,1%,S0805
R6
1
S25000-1500SMT
RESISTOR,SMD,METAL FILM,1/10W,150OHMS,1%,S0805
R7, R9, R111, R112,
R
113, R135, R143, R145,
R147, R149, R172, R173,
R
174, R178, R191, R196,
R197, R198
18
S25001-1001SMT
RESISTOR,SMD,1K,1/4W,1206,1%,TR
R8, R34, R203 3
S25000-6812SMT
RESISTOR,SMD,METAL FILM,1/10W,68.1K,1%,S0805
R10, R11, R52, R53, R90,
R91, R103, R104
8
S25004-1R00SMT
RESISTOR,SMD,1W,1.00OHMS,1%
R12, R13, R14, R15, R26,
R27, R28, R29, R42, R43,
R44, R45, R55, R56, R57,
R58
16
S25003-1210SMT
RESISTOR,SMD,1W,121OHMS,1%
R
16, R17, R30, R31, R32,
R51, R60, R61, R92,
R
167, R194, R195, R208,
R212, R215
15
S25000-1001SMT
RESISTOR,SMD,METAL FILM,1/10W,1.00K,1%,S0805
R18
1
S25000-5622SMT
RESISTOR,SMD,METAL FILM,1/10W,56.2K,1%,S0805
R19, R64, R157, R160,
R165, R170, R217, R218,
R219, R220
10
S25001-47R5SMT
RESISTOR,SMD,47.5OHMS,1/4W,1206,1%,TR
R
20, R36, R41, R54 4
S
25003-15R0SMT
R
ESISTOR,SMD,1W,15.0OHMS,1%
R
21
1
S
25000-7681SMT
R
ESISTOR,SMD,METAL FILM,1/10W,7.68K,1%,S0805
R22
1
S25000-4752SMT
RESISTOR,SMD,METAL FILM,1/10W,47.5K,1%,S0805
R23, R79 2
S25000-2213SMT
RESISTOR,SMD,METAL FILM,1/10W,221K,1%,S0805
R24
1
S25001-2210SMT
RESISTOR,SMD,221OHMS,1/4W,1206,1%,TR
R25, R75 2
S25006-10R0SMT
RESISTOR,SMD,METAL FILM,1/2W,10OHMS,1%,S2010
R33, R38 2
S25008-1002SMT
RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.5%,S0805
R35, R84, R108, R109,
R139, R166
6
S25001-1000SMT
RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR
R37, R85, R106 3
S25000-3322SMT
RESISTOR,SMD,METAL FILM,1/10W,33.2K,1%,S0805
R39, R81, R82, R98,
R128, R131, R177, R182,
R
185, R187, R188, R210,
R
211
13
S25000-4751SMT
RESISTOR,SMD,METAL FILM,1/10W,4.75K,1%,S0805
R40, R46, R47, R73, R74,
R76, R77, R86, R96, R97,
R141, R142, R179, R180
14
S25001-4751SMT
RESISTOR,SMD,4.75K,1/4W,1206,1%,TR
R48, R199, R209, R213,
R214
5
S25000-2210SMT
RESISTOR,SMD,METAL FILM,1/10W,221OHMS,1%,S0805
R59, R136 2
S25000-4750SMT
RESISTOR,SMD,METAL FILM,1/10W,475OHMS,1%,S0805
R62
1
S25000-1000SMT
RESISTOR,SMD,METAL FILM,1/10W,100OHMS,1%,S0805
R63, R120 2
S25000-8251SMT
RESISTOR,SMD,METAL FILM,1/10W,8.25K,1%,S0805
R65, R66, R94, R95,
R130, R137
6
S25008-4751SMT
RESISTOR,SMD,PREC,MF,1/10W,4.75K,0.5%,S0805
R
67
1
S
25000-1003SMT
R
ESISTOR,SMD,METAL FILM,1/10W,100K,1%,S0805
R
70, R117, R119, R121,
R202, R204
6
S
25000-3321SMT
R
ESISTOR,SMD,METAL FILM,1/10W,3.32K,1%,S0805
R
71
1
S
25000-1004SMT
R
ESISTOR,SMD,METAL FILM,1/10W,1.00M,1%,S0805
R
78
1
S
25001-1002SMT
R
ESISTOR,SMD,10K,1/4W,1206,1%,TR
R80, R83, R216 3
S25000-1212SMT
RESISTOR,SMD,METAL FILM,1/10W,12.1K,1%,S0805
R87, R88, R89, R99,
R100, R101, R102, R205,
R206, R207
10
S25000-47R5SMT
RESISTOR,SMD,METAL FILM,1/10W,47.5OHMS,1%,S0805
R93
1
S25000-2671SMT
RESISTOR,SMD,METAL FILM,1/10W,2.67K,1%,S0805
R105, R110 2
S25003-47R5SMT
RESISTOR,SMD,1W,47.5OHMS,1%
R
114
1
S
25000-6811SMT
R
ESISTOR,SMD,METAL FILM,1/10W,6.81K,1%,S0805
R
115
1
S
25000-2212SMT
R
ESISTOR,SMD,METAL FILM,1/10W,22.1K,1%,S0805
R116, R153, R154 3
S25003-2002SMT
RESISTOR,SMD,1W,20.0K,1%
R118
1
S25001-4752SMT
RESISTOR,SMD,47.5K,1/4W,1206,1%,TR
R
123, R133 2
S
25000-2211SMT
R
ESISTOR,SMD,METAL FILM,1/10W,2.21K,1%,S0805
R
124, R125, R127, R171,
R181, R189
6
S
25003-2000SMT
R
ESISTOR,SMD,1W,200OHMS,1%
R126, R138 2
S25001-1213SMT
RESISTOR,SMD,121K,1/4W,1206,1%,TR
R129
1
S25000-2001SMT
RESISTOR,SMD,METAL FILM,1/10W,2.00K,1%,S0805
R134
1
S25000-6813SMT
RESISTOR,SMD,METAL FILM,1/10W,681K,1%,S0805
R140
1
S25000-3323SMT
RESISTOR,SMD,METAL FILM,1/10W,332K,1%,S0805
R144, R146, R148, R150,
R186, R190, R192, R193
8
S25001-2670SMT
RESISTOR,SMD,267OHMS,1/4W,1206,1%,TR
R151, R152, R155, R156,
R158, R159, R163, R164,
R168, R169, R175, R176
12
S25001-1821SMT
RESISTOR,SMD,1.82K,1/4W,1206,1%,TR
R161
1
S25001-7500SMT
RESISTOR,SMD,750OHMS,1/4W,1206,1%,TR
R183
1
S25000-1502SMT
RESISTOR,SMD,METAL FILM,1/10W,15.0K,1%,S0805
R201
1
S25001-2211SMT
RESISTOR,SMD,2.21K,1/4W,1206,1%,TR
S1
1
T13381-16
SWITCH,PUSHBUTTON,SPST
T1, T2 2
T12737-2
TRANSFORMER,PULSE,3-WINDING,1:1:1
TRI1, TRI2, TRI3, TRI4 4
S15161-27
TRIAC,TO220,8A,800V
X1
1
S25073-12SMT
IC,SMD,CMOS,PSOC,8-BIT,CY8C27643,TFN49(SS)
X2
1
S15128-27SMT
IC,OP-AMP,SINGLE,PRECISION,LT1097S8
X3, X4, X14 3
S15128-28SMT
IC,OP-AMP,SMT,QUAD,HIGH-PERF,33074ADT
X5
1
S15128-6
IC,VOLT REG,FIXED,3-T,(+),1A,15V,TO220
X6
1
S15128-10SMT
IC,SMD,VOLTAGE REF,ADJ, PRECISION,431I,SOIC-8
X7
1
M15102-4SMT
IC,SMD,ARRAY,DRIVER,PERIPHERAL,NPN,DARLINGTON
X8
1
S15128-5SMT
IC,VOLT REG,SMD,FIXED,3-T,(+),1A,5V
X9
1
S25072-2SMT
IC,SMD,ACT,BUFFER,OCTAL,3-STATE,TSSOP-20(SS)
X10
1
S15018-21SMT
IC,SMD,CMOS,DRIVER,MOSFET,4451, SOIC-8(SS)
X11
1
S17900-24SMT
IC,SMD,CMOS,GATE,NAND,2-INPUT,QUAD,SCHM(SS)
X12
1
S25065-3SMT
IC,SMD,CMOS,INVERTER,SCHMITT,HEX,VHC14(SS)
X13
1
S15018-11SMT
IC,SMD,CMOS,SWITCH,ANALOG,QUAD,201(SS)
ITEM (USED WITH)*`
QTY
PART NUMBER
DESCRIPTION
11
G5641-C
PC BOARD BLANK
2 (TRI1, TRI3, X5)* 3
CF000003
6-32 X .375 ROUND HEAD MACHINE SCREW
3 (TRI1, TRI3, X5)* 3
E106A-13
# 6 LOCK WASHER
4
(TRI1, TRI3, X5)* AS REQ
E
1868
T
HERMO JOINT COMPOUND
5 (TRI1, TRI3, X5)* 3
S18104-3
HEAT SINK,ALUMINUM,EXTRUDED,FOR 1 TO-220
61
S26585-4
PSOC SOFTWARE
7AS REQ
E2861
SEALANT
8AS REQ
E2519-1
SEALANT
REFERENCES
QTY
PART NUMBER
DESCRIPTION
A
1
1
M
17789-4
E
NCODER,INCREMENTAL,2-BIT,PEC12
C1, C3, C29, C39, C41,
C
42, C43, C58, C60, C78,
C84, C89, C90, C91, C92,
C94, C95, C103, C104,
C109, C110
21
S25020-2SMT
CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%,X7R,S0805
C
2, C10, C35, C111 4
S
25020-9SMT
C
APACITOR,SMD,CERAMIC,47pF,50V,5%,COG,S0805
C4, C23, C38 3
S25024-2SMT
CAPACITOR,SMD,TANTALUM,1.0MF,35V,10%,S3528
C
5, C20, C45 3
S
25020-12SMT
C
APACITOR,SMD,CERAMIC,100pF,100V,5%,COG,S0805
C6, C7, C9, C12, C17,
C18, C24, C30, C31, C32,
C34, C44, C53, C59
14
S25020-10SMT
CAPACITOR,SMD,CERAMIC,4700pF,50V,10%,XR7,S0805
C8, C13, C25, C26 4
S20500-17
CAPACITOR,PPMF,0.1MF,630V,5%,BOX
C11, C14, C19, C21, C22,
C33, C48, C50, C51, C52,
C55, C56, C62, C64, C66,
C68, C74, C75, C76, C79,
C
80, C81, C82, C83, C85,
C93, C98, C100, C105,
C107, C108, C112
32
S25020-3SMT
CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X7R,S0805
C
15, C63 2
S
25020-4SMT
C
APACITOR,SMD,CERAMIC,820pF,50V,5%,COG,S0805
C
16, C40, C113 3
S
25020-14SMT
C
APACITOR,SMD,CERAMIC,330pF,100V,5%,COG,S0805
C
27, C36, C37 3
S
25020-7SMT
C
APACITOR,SMD,CERAMIC,0.22MF,50V,20%,X7R,S1812
C
28
1
S
25020-24SMT
C
APACITOR,SMD,CERAMIC,1.0MF,25V,10% ,X7R,S1206
C46, C49 2
S13490-199
CAPACITOR,ALEL,220,25V,20%,LOW-ESR
C
47
1
S
13490-179
C
APACITOR,ALEL,1000,35V,20%
C
54, C69, C70, C73, C86,
C
96, C99, C101, C106
9
T
11577-52K
C
APACITOR,CD,.0047/.005,1400V,20%
C57, C61, C65 3
S13490-197
CAPACITOR,ALEL,82,35V,20%,LOW-ESR
C67, C77 2
S25020-5SMT
CAPACITOR,SMD,CERAMIC,2700pF,50V,5%,X7R,S0805
C71, C72, C87, C88, C102 5
T11577-58K
CAPACITOR,CD,.0047,3000V,20%
C97
1
S13490-181
CAPACITOR,ALEL,22,63V,20%
D
1, D2, D3, D5, D7, D8,
D
21, D22
8
S25040-1SMT
DIODE,SMD,1A,400V,FAST RECOVERY,DO-214BA
D4, D6, D16, D18, D19,
D20, D28, D31, D32, D35,
D
40, D41
12
S25040-5SMT
DIODE,SMD,DUAL,0.200A,70V,UFR
D
9, D10, D11, D12, D13,
D
14, D15, D17, D23, D29,
D30, D33, D34, D36, D37,
D38, D39
1
7
S
25040-2SMT
D
IODE,SMD,1A,400V,DO-214BA/AC
D24, D25, D26, D27 4
S25040-10SMT
DIODE,SMD,3A,400V,D0-214AB
DISP1
1
S17395-11
LED,DISPLAY,7-SEGMENT,CC,3-DIGIT
DZ1, DZ8, DZ10 3
S25046-4SMT
ZENER DIODE,SMD,0.5W,12V,5%,SOD-123
DZ2, DZ3 2
S25046-3SMT
ZENER DIODE,SMD,0.5W,18V, 5%,SOD123
DZ4
1
S25046-1SMT
ZENER DIODE,SMD,0.5W,5.1V, 5%,SOD123
DZ5, DZ6 2
S25045-1SMT
ZENER DIODE,SMD,225mW,12V,5%,SOT-23
D
Z7, DZ9 2
S
25044-3SMT
Z
ENER DIODE,SMD,3W,12V,5%, SMB
J
1
1
S
24020-2G
C
ONNECTOR,MOLEX,MINI,PCB,2-PIN,GOLD
J
2
1
S
24020-8
C
ONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
J3
1
S24020-12
CONNECTOR,MOLEX,MINI,PCB,12-PIN,TIN
J4
1
S24020-4
CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN
J
5
1
S
24020-6
C
ONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
J6
1
S18248-4
CONNECTOR,MOLEX,MINI,PCB,4-PIN
L1, L2, L3, L4, L5 5
T12218-9
CHOKE,RF,390UH,5%, 225MA,CONFORMAL
LED1
1
T13657-2
LED,T-1,3/4,RED,HLMP-3003
LED2, LED6 2
T13657-14
LED,T-1,3/4,AMBER,HIGH-INTENSITY
LED3, LED4, LED5 3
T13657-3
LED,T-1,3/4,GREEN,HLMP-3502
LED7, LED8, LED9,
LED10, LED15, LED16,
L
ED17
7
S25080-2SMT
LED,SMD,GREEN,CLEAR,S1206
L
ED11, LED12, LED13,
LED14
4
S
25080-1SMT
L
ED,SMD,RED,CLEAR,S1206
M
OV1
1
T
13640-16
M
OV,150VRMS,80J,20MM
M
OV2, MOV3, MOV4,
MOV5
4
T13640-25
MOV,130VRMS,90J,20MM
MOV6, MOV7, MOV8 3
T13640-18
MOV,320VRMS,150J,20MM
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
ALL COMPONENTS AND MATERIALS USED
I
NTHIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253
N
.L.
N.C.
N.
C.,
N.D. N.C.
N.F.
N.
E.
N.
C.,
N.
D.,
N.
H. (3
PL
ACE
S)
N.C.
N.
C.,
N.J.
XXXXX
XXXXX
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
XXXXXX
XXXXX
XXXXXX
XXXXX
X
X
X
X
X
X
X
X
X
X
XXXXXX
X
X
X
X
X
X
X
X
XXXXX
X
X
XXX
XXX
X
X
X
X
X
X
X
X
A1
L
ED
6
R3
S1
L
ED
5
L
ED
1
R2
L
ED
2
DI
SP
1
L
ED
4
L
ED
3
R1
OPPOSITE COMPONENT SIDE
G-8
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