RETURN TO MAIN MENU
IM895
May, 2007
PRECISION TIG 225
11317, 11318, 11319
For use with machines having Code Numbers:
(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 thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
IP 21S
OPERATOR鈥橲 MANUAL
Copyright 漏 2007 Lincoln Global Inc.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
i i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of 鈥淪afety in Welding & Cutting - ANSI Standard Z49.1鈥? from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of 鈥淎rc Welding Safety鈥? booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
powered equipment. radiator pressure cap when the engine is
hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
Mar 驶95
magneto wire as appropriate.
SAFETY
ii ii
ARC RAYS can burn.
ELECTRIC SHOCK can
kill. 4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically 鈥渉ot鈥? when the welder is on. open arc welding. Headshield and filter lens
Do not touch these 鈥渉ot鈥? parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
FUMES AND GASES
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
can be dangerous.
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 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
鈥? Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
鈥? DC Manual (Stick) Welder. your head out of the fume. Use enough
鈥? AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
3.c. In semiautomatic or automatic wire welding, the electrode,
ventilation such as stainless or hard facing (see
electrode reel, welding head, nozzle or semiautomatic
instructions on container or MSDS) or on lead or
welding gun are also electrically 鈥渉ot鈥?.
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
3.d. Always be sure the work cable makes a good electrical
low as possible and below Threshold Limit Values (TLV)
connection with the metal being welded. The connection
using local exhaust or mechanical ventilation. In
should be as close as possible to the area being welded.
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.e. Ground the work or metal to be welded to a good electrical
also required when welding on galvanized steel.
(earth) ground.
5. b. The operation of welding fume control equipment is affected
3.f. Maintain the electrode holder, work clamp, welding cable and
by various factors including proper use and positioning of
welding machine in good, safe operating condition. Replace
the equipment, maintenance of the equipment and the spe-
damaged insulation.
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.g. Never dip the electrode in water for cooling.
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
3.h. Never simultaneously touch electrically 鈥渉ot鈥? parts of
electrode holders connected to two welders because voltage
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
between the two can be the total of the open circuit voltage
coming from degreasing, cleaning or spraying operations.
of both welders.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.i. When working above floor level, use a safety belt to protect
ucts.
yourself from a fall should you get a shock.
5.d. Shielding gases used for arc welding can displace air and
3.j. Also see Items 6.c. and 8.
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始s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer始s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
SAFETY
iii iii
WELDING and CUTTING CYLINDER may explode
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
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 7.c. Cylinders should be located:
situations. Refer to 鈥淪afety in Welding and Cutting鈥? (ANSI 鈥? Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
鈥? A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
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 鈥渉ot鈥? 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 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been 鈥渃leaned鈥?. For information, purchase 鈥淩ecommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances鈥?, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or 鈥淧recautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,鈥? available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
FOR ELECTRICALLY
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
powered equipment.
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
8.b. Install equipment in accordance with the U.S. National
increase the possibility of the welding current passing
Electrical Code, all local codes and the manufacturer始s
through lifting chains, crane cables or other alternate cir-
recommendations.
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer始s recommendations.
6.h. Also see item 1.c.
Jan, 07
6.I. Read and follow NFPA 51B 鈥? Standard for Fire Prevention
During Welding, Cutting and Other Hot Work鈥?, 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.
SAFETY
iv iv
PR脡CAUTIONS DE S脹RET脡 5. Toujours porter des lunettes de s茅curit茅 dans la zone de
soudage. Utiliser des lunettes avec 茅crans lateraux dans les
zones o霉 l始on pique le laitier.
Pour votre propre protection lire et observer toutes les instructions
et les pr茅cautions de s没ret茅 specifiques qui parraissent dans ce
6. Eloigner les mat茅riaux inflammables ou les recouvrir afin de
manuel aussi bien que les pr茅cautions de s没ret茅 g茅n茅rales suiv-
pr茅venir tout risque d始incendie d没 aux 茅tincelles.
antes:
7. Quand on ne soude pas, poser la pince 脿 une endroit isol茅 de
S没ret茅 Pour Soudage A L始Arc
la masse. Un court-circuit accidental peut provoquer un
1. Protegez-vous contre la secousse 茅lectrique:
茅chauffement et un risque d始incendie.
a. Les circuits 脿 l始茅lectrode et 脿 la pi茅ce sont sous tension
8. S始assurer que la masse est connect茅e le plus pr茅s possible
quand la machine 脿 souder est en marche. Eviter toujours
de la zone de travail qu始il est pratique de le faire. Si on place
tout contact entre les parties sous tension et la peau nue
la masse sur la charpente de la construction ou d始autres
ou les v茅tements mouill茅s. Porter des gants secs et sans
endroits 茅loign茅s de la zone de travail, on augmente le risque
trous pour isoler les mains.
de voir passer le courant de soudage par les chaines de lev-
b. Faire tr茅s attention de bien s始isoler de la masse quand on
age, c芒bles de grue, ou autres circuits. Cela peut provoquer
soude dans des endroits humides, ou sur un plancher
des risques d始incendie ou d始echauffement des chaines et des
metallique ou des grilles metalliques, principalement dans
c芒bles jusqu始脿 ce qu始ils se rompent.
les positions assis ou couch茅 pour lesquelles une grande
partie du corps peut 锚tre en contact avec la masse.
9. Assurer une ventilation suffisante dans la zone de soudage.
c. Maintenir le porte-茅lectrode, la pince de masse, le c芒ble
Ceci est particuli茅rement important pour le soudage de t么les
de soudage et la machine 脿 souder en bon et s没r 茅tat
galvanis茅es plomb茅es, ou cadmi茅es ou tout autre m茅tal qui
defonctionnement.
produit des fume茅s toxiques.
d.Ne jamais plonger le porte-茅lectrode dans l始eau pour le
refroidir.
10. Ne pas souder en pr茅sence de vapeurs de chlore provenant
e. Ne jamais toucher simultan茅ment les parties sous tension
d始op茅rations de d茅graissage, nettoyage ou pistolage. La
des porte-茅lectrodes connect茅s 脿 deux machines 脿 souder
chaleur ou les rayons de l始arc peuvent r茅agir avec les vapeurs
parce que la tension entre les deux pinces peut 锚tre le
du solvant pour produire du phosg茅ne (gas fortement toxique)
total de la tension 脿 vide des deux machines.
ou autres produits irritants.
f. Si on utilise la machine 脿 souder comme une source de
courant pour soudage semi-automatique, ces precautions
11. Pour obtenir de plus amples renseignements sur la s没ret茅,
pour le porte-茅lectrode s始applicuent aussi au pistolet de
voir le code 鈥淐ode for safety in welding and cutting鈥? CSA
soudage.
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se prot茅ger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le c芒ble-茅lectrode autour de n始importe quelle partie
PR脡CAUTIONS DE S脹RET脡 POUR
du corps.
LES MACHINES 脌 SOUDER 脌
3. Un coup d始arc peut 锚tre plus s茅v猫re qu始un coup de soliel,
TRANSFORMATEUR ET 脌
donc:
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant appropri茅
ainsi qu始un verre blanc afin de se prot茅ger les yeux du ray-
onnement de l始arc et des projections quand on soude ou
quand on regarde l始arc. 1. Relier 脿 la terre le chassis du poste conformement au code de
b. Porter des v锚tements convenables afin de prot茅ger la l始茅lectricit茅 et aux recommendations du fabricant. Le dispositif
peau de soudeur et des aides contre le rayonnement de de montage ou la piece 脿 souder doit 锚tre branch茅 脿 une
l驶arc. bonne mise 脿 la terre.
c. Prot茅ger l始autre personnel travaillant 脿 proximit茅 au
soudage 脿 l始aide d始茅crans appropri茅s et non-inflammables. 2. Autant que possible, I始installation et l始entretien du poste seront
effectu茅s par un 茅lectricien qualifi茅.
4. Des gouttes de laitier en fusion sont 茅mises de l始arc de
soudage. Se prot茅ger avec des v锚tements de protection libres 3. Avant de faires des travaux 脿 l始interieur de poste, la debranch-
de l始huile, tels que les gants en cuir, chemise 茅paisse, pan- er 脿 l始interrupteur 脿 la boite de fusibles.
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de s没ret茅 脿 leur
place.
Mar. 驶93
SAFETY
v v
EN 60974-10
SAFETY
vi vi
EN 60974-10:
vii vii
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
Thank You 鈥⑩?⑩?? as much pride as we have in bringing this product to you!
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer始s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change 鈥? This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
鈥? For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
鈥? For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose 鈥淨uick Links鈥? and then
鈥淧roduct Registration鈥?. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
TABLE OF CONTENTS viii
viii
Page
Installation.......................................................................................................................Section A
Technical Specifications ................................................................................................A-1,A-2
Safety Precautions ...............................................................................................................A-3
Select Suitable Location................................................................................................A-3
Environmental Rating ....................................................................................................A-3
Grinding.........................................................................................................................A-3
Stacking ........................................................................................................................A-3
Lifting and Moving .........................................................................................................A-3
Tilting.............................................................................................................................A-3
Machine Grounding and High Frequency Interference Protection .......................................A-4
Input and Grounding Connections ................................................................................A-4
Input Reconnect Procedure ..........................................................................................A-5
Output Connections..............................................................................................................A-5
Connections For Tig (GTAW) Welding..........................................................................A-6
Tig Torch Connections ..................................................................................................A-6
Work Cable Connections ..............................................................................................A-6
Shielding Gas Connection.............................................................................................A-6
Remote Control Connection ..........................................................................................A-6
Connections For Stick (SMAW) Welding .............................................................................A-6
Stick Electrode Cable and Work Cable Connection ......................................................A-6
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Graphic Symbols ..................................................................................................................B-1
Product Description ..............................................................................................................B-2
Recommended Processes and Equipment ..........................................................................B-2
Recommended Processes.. ..........................................................................................B-2
Process Limitations ......................................................................................................B-2
Recommended Equipment/Interface.............................................................................B-2
Equipment Limitations ...................................................................................................B-2
Welding Capability................................................................................................................B-2
Controls and Settings ...................................................................................................B-3, B-4
Power-Up Sequence ............................................................................................................B-4
Case Rear Components .......................................................................................................B-5
Operating Steps ...................................................................................................................B-6
Welding in TIG Mode ....................................................................................................B-6
Pulse TIG Mode ............................................................................................................B-6
Remote Control Operation ............................................................................................B-7
Benefits of the Precision TIG 225 .................................................................................B-7
Welding in Stick Mode ..........................................................................................................B-8
Recommended electrode Amperage Ranges ......................................................................B-9
________________________________________________________________________________
Accessories .....................................................................................................Section C
Standard Equipment Options ................................................................................C-1
Factory Installed Options.......................................................................................C-2
Field Installed Options ...........................................................................................C-3
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Maintenance........................................................................D-1
Spark Gap Adjustment ..........................................................................................D-1
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting ..................................................................................E-2 THRU E-7
________________________________________________________________________
Diagrams .........................................................................................................Section F
Wiring Diagram ......................................................................................................F-1
Dimension Print ...............................................................................................F-2,F-3
________________________________________________________________________
Parts List..................................................................................P-536,P-210,P-66 Series
_______________________________________________________________________
INSTALLATION
A-1 A-1
TECHNICAL SPECIFICATIONS - PRECISION TIG 225 (K2533-1AND K2535-1,-2)
INPUT - SINGLE PHASE ONLY
Standard Voltage Power Factor Idle Current
Input Current at Rated Output
PANTONE 420C - SWATCH LIBRARY SOLID COATED
42A / 39A Effective
208/230/1/60 0.62 Min. 3.0A/2.7A Max.
and 94A / 85A Maximum
OUTPUT RANGE
Maximum Open
Output Current Type of Output
Circuit Voltage
Range
(STICK AND TIG) CC (Constant Current)
AC OCV: 75
5-230 Amps (AC) AC/DC
DC OCV: 66
5-230 Amps (DC)
RATED OUTPUT
Weld Current* Weld Voltage (NEMA)
Process Duty Cycle**
GTAW
225A AC/DC 15.7 V AC/DC
10% Duty Cycle
180A AC/DC 15.2 V AC/DC
20% Duty Cycle
90A AC/DC (BAL.) 14.1 V AC/DC
100% Duty Cycle
80A AC (AUTO-BAL.) 14.0 V AC/DC
SMAW
225A AC/DC 29.0 V AC/DC
10% Duty Cycle
180A AC/DC 27.2 V AC/DC
20% Duty Cycle
90A AC/DC 23.4 V AC/DC
100% Duty Cycle
**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.
1
AC/DC Stick and Auto-Balance TIG Output Limits
2
input supply
Using provided input cable for protected
100%
90%
80%
Output Duty Cycle
70%
AC/DC Stick & Bal.TIG
60% with Max. Aux. load or
Auto-Bal. TIG w/o Aux.
50%
AC Auto-Bal. TIG with
40%
Max. Aux. Load
30%
20%
10%
0%
50 70 90 110 130 150 170 190 210 230
Output Limits allow for continuous max. rated load on 115vac auxiliary receptacle.
Output Amps
1
Wiring and protection based on the 2005 U.S. National Electric Code.
2
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
INSTALLATION
A-2 A-2
TECHNICAL SPECIFICATIONS - CANADIAN (K2533-2), 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 1.3 A/1.0 A Max.
0.62 Min.
42 A/33 A Max.
PANTONE 420C - SWATCH LIBRARY SOLID COATED
K2534-1 INPUT (at Rated Output)
Power Factor
Voltage/Phase/Freq. Current Idle Current
0.62 Min.
380/400-415/1/50/60 21 A/20 A Effective 1.5 A/1.4 A Max.
50 A/48 A Max.
N80
OUTPUT RANGE
Output Type
Max. OCV. Weld Current
CC (Constant Current)
75 V (AC) 5-230 A (AC)
AC or DC
66 V (DC) 5-230 A (DC)
RATED OUTPUT
Process Duty Cycle** Weld Current* Weld Voltage (NEMA)
SMAW
15% 225 A AC/DC 29.0 V
20% 180 A AC/DC 27.2 V
100% 90 A AC/DC 23.4 V
GTAW
10% 225 A AC/DC 15.7 V
20% 180 A AC/DC 15.2 V
100% 90 A AC/DC (Bal.) 14.1 V
80 A AC (Auto-Bal.) 14.0 v
* 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 20.71 in. 14.48 in. Approx. 192 lbs.
25.62 in.
(K2533-1,-2) 526 mm 368 mm 87.1 kgs
751 mm
(K2534-1)
Ready-Pak 20.71 in. 14.48 in. Approx. 212lbs..
25.62 in.
(K2535-1) 526 mm 368 mm 96.2 kgs.
651 mm
Ready-PakW/Cart 31.24 in. 19.81 in. Approx. 258lbs.
38.01 in.
(K2535-2) 794 mm 503 mm 117.0 kgs.
966 mm
(2) Dimensions are without Lift Eyebolt and Torch Holder
ENVIRONMENTAL RANGES
Operating Temperature -4掳F to 104掳F (-20掳C to 40掳C)
Storage Temperature -40掳F to 185掳F (-40掳C to 85掳C)
PRECISION TIG 225
INSTALLATION
A-3 A-3
SAFETY PRECAUTIONS
To install; remove the plug button from the case top
and screw the Eyebolt securely into the threaded
Read entire installation section before starting bracket beneath the case top per the below instruc-
installation. tions and warnings provided on the case top decal.
WARNING
Save the removed plug button (LE part No.T10397-2)
to cover the hole when the lift Eyebolt is removed.
WARNING
ELECTRIC SHOCK can kill.
鈥? Only qualified personnel should
鈥? Use only Lincoln provided
perform this installation.
T4550-5 1/2-13 x 1.00 eyebolt.
鈥? Turn the input power OFF at the
鈥? Fully engage threads and
disconnect switch or fuse box
torque eyebolt to 38 ft. lbs.
before working on this equipment.
鈥? Re-torque eyebolt to 38 ft. lbs.
鈥? Do not touch electrically hot before each lift.
parts.
鈥? Lift only with equipment of ade-
鈥? Always connect the PRECISION TIG 225 to a quate lifting capacity.
power supply grounded per the National Electrical FALLING 鈥? Never lift welder with gas
Code and any local codes. EQUIPMENT can cylinder attached.
--------------------------------------------------------------------------- cause injury. 鈥? Never lift welder above personnel.
SELECT SUITABLE LOCATION
MOUNTING 鈥? Lift only with equipment of adequate lifting
capacity.
鈥? Be sure machine is stable when lifting.
Environmental Rating
------------------------------------------------------------------------
The Precision TIG 225 power source carries an IP21S
environmental rating. It may be used in normal indus-
An undercarriage, provided on the Ready-Pak鈩?
trial and commercial environments. Avoid using it in
w/Cart model, is also available to easily move the the
environments which have falling water such as rain.
unit. Refer to the Accessories section of this manual.
Do not attempt to lift the power source with an
Read and follow "Electric Shock Warnings" in the
undercarriage attached.
Safety section if welding must be performed under
electrically hazardous conditions such as welding in
The undercarriage is designed for hand moving only;
wet areas or on or in the workpiece.
mechanized movement can lead to personal injury
and/or damage to the Precision TIG 225.
鈥? The Precision TIG 225 must be located where there
is free circulation of clean air such that air move-
TILTING
ment in and out the back air vents will not be
Each machine must be placed on a secure, level sur-
restricted.
face, either directly or on a recommended undercar-
鈥? Dirt and dust that can be drawn into the Precision
riage. The machine may topple over if this procedure
TIG 225 should be kept to a minimum. Failure to
is not followed.
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
INSTALLATION
A-4 A-4
MACHINE GROUNDING AND HIGH FRE- The ground should be securely made and the ground-
QUENCY INTERFERENCE PROTECTION 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
Locate the Precision TIG 225 away from radio controlled
system can result in re-radiation, effectively making
machinery. The normal operation of the Precision TIG
these members radiating antennas.
225 may adversely affect the operation of RF controlled
equipment, which may result in bodily injury or damage
6. Keep cover and all screws securely in place.
to the equipment.
7. Electrical conductors within 50 ft (15.2m) of the welder
This welder must be grounded! See your local and
should be enclosed in grounded rigid metallic conduit
national electrical codes for proper grounding meth-
or equivalent shielding, wherever possible. Flexible
ods.
metallic conduit is generally not suitable.
The high frequency generator, being similar to a radio
8. When the welder is enclosed in a metal building,the
transmitter, may cause radio, TV and electronic equip-
metal building should be connected to several good
ment interference problems. These problems may be the
earth driven electrical grounds (as in 5 (b) above)
result of radiated interference. Proper grounding meth-
around the periphery of the building.
ods can reduce or eliminate radiated interference.
Failure to observe these recommended installation pro-
Radiated interference can develop in the following four
cedures can cause radio or TV and electronic equipment
ways:
interference problems and result in unsatisfactory weld-
1. Direct interference radiated from the welder.
ing performance resulting from lost high frequency
2. Direct interference radiated from the welding leads.
power.
3. Direct interference radiated from feedback into the
power lines.
INPUT AND GROUNDING CONNECTIONS
4. Interference from re-radiation of 鈥減ickup鈥? by unground-
ed metallic objects.
Only a qualified electrician should connect the Precision
TIG 225. Installation should be made in accordance with
Keeping these contributing factors in mind, installing
the appropriate National Electrical Code, all local codes
equipment per the following instructions should minimize
and the information in this manual.
problems.
1. Keep the welder power supply lines as short as possi- Be sure the voltage, phase, and frequency of the input
ble and enclose as much of them as possible in rigid power is as specified on the rating plate, located on the
metallic conduit or equivalent shielding for a distance rear of the machine.
of 50 feet (15.2m). There should be good electrical
contact between this conduit and the welder case 208/230 volt models have a NEMA 6-50P plug attached
ground. Both ends of the conduit should be connected to the #6-3 input power cord and a NEMA 6 -50R recep-
to a driven ground and the entire length should be tacle is included with the Ready-Pak鈩? models. Other
continuous. voltage models have an #12-3 input power cord but no
2. Keep the work and electrode leads as short as possi- plug or receptacle.
ble and as close together as possible. Lengths should
not exceed 25 ft (7.6m). Tape the leads together when Have a qualified electrician provide input power supply to
practical. the receptacle or cord in accordance with all local and
3. Be sure the torch and work cable rubber coverings are national electrical codes. Use a single phase line or one
free of cuts and cracks that allow high frequency leak- phase of a two or three phase line. Choose an input and
age. grounding wire size according to local or national codes.
Refer to the Technical Specifications page at the
4. Keep the torch in good repair and all connections tight
to reduce high frequency leakage. beginning of this section. Fuse the input circuit with the
5. The work piece must be connected to an earth ground recommended super lag fuses or delay type 1 circuit
close to the work clamp, using one of the following breakers. Using fuses or circuit breakers smaller than
methods: recommended may result
in 鈥渘uisance鈥? shut-offs from welder inrush currents even
a) A metal underground water pipe in direct contact with if not welding at high currents.
the earth for ten feet or more.
b) A 3/4鈥? (19mm) galvanized pipe or a 5/8鈥? (16mm)solid 1Also called 鈥渋nverse time鈥? or 鈥渢hermal/magnetic鈥? circuit breakers;
galvanized iron, steel or copper rod driven at least circuit breakers which have a delay in tripping action that decreases
eight feet into the ground. as the magnitude of the current increases.
PRECISION TIG 225
INSTALLATION
A-5 A-5
INPUT RECONNECT PROCEDURE
On multiple input voltage welders, be sure the INPUT LEADS
machine is connected per the following instructions L1 & L2
for the voltage being supplied to the welder.
CAUTION LEAD H1
Failure to follow these instructions can cause
(DO NOT
REMOVE)
immediate failure of components within the welder
and void machine始s 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 BACK VIEW OF LINE SWITCH
refer to the following instructions.
WARNING FIGURE A.1 Reconnect Leads
ELECTRIC SHOCK can kill.
鈥? Turn the input power OFF at the dis-
connect switch or fuse box before
OUTPUT CONNECTIONS
working on this equipment.
------------------------------------------------------------------------
For the lowest rated voltage connection (Refer to figure A.1):
1. Remove the sheet metal left side cover.
2. Disconnect lead H3 from the power switch and
ELECTRODE/GAS
insulate with the insulation from the H2 lead.
OUTLET
RECEPTACLE
3. Connect lead H2 to the power switch where H3 was
(TWIST-MATE)
connected.
4. Tighten connections.
5. Replace sheet metal cover and all screws
WORK CABLE & CLAMP
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:
1. Remove the sheet metal left side cover.
CONNECTIONS FOR TIG (GTAW) WELDING
FIGURE A.2 Location of Output Connections
2. Disconnect lead H2 from the power switch and
insulate with the insulation from the H3 lead.
TIG TORCH CONNECTION
3. Connect lead H3 to the line switch where H2 was
Refer to Included Equipment in the Operation
connected.
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
INSTALLATION
A-6 A-6
CONNECTIONS FOR TIG (GTAW) WELDING The availiable Under-Storage Cart features a low plat-
form that simplifies loading and unloading of gas cylin-
ders.
TIG TORCH CONNECTION
WARNING
Refer to Included Equipment in the Operation
Section of this manual for TIG welding equipment
CYLINDER could explode
which is included with the PRECISION TIG 225.
if damaged.
鈥? Keep cylinder upright and chained
A PTA-17 Twist-Mate TIG welding torch with cable
to a support.
and connector is supplied with the Ready-Pak Models
鈥? Keep cylinder away from areas
and available for other models (See Accessories
where it could be damaged.
Section). Turn the Power Switch 鈥淥FF鈥?. Connect the
鈥? Never allow the torch to touch the cylinder.
torch cable Twist-Mate quick connect plug into the
鈥? Keep cylinder away from live electrical circuits.
Electrode/Gas Output Receptacle on the front of the
鈥? Maximum inlet pressure 150 psi.
welder and turn it clockwise until it is tight. This is a
------------------------------------------------------------------------
Twist-Mate quick connect terminal and also provides
A cylinder is loaded by leaning it slightly sideways and
the gas connection for the shielding gas to the torch.
rocking it up on the platform, being careful not to
WARNING
allow the Under-Storage Cart to roll. Secure the
cylinder in place with the provided chain. Unload
by following these steps in reverse.
To avoid receiving a high frequency shock, keep
the TIG torch and cables in good condition.
REMOTE CONTROL CONNECTION
------------------------------------------------------------------------
WORK CABLE CONNECTION
A remote control receptacle is provided on the case
front of the welder for connecting a remote control to
A work cable with attached work clamp is factory con-
to the machine. A Foot Amptrol鈩?, foot activated
nected to the PRECISION TIG 225. To minimize high
remote control, is included with the PRECISION TIG
frequency interference, refer to Input and Ground
225 Ready-Pak鈩? models and availiable separately
and High Frequency Interference Protection sec-
for other models. Refer to the Optional Accessories
tion of this manual for the proper procedure on
Section of this manual for other available remote con-
grounding the work clamp and work piece.
trols.
SHIELDING GAS CONNECTION
CONNECTIONS FOR STICK (SMAW)
WELDING
An adjustable gas pressure regulator with flow gage
and hose is supplied with the PRECISION TIG 225
Ready-Pak鈩? models and available separately for STICK ELECTRODE CABLE AND WORK CABLE
other models (See Accessories Section). Obtain the CONNECTION
necessary inert shielding gas (usually argon). Connect
the cylinder of gas with the pressure regulator and Refer to Field Installed Options in the Accessories
flow gage. Install the gas hose between the regulator Section of this manual for STICK welding equipment
and gas inlet (located on the rear of the welder). The which is availiable for use with the PRECISION TIG
gas inlet has a 5/16-18 right hand female thread; 225. An electrode holder with Twist-Mate cable and
CGA#032. Twist-Mate connector are availiable separately for use
with the PRECISION TIG 225. (See Accessories
Section). Turn the Power Switch 鈥淥FF鈥?. Connect
the Twist-Mate quick connect plug into the
Electrode/Gas Output Receptacle and turn it clock-
wise until it is tight. The work cable and work clamp
are factory connected.
PRECISION TIG 225
OPERATION
B-1 B-1
SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON
Read and understand this entire section before oper-
THIS MACHINE OR IN THIS MANUAL
ating the machine.
WARNING
INPUT POWER
ELECTRIC SHOCK
can kill.
POSITIVE OUTPUT
鈥? Do not touch electrically live parts
or electrode with skin or wet cloth-
ing.
鈥? Insulate yourself from work and
NEGATIVE OUTPUT
ground.
鈥? Always wear dry insulating gloves.
鈥? Read and follow 鈥淓lectric Shock Warnings鈥? in the
Safety section if welding must be performed under
DIRECT CURRENT
electrically hazardous conditions such as welding in
wet areas or on or in the workpiece.
--------------------------------------------------------------------------------
PROTECTIVE
FUMES AND GASES
GROUND
can be dangerous.
鈥? Keep your head out of fumes.
WARNING OR
鈥? Use ventilation or exhaust at the
arc, or both, to remove fumes and
CAUTION
gases from breathing zone and
general area.
------------------------------------------------------------------------
DO NOT SWITCH
WELDING SPARKS can cause fire or
WHILE WELDING
explosion
SINGLE PHASE
鈥? Keep flammable material away.
TRANSFORMER AC AND
鈥? Do not weld on containers that
RECTIFIER DC POWER
have held combustibles.
SOURCE
------------------------------------------------------------------------
ARC RAYS can burn.
OFF
鈥? Wear eye, ear and body
protection.
------------------------------------------------------------------------
Observe additional Safety Guidelines detailed in
ON
the beginning of this manual.
------------------------------------------------------------------------
PRECISION TIG 225
OPERATION
B-2 B-2
PRODUCT DESCRIPTION PROCESS LIMITATIONS
The Precision TIG machines are not recommended for arc
The PRECISION TIG 225 is a member of our field
gouging due to its limited output capacity, and are also not
acclaimed Precision TIG family of industrial arc welding
recommended for pipe thawing.
power sources. Premium features include:
RECOMMENDED EQUIPMENT/INTERFACE
1. Precise constant current output.
(See Installed Options in Accessories Section for
2. Full range square wave AC/DC TIG (GTAW) welding.
more details)
3. Enhanced version of the patented Micro-Start II鈩?
Technology for its lower Minimum(5 amps) to higher
The PRECISION TIG 225 will be available as a basic
Maximum (230 amps) output control range.
Machine (Only) and in two Factory-Configured Welding
4. Built-in high frequency stabilization for DC TIG starting
Packages:
and continuous AC TIG welding.
1. Machine(Only) (K2345-1)
5. AC/DC Stick (SMAW capability.) A new undercarriage
2. Ready-Pak (K2347-1)
(with gas bottle rack) is available for field installation, or is
3. Ready-Pak w/Cart (K2347-2)
included with an available Ready-Pak TIG Welding
Package. The Precision TIG patented convenient built-in
Basic module will also be available as with Domestic,
storage provisions for welding components and cable
Canadian and International input voltages for user configu-
management.
ration, with optional accessories.
The PRECISION TIG 225 also provides advanced features 208/230/1/60 Machine with NEMA 6-50P
Select Machine
Plug Cable and Receptacle (K2533-1)
such as: 460/575/1/60 Machine only with cable (K2533-2)
鈥? Digital Meter 380/400/415/1/50/60 Machine only
鈥? Presettable control, adjustable Auto Balance鈩? with cable (K2534-1)
鈥? Fan As Needed (F.A.N.) Torch Starter Kit Air Cooled System: Water Cooled System:
(Select one) TIG-Mate TIG-Mate 20
鈥? Timers for fixed Preflow and variable Postflow shielding Torch Starter Kit* Torch Starter Kit*
gas. Water Cooler Not Applicable 115V 50/60Hz
鈥? Built-in, easy to set single knob Pulse TIG control with a Cool-Arc 40*
"blinking" light to indicate the pulse frequency setting. Under-Storage K2348-(*)
Cart (Optional )
鈥? Auto-Sense remote control selection. Optional Remote Arc Start Switch*
鈥? Tool-less Twist-Mate electrode cable connection. Trigger Device Foot Amptrol*
鈥? Built-in work clamp cable permanently attached. (Select one) Start Pedal Foot Amptrol*
Hand Amptrol*
*For 鈥淧art Numbers鈥? or 鈥淜 Numbers鈥? see Accessories Section.
Four models are available for 60Hz. with Domestic and
EQUIPMENT LIMITATIONS
Canadian input voltages, as well as an International model
with 50/60Hz voltages.
The Precision TIG machines are protected from over loads
An Auxiliary 115vac Receptacle with Circuit Breaker are beyond the output ratings and duty cycles, per the
included on the back panel of the Precision TIG 225 models. Specifications in the Installation Section, with Thermostat pro-
The Canadian (K2533-2) and International (K2534-1) mod- tection of the output power coils and rectifiers.
els are rated 6 amps, while the 208/230/1/60 models
(K2533-1 and K2535-1/-2) are rated 20 amps (for use with The PRECISION TIG 225 machine uses Twist-Mate output ter-
Lincoln始s 115v SP and Power Mig models). minals, 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始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 The PRECISION TIG 225 is rated at 225 amps, 29 volts, at
AC/DC. It is compatible with most Magnum TIG acces- 10% duty cycle on a ten minute basis. It is capable of higher
sories, as well as many industry standard items, such as duty cycles at lower output currents. See rated output graph, on
TIG torches (adapted for Twist-Mate), hoses, and water specification sheet located in the Installation Section. If the duty
coolers. cycle is exceeded, a thermal protector will shut off the output
until the machine cools.
PRECISION TIG 225
OPERATION
B-3 B-3
All operator controls and adjustments are located on the front of the PRECISION TIG 225. Refer to Figure B.1
CONTROLS AND SETTINGS
and corresponding explanations.
FIGURE B.1 - CONTROL PANEL
13 9 5
1. POWER SWITCH
2. POLARITY SWITCH
3. MODE SWITCH
3 4. AC BALANCE CONTROL
5. MAXIMUM OUTPUT CONTROL (AMPS)
6. DIGITAL METERS
7. POST FLOW TIME
8. PULSE TIG CONTROL
9. THERMAL SHUTDOWN LIGHT
10. REMOTE RECEPTACLE
4 11. ELECTRODE/GAS OUTPUT
RECEPTACLE
12. WORK CABLE
13. REMOVABLE LIFT EYEBOLT
6
8
7
1
2
11
10
12
鈥? Auto Balance position indicated by the Green panel
CONTROL FUNCTIONALITY
1. POWER SWITCH 鈥? Input line switch turns input light turning on. This feature automatically provides
the proper amount of cleaning and penetration for
power ON or OFF, as indicated by the on or off sta-
normal AC TIG welding.
tus of the front panel digital display (See Item 6,
also see the following page for Power-Up
5. MAXIMUM OUTPUT CONTROL 鈥? Presets the out-
Sequence).
put welding current over the rated output range of
2. POLARITY SWITCH 鈥? The rotary power switch has the machine:
鈥? With a Remote Current Control (Amptrol) connect-
3-positions for DC+, AC and DC- selections for the
ed to the Remote Receptacle (See item 10), this
electrode output stud welding polarity.
knob sets the Maximum output current level set
CAUTION table with the remote Amptrol.
鈥? For Pulse TIG (See Item 8) this knob sets the
Peak Pulse level, with the Remote Amptrol (if
鈥? Do not switch the polarity switch
while welding or damage may result used).
to the machine.
6. DIGITAL METER 鈥? A 3 digit LED meter is used to
display the preset output current level before weld-
------------------------------------------------------------------------
3. MODE SWITCH 鈥? The push button switch allows ing, and actual output level while welding:
鈥? A lit display indicates input power is turned on.
selection of the two machine welding modes as
(See Item 1).
indicated by colored mode lights:
鈥? STICK mode 鈥? Top position Red light.
7. POST FLOW TIME 鈥? Sets the TIG mode shielding
鈥? TIG mode 鈥? Bottom position Green light.
gas post flow time over the range of about 1 to 30
4. AC BALANCE CONTROL 鈥? The potentiometer seconds after the arc is shut off.
control permits AC TIG wave balance adjustment
Note: Gas preflow time is fixed at 0.5 second only in
from Max. Penetration (~80% negative wave) at full
TIG mode, but no preflow time will occur if the arc is
CW rotation setting, to CCW rotation Max. Cleaning
restarted during Post Flow time, since shielding gas
(~60% positive wave), and includes:
would not have stopped flowing.
PRECISION TIG 225
OPERATION
B-4 B-4
POWER-UP SEQUENCE
8. PULSE TIG CONTROL 鈥? The Pulse TIG feature
built into the PRECISION TIG 225 is simplified to
be a single knob control which sets the Pulse
When the Precision TIG 225 Power switch is initially
Frequency over the peak pulses/sec. range of
turned On , the following will be observed:
about 0.1 to 20 pulses per second:
(Refer to this Section Controls and Settings Figure
鈥? Full CCW (min.) setting of the control knob shuts
B.1)
off Pulse TIG (0.0 pps).
鈥? Peak Pulse level is set by the Max. Output
鈥? The cooling fan will run for about 5 seconds.
Control and the Remote Amptrol (if used).
鈥? Background Current level is typically optimized at
鈥? The previous (prior to Power Off) settings of Mode
a fixed 50% of Peak Pulse level setting.
and Maximum Output will be initiated.
鈥? Peak Pulse % On-time is typically optimized at a
fixed 50%.
鈥? If in TIG Mode, the shielding gas solenoid valve will
A Green light "blinks" with each Peak Pulse to indi-
be activated for the time set by the Post Flow Time
cate the Pulse TIG Control setting before and dur-
control.
ing welding.
9. THERMAL SHUTDOWN LIGHT This Yellow
LED panel light turns on if the machine output is
shutdown because internal overheating has
occurred, and turns off when cooled to reset.
10. REMOTE RECEPTACLE 鈥? 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).
鈥? 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.
鈥? 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.
鈥? 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 provides
electrical connection to the electrode holder and
cable for Stick welding and a combined electrical
and gas connection for the TIG torch when TIG
welding.
12. WORK CABLE - This 10ft.(3.05m) cable with
work clamp is factory connected to the welder and
its clamp is connected to the work piece to com-
plete the welding circuit. Refer to Machine
Grounding and High Frequency Interference
Protection in the Installation section of this manual
for the proper procedure on grounding the work
clamp and work piece to minimize high frequency
interference.
PRECISION TIG 225
OPERATION
B-5 B-5
CASE REAR COMPONENTS
FIGURE B.2
4
3
5
2 1
1. INPUT CABLE鈥? 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 鈥? This is a 5/8-18 right-
hand thread female fitting for connection of input
gas supply.
3. COOLING AIR VENTS 鈥? 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
OPERATION
B-6 B-6
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 鈥淭IG鈥?.
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 鈥淥N鈥?. 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 鈥淭IG鈥?,
depressing the remote control will start a 0.5 second
gas pre-flow before energizing the TIG torch. When
the remote control is released the TIG torch is de-
energized and gas flow will continue for the time set
by the Post Flow Time control. When the polarity
switch is set to DC, the TIG Arc Starter will turn on
and off automatically to start and stabilize the arc. In
AC the TIG Arc Starter will turn on with the output and
remain on continuously until the remote control is
released.
PULSE TIG CONTROL
Use this knob to set the frequency or the number of
pulses per second(pps), from 0.1pps to 20pps.
鈥? 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.
PRECISION TIG 225
OPERATION
B-7 B-7
REMOTE CONTROL OPERATION BENEFITS OF THE PRECISION TIG 225 DESIGN
A Foot Amptrol 鈩s included with the PRECISION In AC TIG welding of aluminum, the positive portion of
TIG 225 Ready-Pak models and availiable for other the AC wave provides cleaning (removal of aluminum
models (See Accessories Section) for remote current oxide) of the work piece. This is desirable on materials
control while TIG welding. An optional Hand Amptrol with a heavy oxide coating. However the positive por-
may also be used. An optional Arc Start Switch may tion may also cause the electrode to overheat at high
be used to start and stop the welding if no remote currents causing 鈥渢ungsten spitting鈥?. The negative por-
control of the current is desired. Refer to the tion of the AC wave offers no cleaning action but con-
Accessories Section of this manual. centrates more heat on the work.
Both the Hand and Foot Amptrol work in a similar The AC waveform of the PRECISION TIG 225 opti-
manner. For simplicity, the following explanation will mizes cleaning and heating of the work. The result is
refer only to 鈥淎mptrols鈥?, meaning both Foot and Hand the capability to weld through the complete range in
models. The term 鈥渕inimum鈥? refers to a foot pedal in AC TIG or DC- TIG requiring only one electrode, a
the 鈥渦p鈥? position, as it would be with no foot pressure, 3/32鈥? 2% thoriated tungsten.
or a Hand Amptrol in the relaxed position, with no
thumb pressure.
鈥淢aximum鈥? 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 tung-
sten 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鈥? tungsten may be used on DC- to weld over the
full range of the machine.
To start the arc, the operator may have to turn the cur-
rent control up and depress the Amptrol approximately
1/4 of the way down. Depressing the Amptrol to its
minimum position may not start the arc. Also if the
current control is set too low, the arc may not start. In
most cases, a large or cold tungsten will not readily
establish an arc at low currents. This is normal. In
Direct Current mode the PRECISION TIG 225 will
start a 3/32鈥?, 2% thoriated tungsten electrode at 15
amperes provided the electrode tip is properly ground-
ed and not contaminated.
PRECISION TIG 225
OPERATION
B-8 B-8
WELDING IN STICK MODE 5. Turn the power switch to 鈥淥N鈥?.
1. Put the electrode holder and cable quick connect 6. Adjust the Current Control to the desired amps.
plug into the electrode output receptacle. Turn
clockwise until tight. Connect the work clamp to the 7. Strike an arc and weld.
work piece.
NOTE: When the TIG/STICK switch is set to 鈥淪TICK鈥?
2. Set the TIG/STICK switch to 鈥淪TICK鈥?. the output is always on when the power switch is on.
A remote control has no effect on the welding current
3. Set the Polarity Switch to the weld mode desired for and the gas flow and high frequency TIG arc starter
the type of electrode being used (most commonly are disabled.
DC+).
4. Place the electrode in the electrode holder.
WARNING
鈥? In Stick Mode the output terminal
and electrode will be electrically hot
whenever the power switch is
turned on.
-----------------------------------------------------------------------
The PRECISION TIG 225 is rated from 5-225 Amps.
RECOMMENDED ELECTRODE AMPERAGE RANGES - PRECISION TIG 225
SMAW Process
ELECTRODE TYPE POLARITY 3/32" 1/8" 5/32"
Welding Amp Range for Stick Electrode Size
Fleetweld 5P, Fleetweld 5P+ E6010 DC+ 40 - 70 75 - 130 90 - 175
Fleetweld 180 E6011 DC+ 40 - 80 55 - 110 105 - 135
Fleetweld 37 E6013 DC+ 70 - 95 100 - 135 145 - 180
Fleetweld 47 E7014 DC- 75 - 95 100 - 145 135 - 200
Excalibur E7018 DC+ 85 - 110 110 - 160 130 - 200
Blue Max Stainless DC+ 40 - 80 75 - 110 95 - 150
Red Baron Stainless DC+ 40 - 70 60 - 100 90 - 140
Mild steel procedures are based on recommended procedures listed in C2.10 8/94 and the maximum rating of the PRECISION TIG 225
Blue Max procedures are based on C6.1 6/95
Red Baron Procedure are based on ES-503 10/93
Electrode Polarity DC- AC Approximate Argon
GTAW Process
Sharpened Balled Gas Flow Rate
Electrode Tip Preparation
EWZr C.F.H. (l/min.)
Electrode Type
EWTh-1, EWTh-2
EWTh-1, EWCe-2
EWP EWCe-2, EWLa-1 Stainless
EWTh-2, EWLa-1
Tungsten Size (in.) EWG EWG Aluminum Steel
.010 Up to 15 A. Up to 10 A. Up to 15 A. 3-8 (2-4) 3-8 (2-4)
.020 Up to 15 A. Up to 15 A. Up to 20 A. 5-10 (3-5) 5-10 (3-5)
.040 Up to 80 A. Up to 40 A. Up to 60 A. 5-10 (3-5) 5-10 (3-5)
1/16 Up to 150 A. Up to 100 A. Up to 130 A. 5-10 (3-5) 9-13 (4-6)
3/32 Up to MAX. A. Up to 160 A. Up to MAX. A. 13-17 (6-8) 11-15 (5-7)
1/8 X Up to MAX. A. X 15-23 (7-11) 11-15 (5-7)
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure ..................................EWP ........green TRI-MIX OF ELEMENTS.............EWG.........gray
+1% Thoria .......................EWTh-1 ...yellow
+2% Thoria .......................EWTh-2 ...red
+2% Ceria.........................EWCe-2...orange
+1.5% Lanthana ...............EWLa-1 ...black
+0.15 to 0.40% Zirconia....EWZr .......brown
Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.
PRECISION TIG 225
ACCESSORIES
C-1 C-1
STANDARD EQUIPMENT PACKAGES 2. PRECISION TIG 225 Ready-Pak w/Cart (K2535-2)
鈥? 208/230/1/60 Machine (K2533-1)
The PRECISION TIG 225 will be available in two
鈥? 9 ft.(2.7m) Input Cable with NEMA 6-50P Plug*
Factory-Configured Welding Packages:
鈥? NEMA 6-50R Receptacle
鈥? Integrated 10 ft.(3.1m) Work Lead w/Clamp*
1. PRECISION TIG 225 Ready-Pak (K2535-1)
鈥? Gas Regulator with 10 ft.(3.1m) Hose
鈥? PTA-17 12.5 ft.(3.8m) One cable Superflex Torch
鈥? 208/230/1/60 Machine (K2533-1)
with 3/32鈥?(2.4mm) Electrode and Parts
鈥? 9 ft. (2.7m) Input Cable with NEMA 6-50P Plug*
鈥? Foot Amptrol (K870)
鈥? NEMA 6-50R Receptacle
鈥? TIG Slide Rule (WC332)*
鈥? Integrated 10 ft.(3.1m)Work Lead w/Clamp*
鈥? GTAW Book (JFLF-834)*
鈥? Gas Regulator with 10 ft.(3.1m). Hose
鈥? Lift Eyebolt*
鈥? PTA-17 12.5鈥?(318mm) Ultra=Flex Torch with
鈥? Under-Storage Cart (K2348-1)
3/32鈥?(2.4mm)Electrode and Parts
鈥? Foot Amptrol (K870)
* Included with K2533-1 Machine Only model.
鈥? TIG Slide Rule ( WC332)*
鈥? GTAW Book (JFLF-834)*
鈥? 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
208/230/1/60 Machine with 9 ft.(2.7m) NEMA 6-50P Plug Cable and Receptacle (K2533-1)
Select Machine
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
K2267-1 TIG-Mate 20 Torch Starter Kit K2266-1 TIG-Mate Torch Starter
(Select one)
K1813-1 115V 50/60Hz Cool-Arc 40 Not Applicable
Water Cooler Not Applicable K1813-1 115V 50/60Hz Cool-Arc 40
Optional Under- K2348-1
Storage Cart
K814 Arc Start Switch
Optional Remote K870 Foot Amptrol
Trigger Device K963-3 Hand Amptrol
(Select one)
PRECISION TIG 225
ACCESSORIES
C-2 C-2
FACTORY INSTALLED OPTIONS 2. PRECISION TIG 225 Ready-Pak w/Cart (K2535-2)
鈥? 208/230/1/60 Machine (K2533-1)
The PRECISION TIG 225 will be available in two
鈥? 9 ft.(2.7m) Input Cable with NEMA 6-50P Plug*
Factory-Configured Welding Packages:
鈥? NEMA 6-50R Receptacle
鈥? Integrated 10 ft.(3.1m) Work Lead w/Clamp*
1. PRECISION TIG 225 Ready-Pak (K2535-1)
鈥? Gas Regulator with 10 ft.(3.1m) Hose
鈥? PTA-17 12.5始 Ultra-Flex Torch (K1782-12) Includes:
鈥? 208/230/1/60 Machine (K2533-1)
- 3/32 2%Th Tungsten
鈥? 9 ft. (2.7m) Input Cable with NEMA 6-50P Plug*
- 3/32 Collet (10N24)
鈥? NEMA 6-50R Receptacle
- 3/32 Collet Body (10N32)
鈥? Integrated 10 ft.(3.1m)Work Lead w/Clamp*
- #7 Alumina Nozzle (10N47)
鈥? Gas Regulator with 10 ft.(3.1m). Hose
鈥? PTA-17 12.5始 Ultra-Flex Torch (K1782-12) Includes:
鈥? Foot Amptrol (K870)
- 3/32 2%Th Tungsten
鈥? TIG Slide Rule (WC332)*
- 3/32 Collet (10N24)
鈥? GTAW Book (JFLF-834)*
- 3/32 Collet Body (10N32)
鈥? Lift Eyebolt*
- #7 Alumina Nozzle (10N47)
鈥? Under-Storage Cart (K2348-1)
鈥? Foot Amptrol (K870)
鈥? TIG Slide Rule ( WC332)*
* Included with K2533-1 Machine Only model.
鈥? GTAW Book (JFLF-834)*
鈥? 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
208/230/1/60 Machine with 9 ft.(2.7m) NEMA 6-50P Plug Cable and Receptacle (K2533-1)
Select Machine
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
K2267-1 TIG-Mate 20 Torch Starter Kit K2266-1 TIG-Mate Torch Starter
(Select one)
Includes: Kit Includes:
鈥? 200A PTW-20 12.5 ft.(3.81m) Torch 鈥? 150A PTA-17 12.5 ft.(3.81m) Torch.
鈥? KP510 Parts Kit 鈥? KP508 Parts Kit.
鈥? Regulator & Hose 鈥? Regulator & Hose.
鈥? K1622-4 Twist Mate Torch Adapter 鈥? K1622-1 Twist Mate Torch Adapter.
鈥? Water Hose & Hose Coupler 鈥? Work Cable & Clamp (Not required for Precision
鈥? Work Cable & Clamp (Not required for TIG 225)
Precision TIG 225)
K1813-1 115V 50/60Hz Cool-Arc 40 Not Applicable
Water Cooler
Optional Under-
K2348-1
Storage Cart
K814 Arc Start Switch
Optional Remote
K870 Foot Amptrol
Trigger Device
K963-3 Hand Amptrol
(Select one)
PRECISION TIG 225
ACCESSORIES
C-3 C-3
FIELD INSTALLED OPTIONS 鈥? Magnum 鈥淧ro-Torch鈩? TIG Torch鈥? assemblies and
Accessories.
Requires Twist-Mate Adapter:
The following Options/Accessories are available for
K1622-1 for PTA-9/-17
the Precision TIG 225:
K1622-3 for PTA-26
K1622-4 for PTW water cooled torch
鈥? K2348-1 Under-Storage Cart
Includes a front magnetic latch storage drawer and
鈥? Harris #3100211 Harris Argon Flow Regulator
rear storage bin on a single bottle undercarriage.
(Includes 10 ft.(3.1m) hose.)
(L12225 Installation Instructions included)
鈥? K2374-1 Electrode Holder and Cable
鈥? K870 Foot Amptrol
200 amp Electrode Holder with 10 ft.(3.1m) cable
Single pedal foot activation of arc start switch and
and Twist-Mate connector.
output control, with 25 ft.(7.6m) plug cable.
鈥? 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:
鈥? K814 Arc Start Switch
Needed for TIG welding without an Amptrol.
Includes 25 ft.(7.6m) plug cable, and attaches to
torch for convenient finger control.
鈥? TIG-Mate Torch Starter Kits:
Includes Torch with Twist-Mate adapter and acces-
sories listed below:
K2266-1 TIG-Mate Torch Starter Kit Includes:
鈥? 150A PTA-17 12.5 ft.(3.8m) Torch
鈥? KP508 Parts Kit
鈥? Regulator & Hose
鈥? K1622-1 Twist Mate Torch Adapter
鈥? Work Cable & Clamp (Not required for Precision
TIG 225)
K2267-1 TIG-Mate 20 Torch Starter Kit Includes:
鈥? 200A PTW-20 12.5 ft.(3.8m) Torch
鈥? KP510 Parts Kit
鈥? Regulator & Hose
鈥? K1622-4 Twist Mate Torch Adapter
鈥? Water Hose & Hose Coupler
鈥? Work Cable & Clamp
(Not required for Precision TIG 225)
PRECISION TIG 225
MAINTENANCE
D-1 D-1
WARNING
SAFETY PRECAUTIONS
WARNING
Use extreme caution when working with circuit of
the high frequency. The high voltages developed
can be lethal. Turn the input power off using the
ELECTRIC SHOCK can kill.
disconnect switch or fuse box before working
inside machine. This is particularly important
鈥? Only qualified personnel should per-
when working on the secondary circuit of the high
form this maintenance.
voltage transformer (T3) because the output volt-
age is dangerously high.
鈥? Turn the input power OFF at the dis-
-----------------------------------------------------------------------
connect switch or fuse box before
Refer to figure D.1. Note in highly dirty environments
working on this equipment.
where there is an abundance of conductive contami-
nants, use a low pressure air stream or a firm piece of
鈥? Do not touch electrically hot parts.
paper to clean the spark gap. Do not disturb the facto-
------------------------------------------------------------------------
ry setting.
WARNING To check the spark gap:
- Turn off input power as specified above.
- Remove the right side panel from the
To avoid receiving a high frequency shock, keep
machine, the spark gap box is located on the
the TIG torch and cables in good condition.
lower right side.
------------------------------------------------------------------------
- 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
1. Disconnect power supply lines to machine before
the front of the unit and tighten the screw in
performing periodic maintenance.
the new position.
If the gap is correct:
2. Periodically clean the inside of the machine with a
- Replace the wraparound.
low pressure air system. Be sure to clean the fol-
lowing components thoroughly.
8. Inspect gas hose and inlet fitting for cracks or leaks.
鈥? Main Transformer
鈥? Electrode/Gas Output Receptacle
9. Replace any unreadable labels or decals.
鈥? Polarity Switch
鈥? Rectifier Assembly
10. Verify that the machine and welding circuit is prop-
鈥? Arc Starter/Spark Gap Assembly
erly grounded.
鈥? PC Boards
FIGURE D.1 SPARK GAP
鈥? Fan Blades
3. Inspect welder output and control cables for fraying,
cuts, and bare spots.
4. Keep TIG torch and cables in good condition.
.020 Spark Gap
5. Clean air louvers to ensure proper air flow and cool-
ing.
FAN MOTOR OR FAN BLADE REPLACEMENT
6. The fan motor has sealed ball bearings which
When installing a new fan blade or fan motor be sure
require no maintenance.
to maintain proper shaft spacing per Figure D.2 below.
7. SPARK GAP ADJUSTMENT
The spark gap .020(.5mm) is set at the factory to a
gap of 0.015 inches (0.4mm) See Figure D.1. This
setting is adequate for most applications. Where
less high frequency is desired, the setting can be
reduced to 0.015 inches (0.4mm).
.30
FIGURE D.2
PRECISION TIG 225
TROUBLESHOOTING
E-1 E-1
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 COURSE OF ACTION
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled 鈥淧ROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)鈥?. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled 鈥淧OSSIBLE CAUSE鈥? lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
PRECISION TIG 225
TROUBLESHOOTING
E-2 E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS
Machine is Dead -No Output - No 1. Make certain that the input power
Fan switch is in the 鈥淥N鈥? position and
machine is plugged in.
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 manual.
3. Blown or missing fuses in input
line. If all recommended possible areas
of misadjustment have been
Fan runs normally at power up - No 1. Check for proper input voltages checked and the problem persists,
output from machine in either Stick per nameplate and voltage recon- Contact your local Lincoln
or TIG modes. nection. Authorized Field Service Facility.
2. Check to make sure polarity
switch is not in between two posi-
tions.
Fan runs at power up - No output 1. Welding application may have
from machine in either Stick or TIG exceed the recommended duty
modes and the yellow light on the cycle. Allow the unit to run until
control panel is on. the fan cools the unit and the yel-
low light goes out.
2. The air vents may be blocked.
Remove air obstruction and
allow unit to cool
Machine does not respond (no gas 1. Machine MUST be in the TIG
flow, no high frequency and no open Mode.
circuit voltage) when arc start switch 2. The Amptrol may be defective.
or Amptrol is activated - fan is work- Check for continuity between
ing. pins 鈥淒鈥? and 鈥淓鈥? on cable con-
nector when Amptrol is
depressed.
Machine regularly over heats - the- 1. Welding application may exceed
mostat opens, Yellow light on front recommended duty cycle. Reduce
panel glows. The fan runs but the duty cycle.
machine has no output. 2. Dirt and dust may have clogged
the cooling channels inside the
machine. Blow out unit with clean,
dry low pressure air.
3. Air vents and exhaust louvers may
be blocked due to inadequate
clearance around machine.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
TROUBLESHOOTING
E-3 E-3
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS
Output current reduced significantly 1. Input power to machine doesn始t
when AC Balance control knob is set have sufficient capacity. Try
near or at max. penetration or when changing Input power to a suffi-
Output control is set near or at full cient supply, refer to Installation
output. section.
2. Machine is powered from an
engine generator or an engine
welder. If welding at high currents
are needed, try powering machine
from electricity grid instead of
engine generator.
3. Set AC Balance control at Auto
Balance position.
The machine does not have output 1. Check the electrode cable and
in the Stick mode. The machine holder for loose or faulty connec-
operates correctly in the TIG mode. tions.
Machine welds at a very low output 1. If welding in the TIG mode the If all recommended possible areas of
regardless of the current control set- remote control device may be misadjustment have been checked
ting. defective. and the problem persists, Contact
your local Lincoln Authorized
2. Make certain the input line voltage Field Service Facility.
is correct for the machine recon-
nect configuration.
3. Check the welding cables and/or
torch for loose or faulty connec-
tions.
The machine welds at a very high 1. If welding in the TIG mode the
output regardless of the current con- remote control device may be
trol setting. defective.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
PRECISION TIG 225
TROUBLESHOOTING
E-4 E-4
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
TIG MODE PROBLEMS
Machine output is intermittently lost. 1. Problem may be caused by high
Gas flow and high frequency are frequency interference. Make sure
also interrupted. that the machine is grounded
properly according to the installa-
tion instructions. If there are other
high frequency sources in the
area, make certain that they are
grounded properly.
2. Check Amptrol for proper opera-
tion and loose connections.
3. Check to make sure that the input If all recommended possible areas of
voltage is correct for the machine misadjustment have been checked
reconnect configuration. Refer to and the problem persists, Contact
Reconnect Procedure in the your local Lincoln Authorized
Installation section of this report. Field Service Facility.
Arc 鈥淔lutters鈥? when TIG welding. 1. Tungsten electrode may be too
large in diameter for the current
setting.
2. Tungsten not 鈥渟harp鈥? when weld-
ing in DC - mode.
3. Gas shielding may be insufficient.
Increase gas flow; reduce tung-
sten stickout beyond gas cup.
4. Check for contaminated gas or
leaks in the gas line, torch, or con-
nections.
5. If a helium blend is used as a
shielding gas, then reduce the
percentage of helium.
Arc 鈥淧ulsates鈥? when AC TIG weld- 1. Make sure the gas and procedure
ing. are correct for the process being
used.
2. Micro Switch mounted on Polarity
Switch is not opening in 鈥淎C鈥?
mode.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
PRECISION TIG 225
TROUBLESHOOTING
E-5 E-5
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
TIG MODE PROBLEMS
Black areas along weld bead. 1. Clean any oily or organic contam-
ination from the work piece.
2. Tungsten electrode may be cont-
aminated. Replace or sharpen.
3. Check for contaminated gas or
leaks in the gas line, torch, or
connections.
4. Gas shielding may be insufficient.
Increase gas flow; reduce tung-
sten stickout beyond gas cup.
Weak high frequency - machine has 1. Check for loose or faulty connec-
normal welding output. tions at the torch and/or welding If all recommended possible areas of
cables. misadjustment have been checked
2. The gas shielding may be insuffi- and the problem persists, Contact
cient. Increase gas flow: reduce your local Lincoln Authorized
tungsten stickout beyond the gas Field Service Facility.
cup.
3. Check spark gap operation and
setting. Normal is (0.020"). Refer
to Maintenance section of this
report.
4. The work and electrode cables
may be in poor condition allowing
the high frequency to "leak off".
Use good quality cables with a
high natural rubber content, such
as Lincoln Stable Arc Cable.
Cables should be as short as pos-
sible.
High frequency 鈥渟park鈥? is present at 1. The torch may be faulty. Check or
tungsten electrode, but operator is replace.
unable to establish a welding arc. 2. The current control may be set too
Machine has normal open circuit low.
voltage (refer to Technical 3. The tungsten electrode may be
Specifications in the Installation contaminated. Replace or sharp-
Chapter). en.
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.
7. This may be a welding procedure
problem.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
PRECISION TIG 225
TROUBLESHOOTING
E-6 E-6
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
TIG WELDING PROBLEMS
No high frequency. Machine is in the 1. If the machine location is in a
TIG Mode and has normal output. highly dirty environment with con-
ductive contaminants, check and
clean the spark gap with a low
pressure air stream per the main-
tenance instructions.
2. Check spark gap operation and
setting. Normal is (0.020"). Refer
to Maintenance section of this
report.
No gas flow when Amptrol is activat- 1. Gas supply is empty or not turned
ed in the TIG Mode. Machine has on. If all recommended possible areas of
output - fan runs. A 鈥淐lick鈥? can be 2. Flow regulator may be set too misadjustment have been checked
heard indicating that the gas sole- low. and the problem persists, Contact
noid valve is operating. 3. Gas hose may be pinched. your local Lincoln Authorized
4. Gas flow may be blocked with Field Service Facility.
dirt. Check filter screen inside gas
inlet fitting to solenoid valve. Use
filters to prevent reoccurrence.
5. Consult your local welder/gas dis-
tributor.
When AC TIG welding, the arc is 1. Tungsten electrode may be too
erratic and there is a loss of 鈥渃lean- small for process. Use a larger
ing鈥? of the work piece. diameter tungsten or a pure tung-
sten.
2. If a helium blend is used as a
shielding gas, then reduce the
percentage of helium.
1. The welding current is too high
The end of the tungsten electrode for the electrode type and/or size.
melts away. See Electrode Amperage Ranges
in the Operation 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 your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
PRECISION TIG 225
TROUBLESHOOTING
E-7 E-7
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
STICK WELDING PROBLEMS
Stick electrode 鈥淏lasts Off鈥? when arc 1. Weld current may be set too high
is struck. for electrode size. Reduce current
control setting, or use a larger
diameter electrode.
Stick electrode 鈥渟ticks鈥? in the weld 1. The weld current may be set too
puddle. low. Increase the current control
setting or use a smaller diameter
electrode.
Variable or sluggish welding arc 1. Check work and electrode cables
when welding in the Stick mode. for loose or poor connections.
2. The weld cables may be too small If all recommended possible areas of
or too long to permit the desired misadjustment have been checked
current to flow. and the problem persists, Contact
3. The weld current may be set too your local Lincoln Authorized
low. Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
PRECISION TIG 225
F-1
DIAGRAMS
PRECISION TIG 225
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
F-2
MACHINE ONLY AND READY-PAK FOR CODES 11317, 11318, 11319, 11320
12.99
7.00
4.83
TOOL RAY DOOR
T
2.44
1
.46DOOR CL SED
O
PRECISION TIG 225
DIMENSION PRINT
1.66
TORCH H
OLSTER
20.25
.24
1.00*
*
.81 *
* 12.38
** 22.00
**
.24
* L CATI N OF (4)
*O O B OUNTI G HOLES.
N
O .284ASE M
14.00 1.62
24.00
A
L12201
F-2
F-3
READY-PAK WITH CART FOR CODE 11321
37.24
12.99
7.00
4.83
TOOL RAY DOOR
T
2.44
.46DOOR CL SED
O
6.00
1.66
TORCH H
OLSTER
20.25
PRECISION TIG 225
30.78
DIMENSION PRINT
10.53
.75 24.00 13.27
14.00
19.81
A
F-3
L12202
WARNING
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
electrode with skin or wet clothing.
AVISO DE
G Insulate yourself from work and
ground.
Spanish
PRECAUCION
G No toque las partes o los electrodos G Mantenga el material combustible G Prot茅jase los ojos, los o铆dos y el
bajo carga con la piel o ropa moja- fuera del 谩rea de trabajo. cuerpo.
da.
G Aislese del trabajo y de la tierra.
ATTENTION
French G Ne laissez ni la peau ni des v锚te- G Gardez 脿 l鈥櫭ヽart de tout mat茅riel G Prot茅gez vos yeux, vos oreilles et
ments mouill茅s entrer en contact inflammable. votre corps.
avec des pi猫ces sous tension.
G Isolez-vous du travail et de la terre.
WARNUNG
German G Ber眉hren Sie keine stromf眉hrenden G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und K枚r-
Teile oder Elektroden mit Ihrem perschutz!
K枚rper oder feuchter Kleidung!
G Isolieren Sie sich von den
ATEN脟脙O
Portuguese
Elektroden und dem Erdboden!
G N茫o toque partes el茅tricas e elec- G Mantenha inflam谩veis bem guarda- G Use prote莽茫o para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
G Isole-se da pe莽a e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER鈥橲 INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER鈥橲 SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERH脺TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
WARNING
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to guards off.
AVISO DE
remove fumes from breathing zone.
Spanish
PRECAUCION
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
piraci贸n. mentaci贸n de poder de la m谩quina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilaci贸n o
ATTENTION
aspiraci贸n para gases.
French
G D茅branchez le courant avant l鈥檈ntre- G N鈥檕p茅rez pas avec les panneaux
G Gardez la t锚te 脿 l鈥櫭ヽart des fum茅es.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
protection enlev茅s.
teur pour 么ter les fum茅es des zones
WARNUNG
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgeh盲use
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom v枚llig 枚ff- oder Innenschutzverkleidung in
Schweibrauch!
G Sorgen Sie f眉r gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entl眉ftung des Arbeitsplatzes!
ATEN脟脙O
Portuguese
G N茫o opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fuma莽a.
G Desligue a corrente antes de fazer
G Use ventila莽茫o e exhaust茫o para moventes.
servi莽o. G N茫o opere com os paineis abertos
remover fumo da zona respirat贸ria.
G N茫o toque as partes el茅tricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRU脟脮ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PR脕TICAS DE SEGURAN脟A DO EMPREGADOR.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
|