Lincoln Electric PRECISION TIG 225 User Manual

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IM895

PRECISION TIG 225

May, 2007

 

For use with machines having Code Numbers:

Safety Depends on You

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

11317, 11318, 11319 (11320 Ready-Pak) (11321 Ready-Pak w/Cart)

IP 21S

OPERATOR’S MANUAL

Copyright © 2007 Lincoln Global Inc.

World's Leader in Welding and Cutting Products •

Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

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

The Above For Gasoline Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes

outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame welding arc or when the engine is running.

Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods

while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

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

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

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

Mar ʻ95

ii

 

SAFETY

 

ii

 

 

 

 

 

ELECTRIC SHOCK can

kill.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder.

DC Manual (Stick) Welder.

AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

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

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5.b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employerʼs safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

AUG 06

iii

SAFETY

iii

WELDING and CUTTING

SPARKS can

cause fire or explosion.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire.

Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma

022690-9101.

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

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

Away from areas where they may be struck or subjected to physical damage.

A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturerʼs recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturerʼs recommendations.

Jan, 07

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

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

Sûreté Pour Soudage A LʼArc

1.Protegez-vous contre la secousse électrique:

a.Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b.Faire trés attention de bien sʼisoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c.Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour le refroidir.

e.Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f.Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode sʼapplicuent aussi au pistolet de soudage.

2.Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de nʼimporte quelle partie du corps.

3.Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:

a.Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au soudage à lʼaide dʼécrans appropriés et non-inflammables.

4.Des gouttes de laitier en fusion sont émises de lʼarc de soudage. Se protéger avec des vêtements de protection libres de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

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

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

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

échauffement et un risque dʼincendie.

8.Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils se rompent.

9.Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10.Ne pas souder en présence de vapeurs de chlore provenant dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11.Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

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

1.Relier à la terre le chassis du poste conformement au code de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2.Autant que possible, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.

3.Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.

4.Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ʻ93

Lincoln Electric PRECISION TIG 225 User Manual

v

 

SAFETY

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EN 60974-10

vi

SAFETY

 

vi

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EN 60974-10:

vii

Thank You

vii

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• 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 equipment. 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 possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs 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 – 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.

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.

For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

“Product Registration”. 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.

viii

TABLE OF CONTENTS

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

 

_______________________________________________________________________

 

A-1

 

 

 

INSTALLATION

 

 

 

 

 

 

A-1

 

TECHNICAL SPECIFICATIONS - PRECISION TIG 225 (K2533-1AND K2535-1,-2)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INPUT - SINGLE PHASE ONLY

 

 

 

 

 

 

 

Standard Voltage

Input Current at Rated Output

Power Factor

 

Idle Current

 

 

208/230/1/60

 

 

 

42A / 39A Effective

 

0.62 Min.

 

3.0A/2.7A Max.

 

 

 

 

and 94A / 85A Maximum

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT RANGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Maximum Open

 

 

 

 

 

 

 

 

 

 

 

Output Current

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Type of Output

 

 

 

Range

 

 

 

Circuit Voltage

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(STICK AND TIG)

 

 

 

 

CC (Constant Current)

 

 

 

 

5-230 Amps (AC)

 

 

 

AC OCV: 75

 

 

 

 

 

AC/DC

 

 

 

 

5-230 Amps (DC)

 

 

 

DC OCV: 66

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RATED OUTPUT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Weld Current*

 

 

 

 

Weld Voltage (NEMA)

 

 

 

Process Duty Cycle**

 

 

 

 

 

 

 

 

 

 

 

GTAW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10% Duty Cycle

 

 

 

225A AC/DC

 

 

 

 

15.7 V AC/DC

 

 

 

 

20% Duty Cycle

 

 

 

180A AC/DC

 

 

 

 

15.2 V AC/DC

 

 

 

 

100% Duty Cycle

 

 

 

90A AC/DC (BAL.)

 

 

 

 

14.1 V AC/DC

 

 

 

 

 

 

 

 

80A AC (AUTO-BAL.)

 

 

 

 

14.0 V AC/DC

 

 

 

 

SMAW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10% Duty Cycle

 

 

 

225A AC/DC

 

 

 

 

29.0 V AC/DC

 

 

 

 

20% Duty Cycle

 

 

 

180A AC/DC

 

 

 

 

27.2 V AC/DC

 

 

 

 

100% Duty Cycle

 

 

 

90A AC/DC

 

 

 

 

23.4 V AC/DC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

**Chart gives max. rated Output Amps @% Duty Cycle (Based on a 10 minute cycle). (Example; 180A@20% for AC/DC Stick and TIG)

* Inputs and ratings include a 20 amp rated load on the 115vac receptacle.

 

 

 

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#%&

 

 

 

 

%&

 

 

 

 

%&

 

 

 

 

)%

+%

-%

% '% )% +% -% # % #'%

 

 

 

 

 

1 Output Limits allow for continuous max. rated load on 115vac auxiliary receptacle.

2 Wiring and protection based on the 2005 U.S. National Electric Code.

Use a Super Lag type fuse or circuit breaker with a delay in tripping action.

Models with NEMA 6-50P plug may be used with a 50 amp protected 6-50R receptacle, or with a maximum 70 amp protected 6-50R receptacle if dedicated for the welder.

PRECISION TIG 225

A-2

 

 

 

 

 

 

 

 

INSTALLATION

 

 

 

 

 

 

 

 

 

 

 

A-2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TECHNICAL SPECIFICATIONS - CANADIAN (K2533-2), INTERNATIONAL K2534-1)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K2533-2 INPUT (at Rated Output)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Voltage/Phase/Freq.

 

 

 

 

 

 

 

 

 

Current

 

 

 

Power Factor

 

 

 

 

Idle Current

 

 

 

460/575/1/60

 

 

 

 

 

 

18 A/15 A Effective

 

 

 

0.62 Min.

 

 

 

 

1.3 A/1.0 A Max.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

42 A/33 A Max.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K2534-1 INPUT (at

Rated

Output)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Voltage/Phase/Freq.

 

 

 

 

 

 

 

 

 

Current

 

 

 

 

 

 

Power Factor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Idle Current

 

 

380/400-415/1/50/60

 

 

 

 

21 A/20 A Effective

 

 

 

0.62 Min.

 

 

 

 

1.5 A/1.4 A Max.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

50 A/48 A Max.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N80

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT RANGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Output Type

 

 

 

 

 

 

 

 

Max. OCV.

 

 

 

 

 

 

 

 

 

 

 

 

Weld Current

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

75 V (AC)

 

 

 

 

 

 

 

 

 

 

 

 

5-230 A (AC)

 

 

 

 

CC (Constant Current)

 

 

 

 

 

 

 

 

 

 

66 V (DC)

 

 

 

 

 

 

 

 

 

 

 

 

5-230 A (DC)

 

 

 

 

 

 

 

 

 

AC or 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.

 

 

 

 

25.62 in.

 

 

 

 

 

Approx. 192 lbs.

 

 

 

 

 

 

 

 

(K2533-1,-2)

 

 

 

 

526 mm

 

 

 

368 mm

 

 

 

 

751 mm

 

 

 

 

 

 

87.1 kgs

 

 

 

 

 

 

 

 

(K2534-1)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Ready-Pak

 

 

 

 

20.71 in.

 

 

 

14.48 in.

 

 

 

 

25.62 in.

 

 

 

 

 

Approx. 212lbs..

 

 

 

 

 

 

 

 

 

 

(K2535-1)

 

 

 

 

526 mm

 

 

 

368 mm

 

 

 

 

651 mm

 

 

 

 

 

 

96.2 kgs.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Ready-PakW/Cart

 

 

 

 

31.24 in.

 

 

 

19.81 in.

 

 

 

 

38.01 in.

 

 

 

 

 

Approx. 258lbs.

 

 

 

 

 

 

 

 

 

 

(K2535-2)

 

 

 

 

794 mm

 

 

 

503 mm

 

 

 

 

966 mm

 

 

 

 

 

 

117.0 kgs.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(2) Dimensions are without Lift Eyebolt and Torch Holder

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ENVIRONMENTAL RANGES

 

 

 

 

 

 

 

 

 

Operating Temperature

 

-4°F to 104°F

(-20°C to 40°C)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Storage Temperature

 

-40°F to 185°F

 

(-40°C to 85°C)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PRECISION TIG 225

A-3

INSTALLATION

A-3

 

 

 

SAFETY PRECAUTIONS

Read entire installation section before starting installation.

WARNING

ELECTRIC SHOCK can kill.

Only qualified personnel should perform this installation.

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

Do not touch electrically hot parts.

Always connect the PRECISION TIG 225 to a power supply grounded per the National Electrical Code and any local codes.

---------------------------------------------------------------------------

SELECT SUITABLE LOCATION MOUNTING

Environmental Rating

The Precision TIG 225 power source carries an IP21S environmental rating. It may be used in normal industrial and commercial environments. Avoid using it in environments which have falling water such as rain.

Read and follow "Electric Shock Warnings" in the Safety section if welding must be performed under electrically hazardous conditions such as welding in wet areas or on or in the workpiece.

The Precision TIG 225 must be located where there is free circulation of clean air such that air movement in and out the back air vents will not be restricted.

Dirt and dust that can be drawn into the Precision TIG 225 should be kept to a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown.

GRINDING

Do not direct grinding particles towards the welder. An abundance of conductive material can cause maintenance problems.

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.

To install; remove the plug button from the case top and screw the Eyebolt securely into the threaded bracket beneath the case top per the below instructions and warnings provided on the case top decal. Save the removed plug button (LE part No.T10397-2) to cover the hole when the lift Eyebolt is removed.

WARNING

 

• Use only Lincoln provided

 

T4550-5 1/2-13 x 1.00 eyebolt.

 

• Fully engage threads and

 

torque eyebolt to 38 ft. lbs.

 

• Re-torque eyebolt to 38 ft. lbs.

 

before each lift.

 

• Lift only with equipment of ade-

FALLING

quate lifting capacity.

• Never lift welder with gas

EQUIPMENT can

cylinder attached.

cause injury.

• Never lift welder above personnel.

Lift only with equipment of adequate lifting capacity.

Be sure machine is stable when lifting.

------------------------------------------------------------------------

An undercarriage, provided on the Ready-Pak™ w/Cart model, is also available to easily move the the unit. Refer to the Accessories section of this manual.

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

The undercarriage is designed for hand moving only; mechanized movement can lead to personal injury and/or damage to the Precision TIG 225.

TILTING

Each machine must be placed on a secure, level surface, either directly or on a recommended undercarriage. The machine may topple over if this procedure is not followed.

PRECISION TIG 225

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