Lincoln Electric PRECISION TIG 225 User Manual

PRECISION TIG 225

RETURN TO MAIN MENU

IM895

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. And, most

importantly, think before you act
and be careful.

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

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

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 •

i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

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.

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

i

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.d. Keep all equipment safety guards, covers and devices in

position 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
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.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
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.

in good repair.Keep hands, hair, clothing and

perform required maintenance. Remove

1.f. Do not put your hands near the engine fan.

Do not
idler by pushing on the throttle control rods
while the engine is running.

or when the engine is running.

attempt to override the governor or

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.

___________________________________________________

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

engine or welding generator during maintenance

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.

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.

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.

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
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
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.

vapors

AUG 06

to

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

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

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.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.

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

Jan, 07

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.

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

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.

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

v

EN 60974-10

SAFETY

v

vi

SAFETY

vi

EN 60974-10:

Thank You

viivii

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!

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.

CUSTOMER ASSISTANCE POLICY

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

“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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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

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

_______________________________________________________________________

viii

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

and 94A / 85A Maximum

0.62 Min.

OUTPUT RANGE

Output Current

Range

5-230 Amps (AC)
5-230 Amps (DC)

Maximum Open

Circuit Voltage

(STICK AND TIG)

AC OCV: 75
DC OCV: 66

CC (Constant Current)

RATED OUTPUT

Process Duty Cycle**

GTAW

10% Duty Cycle

20% Duty Cycle

100% Duty Cycle

SMAW
10% Duty Cycle
20% Duty Cycle

100% Duty Cycle

**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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Weld Current*

225A AC/DC
180A AC/DC

90A AC/DC (BAL.)

80A AC (AUTO-BAL.)

225A AC/DC
180A AC/DC

90A AC/DC

#

$



3.0A/2.7A Max.

Type of Output

AC/DC

Weld Voltage (NEMA)

15.7 V AC/DC

15.2 V AC/DC

14.1 V AC/DC

14.0 V AC/DC

29.0 V AC/DC

27.2 V AC/DC

23.4 V AC/DC

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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.

460/575/1/60

Voltage/Phase/Freq.

380/400-415/1/50/60

N80

Max. OCV.

75 V (AC)
66 V (DC)

Process Duty Cycle**

SMAW

15%
20%

100%

Current

18 A/15 A Effective

42 A/33 A Max.

Power Factor

0.62 Min.

K2534-1 INPUT (at Rated Output)

Current

21 A/20 A Effective

50 A/48 A Max.

Power Factor

0.62 Min.

OUTPUT RANGE

Weld Current

5-230 A (AC)

5-230 A (DC)

RATED OUTPUT

Weld Current*

225 A AC/DC

180 A AC/DC

90 A AC/DC

Idle Current

1.3 A/1.0 A Max.

Idle Current

1.5 A/1.4 A Max.

Output Type

CC (Constant Current)

AC or DC

Weld Voltage (NEMA)

29.0 V

27.2 V

23.4 V

GTAW

10%
20%

100%

225 A AC/DC

180 A AC/DC

90 A AC/DC (Bal.)

80 A AC (Auto-Bal.)

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

PHYSICAL DIMENSIONS

MODEL HEIGHT WIDTH DEPTH WEIGHT

Machine Only

(K2533-1,-2)

(K2534-1)

Ready-Pak

(K2535-1)

Ready-PakW/Cart

(K2535-2)

(2)

Dimensions are without Lift Eyebolt and Torch Holder

20.71 in.
526 mm

20.71 in.
526 mm

31.24 in.
794 mm

14.48 in.
368 mm

14.48 in.
368 mm

19.81 in.
503 mm

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)

(2)

25.62 in.
751 mm

25.62 in.
651 mm

38.01 in.
966 mm

15.7 V

15.2 V

14.1 V

14.0 v

Approx. 192 lbs.

87.1 kgs

Approx. 212lbs..

96.2 kgs.

Approx. 258lbs.

117.0 kgs.

PRECISION TIG 225

A-3

INSTALLATION

SAFETY PRECAUTIONS

Read entire installation section before starting
installation.

WARNING

A-3

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.

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.

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 ade­quate lifting capacity.

FALLING • Never lift welder with gas

EQUIPMENT can cylinder attached.

cause injury. •

• 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.

Never lift welder above personnel.

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.

PRECISION TIG 225

A-4

INSTALLATION

MACHINE GROUNDING AND HIGH FRE­QUENCY INTERFERENCE PROTECTION

Locate the Precision TIG 225 away from radio controlled
machinery. The normal operation of the Precision TIG
225 may adversely affect the operation of RF controlled
equipment, which may result in bodily injury or damage
to the equipment.

A-4

The ground should be securely made and the ground­ing cable should be as short as possible using cable of
the same size as the work cable, or larger. Grounding
to the building frame electrical conduit or along pipe
system can result in re-radiation, effectively making
these members radiating antennas.

6. Keep cover and all screws securely in place.

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

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

Radiated interference can develop in the following four
ways:

1. Direct interference radiated from the welder.

2. Direct interference radiated from the welding leads.

3. Direct interference radiated from feedback into the
power lines.

4. Interference from re-radiation of “pickup” by unground­ed metallic objects.

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

1. Keep the welder power supply lines as short as possi­ble and enclose as much of them as possible in rigid
metallic conduit or equivalent shielding for a distance
of 50 feet (15.2m). There should be good electrical
contact between this conduit and the welder case
ground. Both ends of the conduit should be connected
to a driven ground and the entire length should be
continuous.

2. Keep the work and electrode leads as short as possi­ble and as close together as possible. Lengths should
not exceed 25 ft (7.6m). Tape the leads together when
practical.

3. Be sure the torch and work cable rubber coverings are
free of cuts and cracks that allow high frequency leak­age.

4. Keep the torch in good repair and all connections tight
to reduce high frequency leakage.

5. The work piece must be connected to an earth ground
close to the work clamp, using one of the following
methods:

a) A metal underground water pipe in direct contact with

the earth for ten feet or more.

b) A 3/4” (19mm) galvanized pipe or a 5/8” (16mm)solid

galvanized iron, steel or copper rod driven at least
eight feet into the ground.

7. Electrical conductors within 50 ft (15.2m) of the welder
should be enclosed in grounded rigid metallic conduit
or equivalent shielding, wherever possible. Flexible
metallic conduit is generally not suitable.

8. When the welder is enclosed in a metal building,the
metal building should be connected to several good
earth driven electrical grounds (as in 5 (b) above)
around the periphery of the building.

Failure to observe these recommended installation pro­cedures can cause radio or TV and electronic equipment
interference problems and result in unsatisfactory weld­ing performance resulting from lost high frequency
power.

INPUT AND GROUNDING CONNECTIONS

Only a qualified electrician should connect the Precision
TIG 225. Installation should be made in accordance with
the appropriate National Electrical Code, all local codes

and the information in this manual.

Be sure the voltage, phase, and frequency of the input
power is as specified on the rating plate, located on the
rear of the machine.

208/230 volt models have a NEMA 6-50P plug attached
to the #6-3 input power cord and a NEMA 6 -50R recep­tacle is included with the Ready-Pak™ models. Other
voltage models have an #12-3 input power cord but no
plug or receptacle.

Have a qualified electrician provide input power supply to
the receptacle or cord in accordance with all local and
national electrical codes. Use a single phase line or one
phase of a two or three phase line. Choose an input and
grounding wire size according to local or national codes.
Refer to the Technical Specifications page at the
beginning of this section. Fuse the input circuit with the
recommended super lag fuses or delay type
breakers. Using fuses or circuit breakers smaller than
recommended may result
in “nuisance” shut-offs from welder inrush currents even
if not welding at high currents.

1

Also called “inverse time” or “thermal/magnetic” circuit breakers;
circuit breakers which have a delay in tripping action that decreases
as the magnitude of the current increases.

1

circuit

PRECISION TIG 225

A-5

FIGURE A.1 Reconnect Leads

INPUT LEADS INPUT LEADS

L1 & L2L1 & L2

LEAD H1LEAD H1

(DO NOT (DO NOT
REMOVE)REMOVE)

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

BACK VIEW OF LINE SWITCHBACK VIEW OF LINE SWITCH

INSTALLATION

INPUT RECONNECT PROCEDURE

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

CAUTION

Failure to follow these instructions can cause
immediate failure of components within the welder
and void machineʼs warranty.

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

Multiple voltage models are shipped connected
for the highest voltage. To change this connection
refer to the following instructions.

WARNING

ELECTRIC SHOCK can kill.

A-5

• Turn the input power OFF at the dis-

OUTPUT CONNECTIONS

connect switch or fuse box before
working on this equipment.

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

For the lowest rated voltage connection (Refer to figure A.1):

1. Remove the sheet metal left side cover.

2. Disconnect lead H3 from the power switch and
insulate with the insulation from the H2 lead.

3. Connect lead H2 to the power switch where H3 was
connected.

4. Tighten connections.

5. Replace sheet metal cover and all screws

For the highest rated voltage connection (Refer to figure A.1):

The machine is normally shipped connected for the
highest rated voltage, however verify the following:

1. Remove the sheet metal left side cover.

FIGURE A.2 Location of Output Connections

ELECTRODE/GAS

OUTLET
RECEPTACLE
(TWIST-MATE)

WORK CABLE & CLAMP

2. Disconnect lead H2 from the power switch and
insulate with the insulation from the H3 lead.

3. Connect lead H3 to the line switch where H2 was
connected.

4. Tighten connections.

5. Replace sheet metal cover and all screws.

CONNECTIONS FOR TIG (GTAW) WELDING

TIG TORCH CONNECTION

Refer to Included Equipment in the Operation
Section of this manual for TIG welding equipment
which is included with the PRECISION TIG 225.

PRECISION TIG 225

A-6

INSTALLATION

A-6

CONNECTIONS FOR TIG (GTAW) WELDING

TIG TORCH CONNECTION

Refer to Included Equipment in the Operation
Section of this manual for TIG welding equipment
which is included with the PRECISION TIG 225.

A PTA-17 Twist-Mate TIG welding torch with cable
and connector is supplied with the Ready-Pak Models
and available for other models (See Accessories
Section). Turn the Power Switch “OFF”. Connect the
torch cable Twist-Mate quick connect plug into the
Electrode/Gas Output Receptacle on the front of the
welder and turn it clockwise until it is tight. This is a
Twist-Mate quick connect terminal and also provides
the gas connection for the shielding gas to the torch.

WARNING

To avoid receiving a high frequency shock, keep
the TIG torch and cables in good condition.

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

WORK CABLE CONNECTION

A work cable with attached work clamp is factory con­nected to the PRECISION TIG 225. To minimize high
frequency interference, refer to Input and Ground
and High Frequency Interference Protection sec­tion of this manual for the proper procedure on
grounding the work clamp and work piece.

SHIELDING GAS CONNECTION

An adjustable gas pressure regulator with flow gage
and hose is supplied with the PRECISION TIG 225
Ready-Pak™ models and available separately for
other models (See Accessories Section). Obtain the
necessary inert shielding gas (usually argon). Connect
the cylinder of gas with the pressure regulator and
flow gage. Install the gas hose between the regulator
and gas inlet (located on the rear of the welder). The
gas inlet has a 5/16-18 right hand female thread;
CGA#032.

The availiable Under-Storage Cart features a low plat­form that simplifies loading and unloading of gas cylin­ders.

WARNING

CYLINDER could explode
if damaged.

• Keep cylinder upright and chained
to a support.

• Keep cylinder away from areas
where it could be damaged.

• Never allow the torch to touch the cylinder.

• Keep cylinder away from live electrical circuits.

• Maximum inlet pressure 150 psi.

-----------------------------------------------------------------------­A cylinder is loaded by leaning it slightly sideways and
rocking it up on the platform, being careful not to
allow the Under-Storage Cart to roll. Secure the
cylinder in place with the provided chain. Unload
by following these steps in reverse.

REMOTE CONTROL CONNECTION

A remote control receptacle is provided on the case
front of the welder for connecting a remote control to
to the machine. A Foot Amptrol™, foot activated
remote control, is included with the PRECISION TIG
225 Ready-Pak™ models and availiable separately
for other models. Refer to the Optional Accessories
Section of this manual for other available remote con­trols.

CONNECTIONS FOR STICK (SMAW)
WELDING

STICK ELECTRODE CABLE AND WORK CABLE
CONNECTION

Refer to Field Installed Options in the Accessories
Section of this manual for STICK welding equipment

which is availiable for use with the PRECISION TIG

225. An electrode holder with Twist-Mate cable and
Twist-Mate connector are availiable separately for use
with the PRECISION TIG 225. (See Accessories
Section). Turn the Power Switch “OFF”. Connect
the Twist-Mate quick connect plug into the
Electrode/Gas Output Receptacle and turn it clock­wise until it is tight. The work cable and work clamp
are factory connected.

PRECISION TIG 225

B-1

POSITIVE OUTPUT

OPERATION

B-1

SAFETY PRECAUTIONS

Read and understand this entire section before oper­ating the machine.

WARNING

ELECTRIC SHOCK
can kill.

• Do not touch electrically live parts
or electrode with skin or wet cloth­ing.

•

Insulate yourself from work and
ground.

• Always wear dry insulating gloves.

•

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

-------------------------------------------------------------------------------­FUMES AND GASES
can be dangerous.

• Keep your head out of fumes.

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

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

• Use ventilation or exhaust at the

arc, or both, to remove fumes and
gases from breathing zone and
general area.

WELDING SPARKS can cause fire or
explosion

• Keep flammable material away.

• Do not weld on containers that
have held combustibles.

ARC RAYS can burn.

GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

INPUT POWER

NEGATIVE OUTPUT

DIRECT CURRENT

PROTECTIVE
GROUND

WARNING OR
CAUTION

DO NOT SWITCH
WHILE WELDING

SINGLE PHASE
TRANSFORMER AC AND
RECTIFIER DC POWER
SOURCE

• Wear eye, ear and body
protection.

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

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

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

PRECISION TIG 225

OFF

ON

B-2
PRODUCT DESCRIPTION

OPERATION

PROCESS LIMITATIONS

B-2

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

1. Precise constant current output.

2. Full range square wave AC/DC TIG (GTAW) welding.

3. Enhanced version of the patented Micro-Start II™
Technology for its lower Minimum(5 amps) to higher
Maximum (230 amps) output control range.

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

5. AC/DC Stick (SMAW capability.) A new undercarriage
(with gas bottle rack) is available for field installation, or is
included with an available Ready-Pak TIG Welding
Package. The Precision TIG patented convenient built-in
storage provisions for welding components and cable
management.

The PRECISION TIG 225 also provides advanced features
such as:

• Digital Meter

• Presettable control, adjustable Auto Balance™

• Fan As Needed (F.A.N.)

• Timers for fixed Preflow and variable Postflow shielding

gas.

• Built-in, easy to set single knob Pulse TIG control with a

"blinking" light to indicate the pulse frequency setting.

• Auto-Sense remote control selection.

• Tool-less Twist-Mate electrode cable connection.

• Built-in work clamp cable permanently attached.

Four models are available for 60Hz. with Domestic and
Canadian input voltages, as well as an International model
with 50/60Hz voltages.

An Auxiliary 115vac Receptacle with Circuit Breaker are
included on the back panel of the Precision TIG 225 models.
The Canadian (K2533-2) and International (K2534-1) mod­els are rated 6 amps, while the 208/230/1/60 models
(K2533-1 and K2535-1/-2) are rated 20 amps (for use with
Lincolnʼs 115v SP and Power Mig models).

RECOMMENDED PROCESSES AND EQUIP­MENT

RECOMMENDED PROCESSES

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

RECOMMENDED EQUIPMENT/INTERFACE

(See Installed Options in Accessories Section for
more details)

The PRECISION TIG 225 will be available as a basic
Machine (Only) and in two Factory-Configured Welding
Packages:

1. Machine(Only) (K2345-1)

2. Ready-Pak (K2347-1)

3. Ready-Pak w/Cart (K2347-2)

Basic module will also be available as with Domestic,
Canadian and International input voltages for user configu­ration, with optional accessories.

Select Machine 208/230/1/60 Machine with NEMA 6-50P

Plug Cable and Receptacle (K2533-1)

460/575/1/60 Machine only with cable (K2533-2)
380/400/415/1/50/60 Machine only

with cable (K2534-1)

Torch Starter Kit Air Cooled System: Water Cooled System:
(Select one) TIG-Mate TIG-Mate 20

Torch Starter Kit* Torch Starter Kit*

Water Cooler Not Applicable 115V 50/60Hz

Cool-Arc 40*
Under-Storage K2348-(*)
Cart (Optional )
Optional Remote Arc Start Switch*
Trigger Device Foot Amptrol*
(Select one) Start Pedal Foot Amptrol*

Hand Amptrol*

*For “Part Numbers” or “K Numbers” see Accessories Section.

EQUIPMENT LIMITATIONS

The Precision TIG machines are protected from over loads
beyond the output ratings and duty cycles, per the
Specifications in the Installation Section, with Thermostat pro­tection of the output power coils and rectifiers.

The PRECISION TIG 225 machine uses Twist-Mate output ter­minals, therefore stud connection adapters (such as LECO.
S19257-series) cannot be used for torch connection.

If a PRECISION TIG 225 is powered from an engine generator
which doesnʼt have sufficient capacity, the AC Balance control
and the Output control will not provide full range of control.

The PRECISION TIG 225 is recommended for the TIG
(GTAW) and Stick (SMAW) welding processes within its out­put capacity range of 5 amps DC or AC to 225 amps
AC/DC. It is compatible with most Magnum TIG acces­sories, as well as many industry standard items, such as
TIG torches (adapted for Twist-Mate), hoses, and water
coolers.

PRECISION TIG 225

WELDING CAPABILITY(Duty Cycle)

The PRECISION TIG 225 is rated at 225 amps, 29 volts, at
10% duty cycle on a ten minute basis. It is capable of higher
duty cycles at lower output currents. See rated output graph, on
specification sheet located in the Installation Section. If the duty
cycle is exceeded, a thermal protector will shut off the output
until the machine cools.

B-3

OPERATION

CONTROLS AND SETTINGS

All operator controls and adjustments are located on the front of the PRECISION TIG 225. Refer to Figure B.1
and corresponding explanations.

FIGURE B.1 - CONTROL PANEL

13

3

4

8

1

9

5

1. POWER SWITCH

2. POLARITY SWITCH

3. MODE SWITCH

4. AC BALANCE CONTROL

5. MAXIMUM

6. DIGITAL METERS

7. POST FLOW TIME

8. PULSE TIG CONTROL

9. THERMAL SHUTDOWN LIGHT

10. REMOTE RECEPTACLE

11. ELECTRODE/GAS OUTPUT
RECEPTACLE

12. WORK CABLE

13. REMOVABLE LIFT EYEBOLT

OUTPUT CONTROL (AMPS)

6

7

B-3

2

10

CONTROL FUNCTIONALITY

1. POWER SWITCH – Input line switch turns input

power ON or OFF, as indicated by the on or off sta­tus of the front panel digital display (See Item 6,
also see the following page for Power-Up
Sequence).

2. POLARITY SWITCH – The rotary power switch has

3-positions for DC+, AC and DC- selections for the
electrode output stud welding polarity.

CAUTION

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

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

3. MODE SWITCH – The push button switch allows

selection of the two machine welding modes as
indicated by colored mode lights:

• STICK mode – Top position Red light.

• TIG mode – Bottom position Green light.

4. AC BALANCE CONTROL – The potentiometer

control permits AC TIG wave balance adjustment
from Max. Penetration (~80% negative wave) at full
CW rotation setting, to CCW rotation Max. Cleaning
(~60% positive wave), and includes:

PRECISION TIG 225

11

12

• Auto Balance position indicated by the Green panel

light turning on. This feature automatically provides
the proper amount of cleaning and penetration for
normal AC TIG welding.

5. MAXIMUM OUTPUT CONTROL – Presets the out-

put welding current over the rated output range of
the machine:

• With a Remote Current Control (Amptrol) connect-

ed to the Remote Receptacle (See item 10), this
knob sets the Maximum output current level set
table with the remote Amptrol.

• For Pulse TIG (See Item 8) this knob sets the
Peak Pulse level, with the Remote Amptrol (if
used).

6. DIGITAL METER – A 3 digit LED meter is used to

display the preset output current level before weld­ing, and actual output level while welding:

• A lit display indicates input power is turned on.
(See Item 1).

7. POST FLOW TIME – Sets the TIG mode shielding

gas post flow time over the range of about 1 to 30
seconds after the arc is shut off.

Note: Gas preflow time is fixed at 0.5 second only in
TIG mode, but no preflow time will occur if the arc is

restarted

during Post Flow time, since shielding gas

would not have stopped flowing.

B-4

8. PULSE TIG CONTROL – The Pulse TIG feature

built into the PRECISION TIG 225 is simplified to
be a single knob control which sets the Pulse
Frequency over the peak pulses/sec. range of
about 0.1 to 20 pulses per second:

• Full CCW (min.) setting of the control knob shuts
off Pulse TIG (0.0 pps).

• Peak Pulse level is set by the Max. Output
Control and the Remote Amptrol (if used).

• Background Current level is typically optimized at
a fixed 50% of Peak Pulse level setting.

• Peak Pulse % On-time is typically optimized at a
fixed 50%.

A Green light "blinks" with each Peak Pulse to indi­cate the Pulse TIG Control setting before
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 – Provides for connec-

tion of remote control and/or arc start switch only
in TIG Mode: (There is no remote output control
capability when stick welding).

• Plugging a remote current control (Amptrol) into
this receptacle automatically switches the output
control from the panel Max Output Control (See
Item 5) to the remote control.

• The connected remote control will then control
the output current between the Min. range of the
machine and the setting of the panel Max Output
Control.

• Switching Mode Switch (See Item 3) to Stick will
automatically disable
trol and switch the output control back to the Max
Output panel control.

the connected remote con-

OPERATION

and dur-

B-4

POWER-UP SEQUENCE

When the Precision TIG 225 Power switch is initially
turned On , the following will be observed:
(Refer to this Section Controls and Settings Figure
B.1)

• The cooling fan will run for about 5 seconds.

• The previous (prior to Power Off) settings of Mode
and Maximum Output will be initiated.

• If in TIG Mode, the shielding gas solenoid valve will
be activated for the time set by the Post Flow Time
control.

11. ELECTRODE/GAS OUTPUT RECEPTACLE -

This quick connect Twist-Mate receptacle provides
electrical connection to the electrode holder and
cable for Stick welding and a combined electrical
and gas connection for the TIG torch when TIG
welding.

12. WORK CABLE - This 10ft.(3.05m) cable with

work clamp is factory connected to the welder and
its clamp is connected to the work piece to com­plete the welding circuit. Refer to Machine
Grounding and High Frequency Interference
Protection in the Installation section of this manual
for the proper procedure on grounding the work
clamp and work piece to minimize high frequency
interference.

PRECISION TIG 225

B-5

OPERATION

B-5

CASE REAR COMPONENTS

3

FIGURE B.2

4

5

2

1. INPUT CABLE– This #6-3 (208/230V) or #12-3

(380V and higher) heavy duty cable with cable
clamp is factory installed on all models. The
Domestic models (208/230V) also are equipped
with a NEMA 6-50P plug.

2. GAS INPUT CONNECTOR – This is a 5/8-18 right-

hand thread female fitting for connection of input
gas supply.

3. COOLING AIR VENTS – Air is drawn in through

the upper vents and exhausted out through the
lower vents. The louver baffle steers exhaust air
down and prevents it from re-entering the upper
vents.

4. MACHINE RATING PLATE

1

5. RECEPTACLE AND CIRCUIT BREAKER-115vac

auxiliary NEMA 6-20R .

PRECISION TIG 225

B-6

OPERATION

OPERATING STEPS

WELDING IN TIG MODE

1. Connect the TIG torch and cable Twist-Mate quick
connect plug to the Electrode/Gas output recepta­cle. This receptacle also contains an integral gas
connection for the torch. Connect the work clamp to
the work piece.

2. Set the TIG/STICK switch to “TIG”.

3. Set the Polarity Switch to DC- for welding steel or
stainless steel; or to AC for welding aluminum.

4. Connect the Foot Amptrol to the Remote Control
Connector.

5. Turn on the cylinder gas valve and adjust the flow
regulator to obtain desired flow.

6. Turn the power switch to “ON”. NOTE: There will be
a 15 second gas flow when the power is turned on.

B-6

7. Preset the Output Control on the control panel to
the maximum desired amps, as read on the digital
meter.

8. Depress the Foot Amptrol to energize the torch and
establish an an arc with the work piece. The digital
meter reads the actual amps while welding.

NOTE: When the TIG/STICK switch is set to “TIG”,
depressing the remote control will start a 0.5 second
gas pre-flow before energizing the TIG torch. When
the remote control is released the TIG torch is de­energized 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.

• This setting adjusts heat output and bead shape for

travel speed. Thinner plate that is welded with faster
travel speed will require higher frequency than thick­er plate with slower travel speed. 2-3pps is a typical
starting point.

PRECISION TIG 225

B-7

OPERATION

B-7

REMOTE CONTROL OPERATION

A Foot Amptrol ™is included with the PRECISION
TIG 225 Ready-Pak models and availiable for other
models (See Accessories Section) for remote current
control while TIG welding. An optional Hand Amptrol
may also be used. An optional Arc Start Switch may
be used to start and stop the welding if no remote
control of the current is desired. Refer to the
Accessories Section of this manual.

Both the Hand and Foot Amptrol work in a similar
manner. For simplicity, the following explanation will
refer only to “Amptrols”, meaning both Foot and Hand
models. The term “minimum” refers to a foot pedal in
the “up” position, as it would be with no foot pressure,
or a Hand Amptrol in the relaxed position, with no
thumb pressure.

“Maximum” refers to a fully depressed Foot Amptrol,or
a fully extended Hand Amptrol.

When the welder is in TIG modes activating the
Amptrol energizes the electrode terminal and varies
the output welding current from its minimum value of 5
Amp (DC) or (AC), to the maximum value set by the
Current Control on the control panel. This helps elimi­nate accidental high current damage to the work piece
and/or tungsten, and provides a fine control of the cur­rent. When the welder is in the stick mode a remote
control has no effect and is not used.

BENEFITS OF THE PRECISION TIG 225 DESIGN

In AC TIG welding of aluminum, the positive portion of
the AC wave provides cleaning (removal of aluminum
oxide) of the work piece. This is desirable on materials
with a heavy oxide coating. However the positive por­tion may also cause the electrode to overheat at high
currents causing “tungsten spitting”. The negative por­tion of the AC wave offers no cleaning action but con­centrates more heat on the work.

The AC waveform of the PRECISION TIG 225 opti­mizes cleaning and heating of the work. The result is
the capability to weld through the complete range in
AC TIG or DC- TIG requiring only one electrode, a
3/32” 2% thoriated tungsten.

It is important to note that, in some cases, the tung­sten will not start an arc at the minimum current
because the tungsten may be too large or cold. To
start an arc reliably, it is important to depress the
Amptrol far enough so that the machine output current
is near the tungsten operating range. For example, a
3/32” tungsten may be used on DC- to weld over the
full range of the machine.

To start the arc, the operator may have to turn the cur­rent control up and depress the Amptrol approximately
1/4 of the way down. Depressing the Amptrol to its
minimum position may not start the arc. Also if the
current control is set too low, the arc may not start. In
most cases, a large or cold tungsten will not readily
establish an arc at low currents. This is normal. In
Direct Current mode the PRECISION TIG 225 will
start a 3/32”, 2% thoriated tungsten electrode at 15
amperes provided the electrode tip is properly ground­ed and not contaminated.

PRECISION TIG 225

B-8

OPERATION

B-8

WELDING IN STICK MODE

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

2. Set the TIG/STICK switch to “STICK”.

3. Set the Polarity Switch to the weld mode desired for
the type of electrode being used (most commonly
DC+).

4. Place the electrode in the electrode holder.

WARNING

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

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

5. Turn the power switch to “ON”.

6. Adjust the Current Control to the desired amps.

7. Strike an arc and weld.

NOTE: When the TIG/STICK switch is set to “STICK”
the output is always on when the power switch is on.
A remote control has no effect on the welding current
and the gas flow and high frequency TIG arc starter
are disabled.

RECOMMENDED ELECTRODE AMPERAGE RANGES - PRECISION TIG 225

The PRECISION TIG 225 is rated from 5-225 Amps.

SMAW Process

Welding Amp Range for Stick Electrode Size

ELECTRODE TYPE POLARITY 3/32" 1/8" 5/32"
Fleetweld 5P, Fleetweld 5P+ E6010
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

Electrode Tip Preparation

Electrode Type

Sharpened Balled Gas Flow Rate

EWTh-1, EWCe-2

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.

DC+ 40 - 70 75 - 130 90 - 175

GTAW Process

EWZr C.F.H. (l/min.)

EWTh-1, EWTh-2

EWP EWCe-2, EWLa-1 Stainless

PRECISION TIG 225

C-1

ACCESSORIES

C-1

STANDARD EQUIPMENT PACKAGES

The PRECISION TIG 225 will be available in two
Factory-Configured Welding Packages:

1. PRECISION TIG 225 Ready-Pak (K2535-1)

• 208/230/1/60 Machine (K2533-1)

• 9 ft. (2.7m) Input Cable with NEMA 6-50P Plug*

• NEMA 6-50R Receptacle

• Integrated 10 ft.(3.1m)Work Lead w/Clamp*

• Gas Regulator with 10 ft.(3.1m). Hose

• PTA-17 12.5”(318mm) Ultra=Flex Torch with
3/32”(2.4mm)Electrode and Parts

• Foot Amptrol (K870)

• TIG Slide Rule ( WC332)*

• GTAW Book (JFLF-834)*

• Lift Eyebolt*

The Precision TIG 225 will also be available as Basic models with Domestic, Canadian and International input
voltages for user-configuration:with optional accessories. (See Table C.1)

TABLE C.1

Select Machine

208/230/1/60 Machine with 9 ft.(2.7m) NEMA 6-50P Plug Cable and Receptacle (K2533-1)

2. PRECISION TIG 225 Ready-Pak w/Cart (K2535-2)

• 208/230/1/60 Machine (K2533-1)

• 9 ft.(2.7m) Input Cable with NEMA 6-50P Plug*

• NEMA 6-50R Receptacle

• Integrated 10 ft.(3.1m) Work Lead w/Clamp*

• Gas Regulator with 10 ft.(3.1m) Hose

• PTA-17 12.5 ft.(3.8m) One cable Superflex Torch
with 3/32”(2.4mm) Electrode and Parts

• Foot Amptrol (K870)

• TIG Slide Rule (WC332)*

• GTAW Book (JFLF-834)*

• Lift Eyebolt*

• Under-Storage Cart (K2348-1)

* Included with K2533-1 Machine Only model.

460/575/1/60 Machine only with Cable (K2533-2)
380/400-415/1/50-60 Machine only with Cable (K2534-1)

Optional
Torch Starter Kit
(Select one)

Water Cooler Not Applicable K1813-1 115V 50/60Hz Cool-Arc 40

Optional Under­Storage Cart

Optional Remote
Trigger Device
(Select one)

K2267-1 TIG-Mate 20 Torch Starter Kit
K1813-1 115V 50/60Hz Cool-Arc 40

Water Cooled System

K2266-1 TIG-Mate Torch Starter

K2348-1

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

Air Cooled System

Not Applicable

PRECISION TIG 225

C-2

ACCESSORIES

C-2

FACTORY INSTALLED OPTIONS

The PRECISION TIG 225 will be available in two
Factory-Configured Welding Packages:

1. PRECISION TIG 225 Ready-Pak (K2535-1)

• 208/230/1/60 Machine (K2533-1)

• 9 ft. (2.7m) Input Cable with NEMA 6-50P Plug*

• NEMA 6-50R Receptacle

• Integrated 10 ft.(3.1m)Work Lead w/Clamp*

• Gas Regulator with 10 ft.(3.1m). Hose

• PTA-17 12.5ʼ Ultra-Flex Torch (K1782-12) Includes:

- 3/32 2%Th Tungsten

- 3/32 Collet (10N24)

- 3/32 Collet Body (10N32)

- #7 Alumina Nozzle (10N47)

• Foot Amptrol (K870)

• TIG Slide Rule ( WC332)*

• GTAW Book (JFLF-834)*

• Lift Eyebolt*

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)

2. PRECISION TIG 225 Ready-Pak w/Cart (K2535-2)

• 208/230/1/60 Machine (K2533-1)

• 9 ft.(2.7m) Input Cable with NEMA 6-50P Plug*

• NEMA 6-50R Receptacle

• Integrated 10 ft.(3.1m) Work Lead w/Clamp*

• Gas Regulator with 10 ft.(3.1m) Hose

• PTA-17 12.5ʼ Ultra-Flex Torch (K1782-12) Includes:

- 3/32 2%Th Tungsten

- 3/32 Collet (10N24)

- 3/32 Collet Body (10N32)

- #7 Alumina Nozzle (10N47)

• Foot Amptrol (K870)

• TIG Slide Rule (WC332)*

• GTAW Book (JFLF-834)*

• Lift Eyebolt*

• Under-Storage Cart (K2348-1)

* Included with K2533-1 Machine Only model.

Select Machine

Optional
Torch Starter Kit
(Select one)

Water Cooler

Optional Under­Storage Cart

Optional Remote
Trigger Device
(Select one)

TABLE C.2
208/230/1/60 Machine with 9 ft.(2.7m) NEMA 6-50P Plug Cable and Receptacle (K2533-1)
460/575/1/60 Machine only with Cable (K2533-2)

380/400-415/1/50-60 Machine only with Cable (K2534-1)

Water Cooled System

K2267-1 TIG-Mate 20 Torch Starter Kit
Includes:

• 200A PTW-20 12.5 ft.(3.81m) Torch

• KP510 Parts Kit

• Regulator & Hose

• K1622-4 Twist Mate Torch Adapter

• Water Hose & Hose Coupler

• Work Cable & Clamp (Not required for

Precision TIG 225)

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

K2348-1

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

K2266-1 TIG-Mate Torch Starter
Kit Includes:

• 150A PTA-17 12.5 ft.(3.81m) Torch.

• KP508 Parts Kit.

• Regulator & Hose.

• K1622-1 Twist Mate Torch Adapter.

• Work Cable & Clamp (Not required for Precision
TIG 225)

Not Applicable

Air Cooled System

PRECISION TIG 225

C-3

ACCESSORIES

C-3

FIELD INSTALLED OPTIONS

The following Options/Accessories are available for
the Precision TIG 225:

• K2348-1 Under-Storage Cart

Includes a front magnetic latch storage drawer and
rear storage bin on a single bottle undercarriage.
(L12225 Installation Instructions included)

• K870 Foot Amptrol

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

• K963-3 Hand Amptrol

Fastens to torch for convenient thumb activation of
arc start switch and output control, with 25 ft.(7.6m)
plug cable:

• K814 Arc Start Switch

Needed for TIG welding without an Amptrol.
Includes 25 ft.(7.6m) plug cable, and attaches to
torch for convenient finger control.

• Magnum “Pro-Torch™ TIG Torch” assemblies and

Accessories.

Requires Twist-Mate Adapter:

K1622-1 for PTA-9/-17
K1622-3 for PTA-26
K1622-4 for PTW water cooled torch

• Harris #3100211 Harris Argon Flow Regulator

(Includes 10 ft.(3.1m) hose.)

• K2374-1 Electrode Holder and Cable

200 amp Electrode Holder with 10 ft.(3.1m) cable
and Twist-Mate connector.

• TIG-Mate Torch Starter Kits:

Includes Torch with Twist-Mate adapter and acces­sories listed below:

K2266-1 TIG-Mate Torch Starter Kit Includes:

• 150A PTA-17 12.5 ft.(3.8m) Torch

• KP508 Parts Kit

• Regulator & Hose

• K1622-1 Twist Mate Torch Adapter

• Work Cable & Clamp (Not required for Precision
TIG 225)

K2267-1 TIG-Mate 20 Torch Starter Kit Includes:

• 200A PTW-20 12.5 ft.(3.8m) Torch

• KP510 Parts Kit

• Regulator & Hose

• K1622-4 Twist Mate Torch Adapter

• Water Hose & Hose Coupler

• Work Cable & Clamp

(Not required for Precision TIG 225)

PRECISION TIG 225

D-1

.020 Spark Gap

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should per­form this maintenance.

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

• Do not touch electrically hot parts.

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

WARNING

To avoid receiving a high frequency shock, keep
the TIG torch and cables in good condition.

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

ROUTINE AND PERIODIC MAINTENANCE

1. Disconnect power supply lines to machine before
performing periodic maintenance.

2. Periodically clean the inside of the machine with a
low pressure air system. Be sure to clean the fol­lowing components thoroughly.

• Main Transformer

• Electrode/Gas Output Receptacle

• Polarity Switch

• Rectifier Assembly

• Arc Starter/Spark Gap Assembly

• PC Boards

• Fan Blades

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
disconnect switch or fuse box before working
inside machine. This is particularly important
when working on the secondary circuit of the high
voltage transformer (T3) because the output volt­age is dangerously high.

----------------------------------------------------------------------­Refer to figure D.1. Note in highly dirty environments
where there is an abundance of conductive contami­nants, use a low pressure air stream or a firm piece of
paper to clean the spark gap. Do not disturb the facto­ry setting.

To check the spark gap:

- Turn off input power as specified above.

- Remove the right side panel from the
machine, the spark gap box is located on the
lower right side.

- Check the spark gap with a feeler gauge.

If adjustment is needed:

- Adjust the gap by loosening the allen head
screw in one of the aluminum blocks, near
the front of the unit and tighten the screw in
the new position.

If the gap is correct:

- Replace the wraparound.

8. Inspect gas hose and inlet fitting for cracks or leaks.

9. Replace any unreadable labels or decals.

10. Verify that the machine and welding circuit is prop­erly grounded.

FIGURE D.1 SPARK GAP

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

4. Keep TIG torch and cables in good condition.

5. Clean air louvers to ensure proper air flow and cool­ing.

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

7. SPARK GAP ADJUSTMENT

The spark gap .020(.5mm) is set at the factory to a
gap of 0.015 inches (0.4mm) See Figure D.1. This
setting is adequate for most applications. Where
less high frequency is desired, the setting can be
reduced to 0.015 inches (0.4mm).

PRECISION TIG 225

.020 Spark Gap

FAN MOTOR OR FAN BLADE REPLACEMENT

When installing a new fan blade or fan motor be sure
to maintain proper shaft spacing per Figure D.2 below.

.30

FIGURE D.2

E-1

TROUBLESHOOTING

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.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized 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

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Machine is Dead -No Output - No
Fan

Fan runs normally at power up - No
output from machine in either Stick
or TIG modes.

TROUBLESHOOTING

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. Make certain that the input power
switch is in the “ON” position and
machine is plugged in.

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

3. Blown or missing fuses in input
line.

1. Check for proper input voltages
per nameplate and voltage recon­nection.

E-2

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

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

Machine does not respond (no gas
flow, no high frequency and no open
circuit voltage) when arc start switch
or Amptrol is activated - fan is work­ing.

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

2. Check to make sure polarity
switch is not in between two posi­tions.

1. Welding application may have
exceed the recommended duty
cycle. Allow the unit to run until
the fan cools the unit and the yel­low light goes out.

2. The air vents may be blocked.
Remove air obstruction and
allow unit to cool

1. Machine MUST be in the TIG
Mode.

2. The Amptrol may be defective.
Check for continuity between
pins “D” and “E” on cable con­nector when Amptrol is
depressed.

1. Welding application may exceed
recommended duty cycle. Reduce
the duty cycle.

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.

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Output current reduced significantly
when AC Balance control knob is set
near or at max. penetration or when
Output control is set near or at full
output.

TROUBLESHOOTING

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. Input power to machine doesnʼt
have sufficient capacity. Try
changing Input power to a suffi­cient supply, refer to Installation
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.

E-3

RECOMMENDED

COURSE OF ACTION

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

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

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

1. Check the electrode cable and
holder for loose or faulty connec­tions.

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

2. Make certain the input line voltage
is correct for the machine recon­nect configuration.

3. Check the welding cables and/or
torch for loose or faulty connec­tions.

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

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
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

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

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

TROUBLESHOOTING

POSSIBLE

CAUSE

TIG MODE PROBLEMS

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

2. Check Amptrol for proper opera­tion and loose connections.

E-4

RECOMMENDED

COURSE OF ACTION

Arc “Flutters” when TIG welding.

3. Check to make sure that the input
voltage is correct for the machine
reconnect configuration. Refer to
Reconnect Procedure in the
Installation section of this report.

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

2. Tungsten not “sharp” when weld­ing in DC - mode.

3. Gas shielding may be insufficient.
Increase gas flow; reduce tung­sten stickout beyond gas cup.

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

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

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

Arc “Pulsates” when AC TIG weld­ing.

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

2. Micro Switch mounted on Polarity
Switch is not opening in “AC”
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

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Black areas along weld bead.

TROUBLESHOOTING

POSSIBLE

CAUSE

TIG MODE PROBLEMS

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

2. Tungsten electrode may be cont­aminated. 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 tung­sten stickout beyond gas cup.

E-5

RECOMMENDED

COURSE OF ACTION

Weak high frequency - machine has
normal welding output.

High frequency “spark” is present at
tungsten electrode, but operator is
unable to establish a welding arc.
Machine has normal open circuit
voltage (refer to Technical
Specifications in the Installation
Chapter).

1. Check for loose or faulty connec­tions at the torch and/or welding
cables.

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

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 pos­sible.

1. The torch may be faulty. Check or
replace.

2. The current control may be set too
low.

3. The tungsten electrode may be
contaminated. Replace or sharp­en.

4. The electrode may be too large for
the process.

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

6. Check the welding cables for
loose or faulty connections.

7. This may be a welding procedure
problem.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
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

E-6

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

No high frequency. Machine is in the
TIG Mode and has normal output.

TROUBLESHOOTING

POSSIBLE

CAUSE

TIG WELDING PROBLEMS

1. If the machine location is in a
highly dirty environment with con­ductive contaminants, check and
clean the spark gap with a low
pressure air stream per the main­tenance instructions.

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

E-6

RECOMMENDED

COURSE OF ACTION

No gas flow when Amptrol is activat­ed in the TIG Mode. Machine has
output - fan runs. A “Click” can be
heard indicating that the gas sole­noid valve is operating.

When AC TIG welding, the arc is
erratic and there is a loss of “clean­ing” of the work piece.

The end of the tungsten electrode
melts away.

1. Gas supply is empty or not turned
on.

2. Flow regulator may be set too
low.

3. Gas hose may be pinched.

4. Gas flow may be blocked with
dirt. Check filter screen inside gas
inlet fitting to solenoid valve. Use
filters to prevent reoccurrence.

5. Consult your local welder/gas dis­tributor.

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

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

1. The welding current is too high
for the electrode type and/or size.
See Electrode Amperage Ranges
in the Operation Section of this
manual.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
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

E-7

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Stick electrode “Blasts Off” when arc
is struck.

TROUBLESHOOTING

POSSIBLE

CAUSE

STICK WELDING PROBLEMS

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

E-7

RECOMMENDED

COURSE OF ACTION

Stick electrode “sticks” in the weld
puddle.

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

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

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

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

3. The weld current may be set too
low.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
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

Enhanced Diagam

DIAGRAMS

F-1

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-2

DIMENSION PRINT

2.44

1

.46DOOR CLOSED

F-2

A

1.62

24.00

22.00**

L12201

12.99

4.83

TOOL TRA Y DOOR

.24

20.25

1.66TORC H HOLSTER

1.00**

O .284 BASE MOUNTING HOLES.

** LOCATION OF (4)

MACHINE ONLY AND READY-PAK FOR CODES 11317, 11318, 11319, 11320

7.00

PRECISION TIG 225

.24

14.00

12.38**.81**

F-3

DIMENSION PRINT

6.00

37.24

2.44

.46DOOR CLOSED

F-3

A

L12202

13.27

24.00

12.99

4.83

READY-PAK WITH CART FOR CODE 11321

7.00

TOOL TRA Y DOOR

.75

20.25

30.78

1.66TORCH HOLSTER

10.53

14.00

19.81

PRECISION TIG 225

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S 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 HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

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Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com