Lincoln Electric SVM186-A User Manual
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®
PRECISION TIG 225
SVM186-A
October, 2008
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.
For use with machine code numbers:
11317, 11318, 11319
(11320 Ready-Pak)
(11321 Ready-Pak w/Cart)
View Safety Info View Safety Info View Safety Info View Safety Info
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.888.935-3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i 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
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 posi-
tion
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
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 or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
and in good repair.Keep hands, hair, clothing and tools
to perform required maintenance. Remove
1.f. Do not put your hands near the engine fan.
Do
not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.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 engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
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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 ‘95
ii ii
SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable
and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
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.
vapors
to
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5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
Aug ‘06
iii iii
SAFETY
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
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.
If this is not possible, cover them to prevent
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 manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s 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.
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Jan ‘07
iv iv
SAFETY
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 l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher 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 l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie 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 d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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Mar ‘93
v v
SAFETY
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
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h) the time of day that welding or other activities are to be carried out.
L10093 3-1-96H
vi vi
SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
1
tions.
_________________________
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1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
L10093 3-1-96H
I I
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
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Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation..................................................................SectionA
Operation ..................................................................SectionB
Accessories ................................................................SectionC
Maintenance ................................................................SectionD
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
TroubleshootingandRepair ...................................................SectionF
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-536, P-210-R, P-66-J.6
PRECISION TIG® 225
A-1 A-1
Installation.............................................................................A-1
TechnicalSpecifications.............................................................A-2,A-3
SafetyPrecautions ....................................................................A-4
Select Suitable Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Environmental Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Grinding ............................................................................A-4
Stacking ............................................................................A-4
LiftingandMoving ....................................................................A-4
Tilting ..............................................................................A-4
TABLE OF CONTENTS - INSTALLATION SECTION
Machine Grounding and High Frequency Interference Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Input and Grounding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
InputReconnectProcedure .............................................................A-6
OutputConnections ...................................................................A-6
ConnectionsForTig(GTAW)Welding .....................................................A-7
Tig Torch Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Work Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Shielding Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
RemoteControlConnection .............................................................A-7
Connections For Stick (SMAW) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Stick Electrode Cable and Work Cable Connection ..........................................A-7
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PRECISION TIG® 225
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - PRECISION TIG® 225 (K2533-1AND K2535-1,-2)
INPUT - SINGLE PHASE ONLY
Standard Voltage
Input Current at Rated Output
Power Factor
Idle Current
208/230/1/60
42A / 39A Effective
0.62 Min.
and 94A / 85A Maximum
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**
Weld Current*
GTAW
10% Duty Cycle
20% Duty Cycle
100% Duty Cycle
225A AC/DC
180A AC/DC
90A AC/DC (BAL.)
80A AC (AUTO-BAL.)
SMAW
10% Duty Cycle
20% Duty Cycle
100% Duty Cycle
225A AC/DC
180A AC/DC
90A AC/DC
**Chart gives max. rated Output Amps @% Duty Cycle (Based on a 10 minute cycle).
(Example; 180A@20% for AC/DC Stick and TIG)
* Inputs and ratings include a 20 amp rated load on the 115vac receptacle.
AC/DC Stick and Auto-Balance TIG Output Limits
2
Using provided input cable for protected
input supply
1
Weld Voltage (NEMA)
3.0A/2.7A Max.
Type of Output
AC/DC
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
100%
90%
80%
70%
AC/DC Stick & Bal.TIG
60%
50%
40%
30%
Output Duty Cycle
with Max. Aux. load or
Auto-B al. TIG w/o Aux.
AC Auto -B al. T IG w ith
Max. Aux. L oad
20%
10%
0%
50 70 90 110 130 150 170 190 210 230
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.
Output Amps
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PRECISION TIG® 225
A-3 A-3
INSTALLATION
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.
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PRECISION TIG® 225
A-4 A-4
SAFETY PRECAUTIONS
Read entire installation section before starting
installation.
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
• Do not touch electrically hot parts.
• Always connect the PRECISION TIG® 225 to a
power supply grounded per the National Electrical
Code and any local codes.
----------------------------------------------------------------------------
SELECT SUITABLE LOCATION
MOUNTING
INSTALLATION
To install; remove the plug button from the case top
and screw the Eyebolt securely into the threaded
bracket beneath the case top per the below 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.
An undercarriage, provided on the Ready-Pak™
w/Cart model, is also available to easily move the unit.
Refer to the Accessories section of this manual.
WARNING
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.
Environmental Rating
The PRECISION TIG® 225 power source carries an
IP21S environmental rating. It may be used in normal
industrial and commercial environments. Avoid using it
in environments which have falling water such as rain.
Read and follow "Electric Shock Warnings" in the
Safety section if welding must be performed under
electrically hazardous conditions such as welding in
wet areas or on or in the workpiece.
• The PRECISION TIG® 225 must be located where
there is free circulation of clean air such that air
movement in and out the back air vents will not be
restricted.
• Dirt and dust that can be drawn into the PRECISION
TIG® 225 should be kept to a minimum. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdown.
GRINDING
Do not direct grinding particles towards the welder. An
abundance of conductive material can cause maintenance problems.
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.
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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.
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PRECISION TIG® 225
A-5 A-5
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.
INSTALLATION
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 covers 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 begin-
ning of this section. Fuse the input circuit with the recommended super lag fuses or delay type
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 breakers.
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PRECISION TIG® 225
A-6 A-6
FIGURE A.1 Reconnect Leads
INPUT LEADSINPUT 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.
• Turn the input power OFF at the disconnect 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.
OUTPUT CONNECTIONS
ELECTRODE/GAS
OUTLET
RECEPTACLE
(TWIST-MATE)
WORK CABLE & CLAMP
FIGURE A.2 Location of Output Connections
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
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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-7 A-7
CONNECTIONS FOR TIG (GTAW) WELDING
TIG TORCH CONNECTION
INSTALLATION
The available Under-Storage Cart features a low platform that simplifies loading and unloading of gas cylinders.
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.
To avoid receiving a high frequency shock, keep
the TIG torch and cables in good condition.
------------------------------------------------------------------------
WORK CABLE CONNECTION
WARNING
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.
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 available 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 available for use with the PRECISION TIG®
225. An electrode holder with Twist-Mate™ cable and
Twist-Mate™ connector are available separately for
use with the PRECISION TIG® 225. (See
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.
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PRECISION TIG® 225
A-8 A-8
NOTES
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PRECISION TIG® 225
B-1 B-1
Operation..............................................................................B-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
GraphicSymbols .....................................................................B-2
Product Description . . . . . . . . . . . . . . . . . . . . . . . . ...........................................B-3
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
RecommendedProcesses ..............................................................B-3
ProcessLimitations ...................................................................B-3
Recommended Equipment/Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
EquipmentLimitation ..................................................................B-3
TABLE OF CONTENTS - OPERATION SECTION
WeldingCapability ....................................................................B-3
Controls and Settings . . . . . . . . . . . . . . . . . . . . ..........................................B-4,B-5
Power-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
CaseRearComponents................................................................B-6
OperatingSteps ......................................................................B-7
WeldinginTIGMode ..................................................................B-7
PulseTIGMode ......................................................................B-7
RemoteControlOperation ..............................................................B-8
Benefits of the PRECISION TIG® 225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
WeldinginStickMode .................................................................B-9
Recommended Electrode Amperage Ranges ...............................................B-9
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PRECISION TIG® 225
B-2 B-2
T
SAFETY PRECAUTIONS
OPERATION
GRAPHIC SYMBOLS THAT APPEAR ON
HIS MACHINE OR IN THIS MANUAL
Read and understand this entire section before operating the machine.
INPUT POWER
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.
POSITIVE OUTPUT
NEGATIVE OUTPUT
DIRECT CURRENT
PROTECTIVE
GROUND
WARNING OR
CAUTION
DO NOT SWITCH
WHILE WELDING
SINGLE PHASE
TRANSFORMER AC AND
RECTIFIER DC POWER
SOURCE
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• Wear eye, ear and body
protection.
------------------------------------------------------------------------
Observe additional Safety Guidelines detailed in
the beginning of this manual.
------------------------------------------------------------------------
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OFF
ON
PRECISION TIG® 225
B-3 B-3
PRODUCT DESCRIPTION
OPERATION
PROCESS LIMITATIONS
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
Lincoln’s 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 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 doesn’t have sufficient capacity, the AC Balance control
and the Output control will not provide full range of control.
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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.
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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.
PRECISION TIG® 225
B-4 B-4
OPERATION
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the front of the PRECISION TIG 225. Refer to Figure B.1
and corresponding explanations.
FIGURE B.1 - CONTROL PANEL
13
9
5
3
4
8
1
2
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
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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:
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• 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
would not have stopped flowing.
PRECISION TIG® 225
11
12
during Post Flow time, since shielding gas
B-5 B-5
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)toStickwill
automatically disable
trol and switch the output control back to the Max
Output panel control.
the connected remote con-
OPERATION
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
and dur-
be activated for the time set by the Post Flow Time
control.
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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.
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PRECISION TIG® 225
B-6 B-6
OPERATION
CASE REAR COMPONENTS
FIGURE B.2
4
3
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
5. RECEPTACLE AND CIRCUIT BREAKER-115vac
auxiliary NEMA 6-20R .
1
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PRECISION TIG® 225
B-7 B-7
OPERATION
OPERATING STEPS
WELDING IN TIG MODE
1. Connect the TIG torch and cable Twist-Mate™ quick
connect plug to the Electrode/Gas output 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.
7. Preset the Output Control on the control panel to the
maximum desired amps, as read on the digital
meter.
8. Depress the Foot Amptrol to energize the torch and
establish an an arc with the work piece. The digital
meter reads the actual amps while welding.
NOTE: When the TIG/STICK switch is set to “TIG”,
depressing the remote control will start a 0.5
second gas pre-flow before energizing the TIG
torch. When the remote control is released the
TIG torch is de-energized and gas flow will 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.
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• 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.
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PRECISION TIG® 225
B-8 B-8
REMOTE CONTROL OPERATION
OPERATION
BENEFITS OF THE PRECISION TIG® 225 DESIGN
A Foot Amptrol is included with the PRECISION TIG®
225 Ready-Pak models and available 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.
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.
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PRECISION TIG® 225
B-9 B-9
WELDING IN STICK MODE
OPERATION
5. Turn the power switch to “ON”.
1. Put the electrode holder and cable quick connect
6. Adjust the Current Control to the desired amps.
plug into the electrode output receptacle. Turn clockwise until tight. Connect the work clamp to the work
7. Strike an arc and weld.
piece.
NOTE: When the TIG/STICK switch is set to “STICK”
2. Set the TIG/STICK switch to “STICK”.
the output is always on when the power switch
is on. A remote control has no effect on the
3. Set the Polarity Switch to the weld mode desired for
the type of electrode being used (most commonly
welding current and the gas flow and high frequency TIG arc starter are disabled.
DC+).
4. Place the electrode in the electrode holder.
WARNING
• In Stick Mode the output terminal
and electrode will be electrically hot
whenever the power switch is turned
on.
------------------------------------------------------------------------
RECOMMENDED ELECTRODE AMPERAGE RANGES - PRECISION TIG 225
The PRECISION TIG 225 is rated from 5-225 Amps.
SMAW Process
Welding Amp Range for Stick Electrode Size
ELECTRODE TYPE POLARITY 3/32" 1/8" 5/32"
Fleetweld 5P, Fleetweld 5P+ E6010 DC+ 40 - 70 75 - 130 90 - 175
Fleetweld 180 E6011 DC+ 40 - 80 55 - 110 105 - 135
Fleetweld 37 E6013 DC+ 70 - 95 100 - 135 145 - 180
Fleetweld 47 E7014 DC- 75 - 95 100 - 145 135 - 200
Excalibur E7018 DC+ 85 - 110 110 - 160 130 - 200
Blue Max Stainless DC+ 40 - 80 75 - 110 95 - 150
Red Baron Stainless DC+ 40 - 70 60 - 100 90 - 140
Mild steel procedures are based on recommended procedures listed in C2.10 8/94 and the maximum rating of the PRECISION TIG 225
Blue Max procedures are based on C6.1 6/95
Red Baron Procedure are based on ES-503 10/93
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GTAW Process
Electrode Polarity DC- AC Approximate Argon
Electrode Tip Preparation
Electrode Type
Sharpened Balled Gas Flow Rate
EWZr C.F.H. (l/min.)
EWTh-1, EWCe-2
EWTh-2, EWLa-1
EWP EWCe-2, EWLa-1 Stainless
EWTh-1, EWTh-2
Tungsten Size (in.) EWG EWG Aluminum Steel
.010 Up to 15 A. Up to 10 A. Up to 15 A. 3-8 (2-4) 3-8 (2-4)
.020 Up to 15 A. Up to 15 A. Up to 20 A. 5-10 (3-5) 5-10 (3-5)
.040 Up to 80 A. Up to 40 A. Up to 60 A. 5-10 (3-5) 5-10 (3-5)
1/16 Up to 150 A. Up to 100 A. Up to 130 A. 5-10 (3-5) 9-13 (4-6)
3/32 Up to MAX. A. Up to 160 A. Up to MAX. A. 13-17 (6-8) 11-15 (5-7)
1/8 X Up to MAX. A. X 15-23 (7-11) 11-15 (5-7)
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure ..................................EWP ........green TRI-MIX OF ELEMENTS.............EWG.........gray
+1% Thoria .......................EWTh-1 ...yellow
+2% Thoria .......................EWTh-2 ...red
+2% Ceria.........................EWCe-2...orange
+1.5% Lanthana ...............EWLa-1...black
+0.15 to 0.40% Zirconia....EWZr.......brown
Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.
PRECISION TIG® 225
B-10 B-10
NOTES
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PRECISION TIG® 225
C-1 C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Standard Equipment Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
FactoryInstalledOptions ...............................................................C-3
FieldInstalledOptions .................................................................C-4
TABLE OF CONTENTS - ACCESSORIES SECTION
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PRECISION TIG® 225
C-2 C-2
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)
ACCESSORIES
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.
TABLE C.1
Select Machine
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)
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
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
Air Cooled System
Not Applicable
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PRECISION TIG® 225
C-3 C-3
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 12.5’ 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)
ACCESSORIES
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’ 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
•WaterHose&HoseCoupler
• 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
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PRECISION TIG® 225
C-4 C-4
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)
ACCESSORIES
• 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.)
• 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.
• 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)
• K2374-1 Electrode Holder and Cable
200 amp Electrode Holder with 10 ft.(3.1m) cable
and Twist-Mate™ connector.
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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
•WorkCable&Clamp
(Not required for PRECISION TIG® 225)
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PRECISION TIG® 225
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