i

SAFETY

i

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

The Above For Diesel Engines

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

The Above For Gasoline Engines

FOR ENGINE powered equipment.

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

____________________________________________________

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

outdoors.

____________________________________________________

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

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

____________________________________________________

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

____________________________________________________

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

___________________________________________________

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

while the engine is running.

___________________________________________________

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

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

ELECTRIC AND

MAGNETIC FIELDS may be dangerous

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

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

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

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

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

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

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

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

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

Mar ??95

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 spe- cific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

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

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 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.

5.f. Also see item 1.b.

iii

SAFETY

iii

WELDING and CUTTING

SPARKS can

cause fire or explosion.

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

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

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

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

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

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

(see address above).

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

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

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

6.h. Also see item 1.c.

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

022690-9101.

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

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders

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

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

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

7.c. Cylinders should be located:

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

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

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

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

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

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

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

FOR ELECTRICALLY powered equipment.

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

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

Electrical Code, all local codes and the manufacturer??s recommendations.

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

Electrical Code and the manufacturer??s recommendations.

Jan, 07

iv

SAFETY

iv

PR??CAUTIONS DE S??RET??

Pour votre propre protection lire et observer toutes les instructions et les pr??cautions de s??ret?? specifiques qui parraissent dans ce manuel aussi bien que les pr??cautions de s??ret?? g??n??rales suiv- antes:

S??ret?? Pour Soudage A L??Arc

1.Protegez-vous contre la secousse ??lectrique:

a.Les circuits ?? l????lectrode et ?? la pi??ce sont sous tension quand la machine ?? souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v??tements mouill??s. Porter des gants secs et sans trous pour isoler les mains.

b.Faire tr??s 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 couch?? pour lesquelles une grande partie du corps peut ??tre en contact avec la masse.

c.Maintenir le porte-??lectrode, la pince de masse, le c??ble

de soudage et la machine ?? souder en bon et s??r ??tat defonctionnement.

d.Ne jamais plonger le porte-??lectrode dans l??eau pour le refroidir.

e.Ne jamais toucher simultan??ment les parties sous tension des porte-??lectrodes connect??s ?? deux machines ?? souder parce que la tension entre les deux pinces peut ??tre le total de la tension ?? vide des deux machines.

f.Si on utilise la machine ?? souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-??lectrode s??applicuent aussi au pistolet de soudage.

2.Dans le cas de travail au dessus du niveau du sol, se prot??ger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le c??ble-??lectrode autour de n??importe quelle partie du corps.

3.Un coup d??arc peut ??tre plus s??v??re qu??un coup de soliel, donc:

a.Utiliser un bon masque avec un verre filtrant appropri??

ainsi qu??un verre blanc afin de se prot??ger les yeux du ray- onnement de l??arc et des projections quand on soude ou quand on regarde l??arc.

b. Porter des v??tements convenables afin de prot??ger la peau de soudeur et des aides contre le rayonnement de l??arc.

c. Prot??ger l??autre personnel travaillant ?? proximit?? au soudage ?? l??aide d????crans appropri??s et non-inflammables.

4.Des gouttes de laitier en fusion sont ??mises de l??arc de soudage. Se prot??ger avec des v??tements de protection libres de l??huile, tels que les gants en cuir, chemise ??paisse, pan- talons sans revers, et chaussures montantes.

5.Toujours porter des lunettes de s??curit?? dans la zone de soudage. Utiliser des lunettes avec ??crans lateraux dans les zones o?? l??on pique le laitier.

6.Eloigner les mat??riaux inflammables ou les recouvrir afin de pr??venir tout risque d??incendie d?? aux ??tincelles.

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

??chauffement et un risque d??incendie.

8.S??assurer que la masse est connect??e le plus pr??s 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 ??loign??s de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de lev- age, c??bles de grue, ou autres circuits. Cela peut provoquer des risques d??incendie ou d??echauffement des chaines et des c??bles jusqu???? ce qu??ils se rompent.

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

Ceci est particuli??rement important pour le soudage de t??les galvanis??es plomb??es, ou cadmi??es ou tout autre m??tal qui produit des fume??s toxiques.

10.Ne pas souder en pr??sence de vapeurs de chlore provenant d??op??rations de d??graissage, nettoyage ou pistolage. La chaleur ou les rayons de l??arc peuvent r??agir avec les vapeurs du solvant pour produire du phosg??ne (gas fortement toxique) ou autres produits irritants.

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

PR??CAUTIONS DE S??RET?? POUR

LES MACHINES ?? SOUDER ??

TRANSFORMATEUR ET ??

REDRESSEUR

1.Relier ?? la terre le chassis du poste conformement au code de l????lectricit?? et aux recommendations du fabricant. Le dispositif de montage ou la piece ?? souder doit ??tre branch?? ?? une bonne mise ?? la terre.

2.Autant que possible, I??installation et l??entretien du poste seront effectu??s par un ??lectricien qualifi??.

3.Avant de faires des travaux ?? l??interieur de poste, la debranch- er ?? l??interrupteur ?? la boite de fusibles.

4.Garder tous les couvercles et dispositifs de s??ret?? ?? leur place.

vii

Thank You

vii

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

????????? as much pride as we have in bringing this product to you!

SAFETY PRECAUTIONS

Read entire installation section before starting installation.

WARNING

ELECTRIC SHOCK can kill.

???Only qualified personnel should perform this installation.

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

???Do not touch electrically hot parts.

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

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

SELECT SUITABLE LOCATION

MOUNTING

Environmental Rating

The Precision TIG 225 power source carries an IP21S environmental rating. It may be used in normal indus- trial 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 move- ment 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 mainte- nance problems.

STACKING

Precision TIG 225 cannot be stacked.

LIFTING AND MOVING

The PRECISION TIG 225 models are provided with an Eyebolt used for lifting the unit with a hoist.

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 instruc- tions and warnings provided on the case top decal. Save the removed plug button (LE part No.T10397-2) to cover the hole when the lift Eyebolt is removed.

WARNING

???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 sur- face, either directly or on a recommended undercar- riage. The machine may topple over if this procedure is not followed.

MACHINE GROUNDING AND HIGH FRE-

QUENCY 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.

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

The high frequency generator, being similar to a radio transmitter, may cause radio, TV and electronic equip- ment interference problems. These problems may be the result of radiated interference. Proper grounding meth- ods 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 unground- ed 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 possi- ble 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 possi- ble 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 leak- age.

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.

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

6.Keep cover and all screws securely in place.

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 pro- cedures can cause radio or TV and electronic equipment interference problems and result in unsatisfactory weld- ing 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 recep- tacle 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 type1 circuit 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.

1Also 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.

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 machine??s warranty.

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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 dis- 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

INPUT LEADS

L1 & L2

LEAD H1

(DO NOT

REMOVE)

FOR LOWEST RATED VOLTAGE

: H2 CONNECTED

FOR HIGHEST RATED VOLTAGE

: H3 CONNECTED

BACK VIEW OF LINE SWITCH

FIGURE A.1 Reconnect Leads

OUTPUT CONNECTIONS

ELECTRODE/GAS

OUTLET

RECEPTACLE (TWIST-MATE)

WORK CABLE & CLAMP

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

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

1.Remove the sheet metal left side cover.

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.

FIGURE A.2 Location of Output Connections

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.

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 con- nected to the PRECISION TIG 225. To minimize high frequency interference, refer to Input and Ground and High Frequency Interference Protection sec- tion 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 plat- form that simplifies loading and unloading of gas cylin- ders.

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 con- trols.

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 clock- wise until it is tight. The work cable and work clamp are factory connected.

SAFETY PRECAUTIONS

Read and understand this entire section before oper- ating the machine.

WARNING

ELECTRIC SHOCK can kill.

???Do not touch electrically live parts or electrode with skin or wet cloth- ing.

???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.

??? Wear eye, ear and body protection.

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

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

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

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

INPUT POWER

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

OFF

ON

PRODUCT DESCRIPTION

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) mod- els are rated 6 amps, while the 208/230/1/60 models (K2533-1 and K2535-1/-2) are rated 20 amps (for use with Lincoln??s 115v SP and Power Mig models).

RECOMMENDED PROCESSES AND EQUIP-

MENT

RECOMMENDED PROCESSES

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

PROCESS LIMITATIONS

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 configu- ration, with optional accessories.

*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 pro- tection of the output power coils and rectifiers.

The PRECISION TIG 225 machine uses Twist-Mate output ter- minals, 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.

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.

CONTROL FUNCTIONALITY

1.POWER SWITCH ??? Input line switch turns input power ON or OFF, as indicated by the on or off sta- tus 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.

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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:

???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 weld- ing, 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.

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 indi- cate the Pulse TIG Control setting before and dur- 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 the connected remote con- trol and switch the output control back to the Max Output panel control.

11.ELECTRODE/GAS OUTPUT RECEPTACLE -

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

12.WORK CABLE - This 10ft.(3.05m) cable with work clamp is factory connected to the welder and its clamp is connected to the work piece to com- plete the welding circuit. Refer to Machine Grounding and High Frequency Interference Protection in the Installation section of this manual for the proper procedure on grounding the work clamp and work piece to minimize high frequency interference.

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.

CASE REAR COMPONENTS

FIGURE B.2

3

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 .

4

5

1

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 elimi- nate accidental high current damage to the work piece and/or tungsten, and provides a fine control of the cur- rent. When the welder is in the stick mode a remote control has no effect and is not used.

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

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

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 por- tion may also cause the electrode to overheat at high currents causing ???tungsten spitting???. The negative por- tion of the AC wave offers no cleaning action but con- centrates more heat on the work.

The AC waveform of the PRECISION TIG 225 opti- mizes 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.

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

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.

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*

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.

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*

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.

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.

???TIG-Mate Torch Starter Kits:

Includes Torch with Twist-Mate adapter and acces- sories 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)

???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.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

???Only qualified personnel should per- form this maintenance.

???Turn the input power OFF at the dis- connect switch or fuse box before working on this equipment.

???Do not touch electrically hot parts.

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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 fol- lowing components thoroughly.

???Main Transformer

???Electrode/Gas Output Receptacle

???Polarity Switch

???Rectifier Assembly

???Arc Starter/Spark Gap Assembly

???PC Boards

???Fan Blades

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 cool- ing.

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).

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 volt- age is dangerously high.

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Refer to figure D.1. Note in highly dirty environments where there is an abundance of conductive contami- nants, use a low pressure air stream or a firm piece of paper to clean the spark gap. Do not disturb the facto- ry 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 prop- erly grounded.

FIGURE D.1 SPARK GAP

.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

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 (SYMP- TOMS)???. 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.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.