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Lincoln Electric 225 manual

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Table of contents for the manual

  • Page 1

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • OPERA TOR’S MANUAL IM 895 May, 2007 Safety Depends on You Lincoln arc welding and cutting equipment is designe[...]

  • Page 2

    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. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS 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 ski[...]

  • Page 4

    iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 . b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. Natio[...]

  • Page 5

    iv SAFETY iv Mar. ʻ93 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 suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les c[...]

  • Page 6

    v SAFETY v EN 60974-10[...]

  • Page 7

    vi SAFETY vi EN 60974-10:[...]

  • Page 8

    vii vii Thank You 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference.[...]

  • Page 9

    viii viii T ABLE OF CONTENTS Page Installation ................................................................................................................... .... Section A Technical Specifications ................................................................................................A-1,A-2 Safety Precautions ........................[...]

  • Page 10

    A-1 INST ALLA TION PRECISION TIG 225 A-1 TECHNICAL SPECIFICA TIONS - PRECISION TIG 225 (K2533-1AND K2535-1,-2) Weld Voltage (NEMA) 15.7 V AC/DC 15.2 V AC/DC 14.1 V AC/DC 14.0 V AC/DC 29.0 V AC/DC 27.2 V AC/DC 23.4 V AC/DC Type of Output CC (Constant Current) AC/DC Weld Current* 225A AC/DC 180A AC/DC 90A AC/DC (BAL.) 80A AC (AUTO-BAL.) 225A AC/DC 18[...]

  • Page 11

    A-2 INST ALLA TION PRECISION TIG 225 A-2 TECHNICAL SPECIFICA TIONS - CANADIAN (K2533-2), INTERNA TIONAL K2534-1) MODEL HEIGHT WIDTH DEPTH WEIGHT PHYSICAL DIMENSIONS (2) Weld Voltage (NEMA) 29.0 V 27.2 V 23.4 V 15.7 V 15.2 V 14.1 V 14.0 v Output Type CC (Constant Current) AC or DC Weld Current* 225 A AC/DC 180 A AC/DC 90 A AC/DC 225 A AC/DC 180 A AC[...]

  • Page 12

    A-3 INST ALLA TION PRECISION TIG 225 A-3 SAFETY PRECAUTIONS SELECT SUIT ABLE LOCA TION 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 "[...]

  • Page 13

    A-4 INST ALLA TION PRECISION TIG 225 A-4 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 wel[...]

  • Page 14

    A-5 INST ALLA TION PRECISION TIG 225 A-5 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. Failure to follow these instructions can cause immediate failure of components within the welder and void machineʼs warranty. -----------[...]

  • Page 15

    A-6 INST ALLA TION PRECISION TIG 225 A-6 CONNECTIONS FOR TIG (GT A W) 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 availa[...]

  • Page 16

    B-1 OPERA TION PRECISION TIG 225 B-1 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 ha[...]

  • Page 17

    B-2 OPERA TION B-2 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 lowe[...]

  • Page 18

    B-3 OPERA TION B-3 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 e[...]

  • Page 19

    B-4 OPERA TION B-4 8. PULSE TIG CONTROL – The Pulse TIG feature built into the PRECISION TIG 225 is simplified to be a single knob control which sets the Pulse Frequency over the peak pulses/sec. range of about 0.1 to 20 pulses per second: • Full CCW (min.) setting of the control knob shuts off Pulse TIG (0.0 pps). • Peak Pulse level is set b[...]

  • Page 20

    B-5 OPERA TION B-5 CASE REAR COMPONENTS 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 inpu[...]

  • Page 21

    B-6 OPERA TION B-6 PRECISION TIG 225 OPERA TING STEPS WELDING IN TIG MODE 1. Connect the TIG torch and cable Twist-Mate quick connect plug to the Electrode/Gas output recepta- cle. This receptacle also contains an integral gas connection for the torch. Connect the work clamp to the work piece. 2. Set the TIG/STICK switch to “TIG”. 3. Set the Po[...]

  • Page 22

    B-7 OPERA TION B-7 REMOTE CONTROL OPERATION A Foot Amptrol ™is included with the PRECISION TIG 225 Ready-Pak models and availiable for other models (See Accessories Section) for remote current control while TIG welding. An optional Hand Amptrol may also be used. An optional Arc Start Switch may be used to start and stop the welding if no remote c[...]

  • Page 23

    B-8 OPERA TION B-8 WELDING IN STICK MODE 1. Put the electrode holder and cable quick connect plug into the electrode output receptacle. Turn clockwise until tight. Connect the work clamp to the work piece. 2. Set the TIG/STICK switch to “STICK”. 3. Set the Polarity Switch to the weld mode desired for the type of electrode being used (most commo[...]

  • Page 24

    TABLE C.1 C-1 ACCESSORIES C-1 ST ANDARD EQUIPMENT P ACKAGES 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[...]

  • Page 25

    C-2 ACCESSORIES C-2 PRECISION TIG 225 F ACTOR Y INST ALLED 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* [...]

  • Page 26

    C-3 ACCESSORIES C-3 FIELD INST ALLED OPTIONS The following Options/Accessories are available for the Precision TIG 225: • K2348-1 Under-Storage Car t 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 o[...]

  • Page 27

    D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS 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. ------------------------------------------------------------------------ To avo[...]

  • Page 28

    E-1 TROUBLESHOOTING E-1 PRECISION TIG 225 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repai[...]

  • Page 29

    E-2 TROUBLESHOOTING E-2 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POS[...]

  • Page 30

    E-3 TROUBLESHOOTING E-3 PRECISION TIG 225 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBL[...]

  • Page 31

    E-4 TROUBLESHOOTING E-4 PRECISION TIG 225 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBL[...]

  • Page 32

    E-5 TROUBLESHOOTING E-5 PRECISION TIG 225 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBL[...]

  • Page 33

    E-6 TROUBLESHOOTING E-6 PRECISION TIG 225 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBL[...]

  • Page 34

    E-7 TROUBLESHOOTING E-7 PRECISION TIG 225 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBL[...]

  • Page 35

    F-1 DIAGRAMS F-1 PRECISION TIG 225 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code n[...]

  • Page 36

    F-2 DIMENSION PRINT F-2 PRECISION TIG 225 1 L 12201 A 14.00 20.25 .24 .46 DOOR CL O SED 2.44 4.83 TO OL T RAY DOOR 22.00 * * .24 12.38 * * .81 * * 7.00 1.66 TO RCH H OL S T E R * * L OCATI ON OF (4) O .284 B ASE M OUNTI NG HOL ES. 12.99 24.00 1.00 * * 1.62 MACHINE ONLY AND READY-PAK FOR CODES 11317, 11318, 11319, 11320[...]

  • Page 37

    F-3 DIMENSION PRINT F-3 PRECISION TIG 225 L 12202 A 19.81 14.00 24.00 1.66 TORCH H OL ST E R 6.00 2.44 7.00 30.78 .75 4.83 TO OL T RAY DOOR 20.25 10.53 .46 DOOR CL O SED 12.99 37.24 13.27 READY-PAK WITH CART FOR CODE 11321[...]

  • Page 38

    W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA [...]

  • Page 39

    W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

  • Page 40

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]