Lincoln Electric Ac225 Arc Welder Manual

The Lincoln Electric 225A/25V/20% DC arc welder comes with a 50-amp output range, two wheels, and assembly hardware. The wire harness and 125A/25V/20% DC wiring harness are included, making the welding process easy and quick.

Who doesn’t enjoy a new project, even though it would have likely been less expensive in the long run to simply get an AC/DC stick welder? Much of what I’m doing is following Gregory Hildstrom’s essay on doing much of the same work on his own AC-225, as I did in my initial post about the welder. I doubt I would have begun this if it weren’t for his articles.


Cast iron, carbon, low alloy, and stainless steels, as well as other materials, may all be welded with the AC225 small stick welder thanks to its incredibly smooth AC arc.

Installation is simple because a 6 ft. (1.8 m) input power cable and NEMA 6-50P socket are included.
Simple to use – Full range 40-225 amp selector switch adjusts welding current rapidly and provides a consistent arc each and every time you weld.

Smooth arc: Makes it simple to weld with various electrodes, such as hardfacing, stainless steel, low hydrogen, and mild steel electrodes.
For general-purpose mild steel electrodes with a diameter of 3/16″ (4.8 mm) and other electrodes with a diameter of 5/32″ (4.0 mm), a 225 amp AC output is sufficient.
UL listed, ULCSA authorized, and NEMA rated.


  • Simple to use – Wide range The welding current is readily set via the 40-225 amp selection switch.
  • Easy to weld thanks to the smooth arc.
  • 3/16 (4.8 mm) diameter general-purpose mild steel electrodes can be used with a 225 amp AC output.
  • NEMA rated, UL listed, and ULCSA certified; comes with connected input power cord; easy to install

Wire Connectors

I attached connections to one end of 24 12 gauge wires by cutting them to a little over 12′′ apiece. Six rectifiers altogether, four each rectifier. After finishing the entire installation, 12′′ felt a little short. The next time, I would use 16′′ to ensure that none of the wires are under stress.

Related – MIG Welder Carts


I created a tiny choke using an old microwave transformer core and four twists of 2 gauge wire after reading up on this modification (see the links below). This is connected to the DC output’s positive side. I do think the arc runs a little bit more smoothly with the choke than without it, based on some tests I’ve done. The sole drawback is that the wire jacket of the transformer was eaten up by its razor-sharp edges.

It makes me ponder whether it would still work if I wrapped the wire entirely around the transformer rather than just through the middle.


DC appears to function fairly well. I intend to conduct some testing on various rods and the amps that they perform best at. It was intriguing to observe how rapidly the rectifiers and the aluminum L-bar heated up during a few tests. The rectifiers quickly exceeded 100°F in a 6′′ run at 90 or 115 amps, but because of the solid piece of aluminum on which they are attached, they cooled down in approximately two minutes. I also measured the temperature of the transformer, and even though it heated up more slowly than the rectifiers, it still reached above 100°F in two 6′′ beads. Although I was unable to locate a datasheet for these specific rectifiers, comparable ones mention a maximum operating temperature of 150°C (302°F).

Related – Miller 185 Mig Welder

Limiting the power supplied to the lincoln electric ac225 arc welder

The Lincoln Electric ac225 arc wedder has several different methods for controlling the current that is supplied to it. One way is by controlling the auxiliary power supply 175. This power supply shares the primary DC bus 115 with the welding output 165. A large current draw can decrease the voltage of the primary bus and affect the welding output 165. Another method is to limit the power supplied to the welder when it is in operation.

Regardless of the method you choose to limit the power supplied to the Lincoln AC225 arc welder, it is important to follow the recommendations provided by the manufacturer of the machine. For example, a welder that draws over 120 volts should be operated on a 60 amp breaker. However, it is possible to use a welder with a lower amp breaker on a higher amp circuit, if the breaker is sized correctly.

When using a Lincoln ac225 arc welder, the operator must limit the power that is supplied to the arc to ensure that the device will not overheat. The machine’s control panel has a display that shows the maximum power available. It will also display the maximum power output for the wire feed speed.

The auxiliary power output demand can be limited by adjusting the voltage pulse width. A spike in the auxiliary power output demand can be caused by the initial start of a power tool. This auxiliary power output demand can increase by up to three times if the tool does not start properly.

In addition, limiting the power supplied to the Lincoln Electric aac225 arc welder is also possible through the use of a secondary winding 145. It eliminates the need for a separate transformer and can be added to any welder. This secondary winding can be connected to the DC bus 115 for additional power.

The Lincoln AC225 arc welder is capable of welding in a wide range of materials. The Micro-Start TIG technology, which employs an independent power supply, is especially useful for welds of low amperages. In this way, operators can weld thin materials with high quality. The Micro-Start TIG technology also provides a smooth transition from low to high outputs.


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