Lincoln Electric IM528-B User Manual

For use with Equipment having Code Number 10135, 10203, 10284, 11010

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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.

importantly, think before you act and be careful.

And, most

IM528-B

March, 2005

TIG Module

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• 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

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.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.

____________________________________________________

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.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.

___________________________________________________

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.

TIG MODULE

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

Mar ‘95

- i -

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.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

5.a.Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

3.f.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

5.b.

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.c. 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.d. 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.e. Also see item 1.b.

Mar ‘95

vapors

- ii -

TIG MODULE

iii

SAFETY

iii

WELDING 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.

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.

Remember that welding sparks and hot

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.

TIG MODULE

Mar ‘95

- iii -

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sû reté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

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 soudage.

’applicuent aussi au pistolet de

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.

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 phosg 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.

éne (gas

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 approprié s 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.

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 sûretéà leur place.

Mar. ‘93

- iv -

TIG MODULE

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

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

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number____________________________________________________________________________ Date Purchased___________________________________________________________________________ Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

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

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

TIG MODULE

- v -

TABLE OF CONTENTS

Page

Safety .....................................................................................................................i-iv

Installation................................................................................................................1-17

Technical Specifications ............................................................................................1

Input and Rated Capacities Recommended Welding Cables

Physical Dimensions

Location .....................................................................................................................2

Environmental Protection...........................................................................................2

High Frequency Interference Protection....................................................................2

Supply Connections...................................................................................................3

Input & Output Connections.......................................................................................3

Installation of Field Installed Accessories..................................................................4

Installation with a Power Source...........................................................................5-17

Ranger 8 Installation...........................................................................................5-8

Ranger 9 Installation.........................................................................................9-10

Ranger 10 & Ranger 300 D Installation..........................................................11-12

Ranger 10-LX & Ranger 300 DLX Installation................................................13-14

Installation with other Lincoln Power Sources ................................................15-17

Operation................................................................................................................18-30

Safety Instructions ...................................................................................................18

Graphic Symbols......................................................................................................19

Product Description..................................................................................................20

Recommended Processes and Equipment..............................................................20

Design Summary .....................................................................................................20

Controls and Settings .........................................................................................21-22

Ranger 8 Operation............................................................................................23-24

Figure 9....................................................................................................................25

Ranger 9 Operation .................................................................................................26

Ranger 10 & Ranger 300 D Operation.....................................................................27

Ranger 10-LX & Ranger 300 DLX Operation...........................................................28

Operation on other Lincoln Power Sources.............................................................29

TIG Welding Information..........................................................................................30

Accessories.................................................................................................................31

Maintenance ................................................................................................................32

Safety Precautions...................................................................................................32

Periodic Maintenance ..............................................................................................32

Troubleshooting ....................................................................................................33-36

How To Use Troubleshooting Guide........................................................................33

Troubleshooting Guide .......................................................................................34-36

Wiring Diagram ...........................................................................................................37

Parts Manual ...................................................................................................Appendix

- vi -

TIG MODULE

INSTALLATION

TECHNICAL SPECIFICATIONS - TIG MODULE

INPUT - SINGLE PHASE ONLY

Standard

Voltage

Input Current

Code

Number

115 VAC 50/60

(60VAC TO 130 VAC) 50/60 HZ.

(MIN. TO MAX.)

Duty Cycle

100%

60% 20%

RECOMMENDED WELDING CABLES

Duty Cycle

100%

60%

1.3 amperes

RATED CAPACITIES

Amps

200 amps AC/DC 300 amps AC/DC 400 amps AC/DC

Amps

200 amps AC/DC 300 amps AC/DC

10135 10203 10284 11010

Total Capacity Range

15 - 400 amps AC/DC

Cable sizes* (mm2)

#2 AWG (30) #1 AWG (35)

20%

(*) Correct Cable size if the cable length is 150 feet (45.7 meters) or less.

PHYSICAL DIMENSIONS

Height Width Depth Weight

12.0 in. 15.0 in. 10.5 in. 33 lbs 305 mm 381 mm 267 mm (15 kg)

Insulation Class 155(F)

400 amps AC/DC

#1/0 AWG (50)

TIG MODULE

– 1 –

INSTALLATION

Read entire installation section before starting installation.

Safety Precautions

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Turn the Power Source input power OFF at the disconnect switch or stop the engine before attempting to connect the TIG Module

• Do not touch electrically hot parts.

Users should familiarize themselves with Figure 8, Rear Connections, in the Operating Section of this manual before proceeding.

LOCATION

The TIG Module can be mounted in or carried to any convenient location. It is designed to be portable. If placed on the roof of engine welders, it must be mounted securely. A Docking Kit option is available for this purpose. See the Accessories section.

ENVIRONMENTAL PROTECTION

2. Direct interference radiated from the welding leads.

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

4. Interference from reradiation of “ pickup” by

ungrounded metallic objects.

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

1. Keep the power source input supply lines as short as possible and completely enclose them in rigid metallic conduit or equivalent shielding for a minimum distance of 50 feet (15.2 m). There should be good electrical contact between this conduit and the welder. 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 feet (7.6 m). 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. Cables with high natural rubber content, such as Lincoln Stable-Arc® better resist high frequency leakage than neoprene and other synthetic rubber insulated cables.

This accessory qualifies for an IP23 rating. It is suited for use in damp, dirty and dusty locations. (In locations where there are large amounts of conductive metal or salt particles in the air, additional maintenance may be required.) It is protected against rainfall. Excessive moisture can, however, cause short term operational difficulties. Difficulties can occur with the spark gap; it may not “spark” when the unit is first turned on after prolonged exposure to moisture. Usually, allowing the unit to operate for 5 to 15 minutes will allow the spark gap to dry out, and return to normal operation.

HIGH FREQUENCY INTERFERENCE

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

5. The work terminal must be connected to a ground within ten feet of the welder, 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” (19 mm) galvanized pipe or conduit

or a 5/8” (16 mm) solid galvanized iron or steel or copper rod driven at least eight feet into the ground.

PROTECTION

The ground should be securely made and the

Since the spark gap oscillator in the TIG Module is similar to a radio transmitter, improper installation can result in radio and TV interference or problems with nearby electronic equipment.

Radiated interference can develop in the following four ways:

1. Direct interference radiated from the welder and the TIG Module.

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 a long pipe system can result in reradiation, effectively making these members radiating antennas.

NOTE: The welder frame MUST also be grounded.

The work terminal ground does not ground the welder frame.

– 2 –

TIG MODULE

INSTALLATION

6. Keep all access panels and covers securely in place.

7. All electrical conductors within 50 feet (15.2 m) of the welder should be enclosed in grounded rigid metallic conduit or equivalent shielding. Flexible helically-wrapped metallic conduit is generally not suitable.

8. When the welder is enclosed in a metal building, several good earth driven electrical grounds (as in 5 (b)) around the periphery of the building are recommended.

SUPPLY CONNECTIONS

Control cables are needed to connect the TIG Module’s 9-pin Input Receptacle to the power source. Four different cables are available. The proper choice of cable depends on the power source being used. Included in this report are charts which specify which cable is used with a particular power source. The cables come in standard 5 ft.(1.5m) lengths. 22(6.7m) and 45(13.7) ft. extensions are available.

Note that two of the studs are labeled “FROM POWER SOURCE”; these are to be connected to the power source work and electrode terminals. If the power source output terminals are not labeled

“WORK” and “ELECTRODE”, the TIG Module “FROM POWER SOURCE ELECTRODE”

terminal should go to the power source output terminal which matches the desired welding polarity. This is the negative (-) terminal when welding DC-. The choice of power source terminal will have no effect when welding AC.

TIG Torch and Workpiece Connections

One terminal is labeled “TO TIG TORCH”. Use that terminal for the TIG torch connection. TIG torches come in 12.5ft.(3.8m) and 25ft.(7.6m) lengths; use the shorter size whenever possible to minimize the possibility of high frequency interference.

The last terminal is labeled “TO WORKPIECE”. Use short lengths whenever possible to minimize the possibility of high frequency interference.

Input power should be nominally 115 volts AC, but the TIG Module will operate properly on any AC voltage from 60 to 130 volts, 50 or 60 Hz. Input current draw is 1.3 amps at 115 volts.

INPUT AND OUTPUT CONNECTIONS

Input Connections

The user must provide welding cables for the connections between the work and electrode terminals of the power source, and the “FROM POWER SOURCE WORK” and “FROM POWER SOURCE ELECTRODE” terminals of the TIG Module. All connections are made with 1/2-13 threaded stud output terminals. Choose cables according to the output currents and duty cycles listed below.

200 Amps 100% Duty Cycle #2 AWG(30mm (minimum) Cable

300 Amps 60% Duty Cycle #1 AWG(35mm2) (minimum) Cable

400 Amps 20% Duty Cycle #1/0 AWG(50mm (minimum) Cable

These ratings are for cables lengths of 150 ft.(46.0m) or less.

)

Shielding Gas Connections

The gas valve connections are labeled “GAS INPUT” and “GAS OUTPUT”. Any torch and gas supply conforming to Compressed Gas Association (CGA) standards can be connected via the 5/8-18 right hand threaded fittings. The cylinder of shielding gas must be equipped with a regulator and flowmeter. Install a hose between the flowmeter and the input fitting.

Water Valve Connection

The optional K844-1 Water Valve Kit can be installed in the TIG Module to provide on/off flow control for cooling water. The water valve opens and closes at the same time as the gas valve, so cooling water flows during the afterflow period. Connections are made via the two 5/8-18 left hand threaded connections. If using a watercooled torch with a free running water supply, install a water line between the water supply and the “WATER INPUT” fitting on the TIG Module. Include a strainer in the supply line to prevent dirt particles from obstructing the water flow in the valve and cooling chamber of the TIG torch. Failure to do so could result in overheating of the water-cooled torch. Connect the torch water line to the “WATER OUTPUT” fitting. Use a nonmetallic drain line from the TIG torch power block to the drain.

TIG MODULE

– 3 –

INSTALLATION

If using a water cooled torch with a water cooler,

do not install the water valve. It will block the water flow, possibly damaging the pump. Magnum water coolers are an exception to this rule. Refer to the manufacturer’s instructions provided with the cooler.

INSTALLATION OF FIELD INSTALLED ACCESSORIES

Installation of the K963 Hand Amptrol, K870 Foot Amptrol, and K814 Arc Start Switch is as follows:

Connect the 6-pin MS-type circular connector to the Remote Receptacle on the TIG Module. Secure with the threaded collar.

Installation of the K936-[ ] Input Cables and K937-[ ] Extension Cables is as follows:

Connect the 9-socket MS-type circular connector on the Input Cable to the Input Receptacle on the TIG Module. Secure with the threaded collar. If one or more K937-[ ] Extension Cables are used, connect them between the TIG Module and the K936-[ ] Input cable.

Installation instructions for the K938-1 Contactor Kit, K844-1 Water Valve Kit and the K939-1 Docking Kit are included with those kits.

– 4 –

TIG MODULE

INSTALLATION

INSTALLATION WITH A POWER SOURCE

Ranger 8 Installation

Tables 1 and 2 list the required and optional equipment for installing and operating the TIG Module with a Ranger 8. Table 1 is for the Ranger 8, and table 2 is for the Ranger 8 with the K892-1 Remote Kit installed. The Remote Kit installation is identified by the presence of a 6-pin remote connector located between the output studs.

RANGER 8 (WITH NO K892-1 REMOTE KIT) AND THE TIG MODULE

REQUIRED EQUIPMENT

Control

Cable

Contactor

Kit

Work and Electrode

Leads from Ranger 8 to TIG Module

TIG

Torch

Refer to the Connection Diagrams Figures 1 and

2. Figure 1 is for the Ranger 8, and figure 2, for the Ranger 8 with the K892-1 Remote Kit installed. Make sure all connections are tight before proceeding.

Work

Lead

Shielding Gas,

Regulator, Flowmeter

Arc Start

Switch

K936-4 9-pin to

115V Plug

Control

Cable

Extension K937 - [ ]

Extension

9-pin to 9-pin

K938-1

Field

Installed

User Supplied;

Length as

Req’d. Cable

Sized to Match

Current and

Duty Cycle

User

Supplied

User Supplied;

Length as

Req’d. Cable

Sized to Match

Current and

Duty Cycle

User

Supplied

RANGER 8 (WITH NO K892-1 REMOTE KIT) AND THE TIG MODULE

OPTIONAL EQUIPMENT

Water

Valve

K844-1 K939-1

Docking

Kit

Mounts to

Ranger 8 Roof

TABLE 1

K814

TIG MODULE

– 5 –

INSTALLATION

Only qualified personnel should install,use

Keep guards in place.

or service this equipment.

Keep away from moving parts.

K814 ARC START SWITCH

12-1-94

M17530

40 4

4 L9

LOCAL

LOCAL SERIAL NO.

SERIAL NO.

SWITCH

CURRENT

CONTROL

REMOTE AMPTROL

WARNING

CODE

8 7

100%

60%

250A 180A

20%

350A

0 4

1 3

CURRENT CONTROL

20A TO 350A

20A TO 350A RATED CAPACITY

RATED CAPACITY

45 40

55 S

55 S 35

AFTERFLOW

10 20

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

START ONLY

INPUT

WARNING

Do not operate with panels open.

Disconnect NEGATIVE (-) BATTERY LEAD

before servicing.

Do not touch electrically live parts.

FIGURE 1: RANGER 8 / TIG MODULE CONNECTION DIAGRAM

INPUT

OFF

115 V 1.3 A 50/60 Hz

CONTINUOUS

HIGH FREQUENCY

ELECTRIC

MODEL

POWER

LINCOLN

PORTABLE HI-FREQ

OFF

INPUT

FITTING

TO GAS

WELDING CABLES MUST BE PROPERLY SIZED FOR THE CURRENT AND DUTY CYCLE OF APPLICATION

REGULATOR

FLOWMETER

CYLINDER

ARGON GAS

– 6 –

TIG MODULE

NOTE: This diagram is for reference only. It was accurate at the time of printing , however Lincoln Electric reserves the right to make improvements and modifications

as necessary, if you supect this information to be inaccurate, write to the Service Department for a replacement. Give the equipment code number..

INSTALLATION

RANGER 8 (WITH THE OPTIONAL K892-1 REMOTE KIT INSTALLED) AND THE TIG MODULE

REQUIRED EQUIPMENT

Control

Cable

K936-3

9-pin to

6-pin

plus

115V Plug

RANGER 8 (WITH THE OPTIONAL REMOTE KIT INSTALLED) AND THE TIG MODULE

Control

Cable

Extension

Contactor

Kit

K938-1

Field

Installed

Water

Valve

Work and Electrode

Leads from Ranger 8 to TIG Module

User Supplied;

Length as

Req’d. Cable

Sized to Match

Current and

Duty Cycle

OPTIONAL EQUIPMENT

Arc Start

Switch

TIG

Torch

User

Supplied

Hand

Amptrol

Work Lead

User Supplied;

Length as

Req’d. Cable

Sized to Match

Current and

Duty Cycle

Foot

Amptrol

Shielding Gas,

Regulator, Flowmeter

User

Supplied

Docking

Kit

Arc Start

Switch

See

Optional

Equipment

Below

K937 - [ ] Extension

9-pin to 9-pin

K844-1 K814 K963 K870 K939-1

Mounts to

Ranger 8 Roof

TABLE 2

TIG MODULE

– 7 –

INSTALLATION

-OR-

4-19-96D

M17531

Only qualified personnel should install,use

Keep guards in place.

WARNING

or service this equipment.

Keep away from moving parts.

LOCAL

LOCAL SERIAL NO.

SERIAL NO.

CODE

100%

60%

250A 180A

20%

350A

20A TO 350A

20A TO 350A RATED CAPACITY

RATED CAPACITY

INPUT

115 V 1.3 A 50/60 Hz

CONTINUOUS

MODEL

PORTABLE HI-FREQ

K870 FOOT AMPTROL

40 4

4 L9

SWITCH

SWITCH CURRENT

CURRENT

CONTROL

REMOTE AMPTROL

WARNING

8 7

1 3

CURRENT CONTROL

45 40

55 S

AFTERFLOW

10 20

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

START ONLY

OFF

HIGH FREQUENCY

ELECTRIC

POWER

LINCOLN

OFF

K963 HAND AMPTROL

K814 ARC START SWITCH

Do not operate with panels open.

Disconnect NEGATIVE (-) BATTERY LEAD

before servicing.

Do not touch electrically live parts.

INPUT

FITTING

TO GAS

WELDING CABLES MUST BE PROPERLY SIZED FOR THE CURRENT AND DUTY CYCLE OF APPLICATION

FIGURE 2: RANGER 8 / K892-1 REMOTE KIT / TIG MODULE CONNECTION DIAGRAM

REGULATOR

FLOWMETER

CYLINDER

ARGON GAS

– 8 –

TIG MODULE

NOTE: This diagram is for reference only. It was accurate at the time of printing , however Lincoln Electric reserves the right to make improvements and modifications

as necessary, if you supect this information to be inaccurate, write to the Service Department for a replacement. Give the equipment code number..

INSTALLATION

Ranger 9 Installation

Table 3 lists the required and optional equipment for installing and operating the TIG Module with a Ranger 9.

Refer to Figure 3 for the TIG Module/Ranger 9 connection diagram. Make sure all connections are tight before proceeding.

RANGER 9 AND THE TIG MODULE

REQUIRED EQUIPMENT

Control

Cable

K936-1

9-pin to 14-pin

Control Cable

Extension

Work and

Electrode

Leads from Ranger 9 to TIG Module

User Supplied;

Length as Req’d.

Cable Sized to

Match Current

and Duty Cycle

RANGER 9 AND THE TIG MODULE

Water

Valve

TIG

Torch

User

Supplied

Work Lead

User Supplied;

Length as Req’d.

Cable Sized to

Match Current

and Duty Cycle

OPTIONAL EQUIPMENT

Arc Start

Switch

Hand

Amptrol

Shielding Gas,

Regulator, Flowmeter

User

Supplied

Foot

Amptrol

Arc Start

Switch

- OR -

Amptrol

See

Optional

Equipment

Below

Docking

Kit

K937 - [ ] Extension

9-pin to 9-pin

TIG MODULE

K844-1

Field

Installed

K814 K963 K870 K939-1

Mounts to

Ranger 9 Roof

TABLE 3

– 9 –

INSTALLATION

-OR-

4-19-96D

M17532

Only qualified personnel should install,use

Keep guards in place.

WARNING

or service this equipment.

Keep away from moving parts.

LOCAL

LOCAL SERIAL NO.

SERIAL NO.

CODE

100%

60%

250A 180A

20%

350A

20A TO 350A

20A TO 350A RATED CAPACITY

RATED CAPACITY

INPUT

115 V 1.3 A 50/60 Hz

CONTINUOUS

MODEL

PORTABLE HI-FREQ

K870 FOOT AMPTROL

L9440

SWITCH

SWITCH CURRENT

CURRENT

CONTROL

REMOTE AMPTROL

WARNING

8 7

1 3

CURRENT CONTROL

45 40

55 S

AFTERFLOW

10 20

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

START ONLY

OFF

HIGH FREQUENCY

ELECTRIC

POWER

LINCOLN

OFF

K963 HAND AMPTROL

K814 ARC START SWITCH

Do not operate with panels open.

Disconnect NEGATIVE (-) BATTERY LEAD

before servicing.

Do not touch electrically live parts.

INPUT

FITTING

FIGURE 3: RANGER 9 / TIG MODULE CONNECTION DIAGRAM

REGULATOR

FLOWMETER

TO GAS

CYLINDER

ARGON GAS

– 10 –

WELDING CABLES MUST BE PROPERLY SIZED FOR THE CURRENT AND DUTY CYCLE OF APPLICATION

NOTE: This diagram is for reference only. It was accurate at the time of printing , however Lincoln Electric reserves the right to make improvements and modifications

as necessary, if you supect this information to be inaccurate, write to the Service Department for a replacement. Give the equipment code number..

TIG MODULE

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