Lincoln Electric IM528-B manual

TIG M odule OPERA TOR’S MANUAL For use with Equipment having Code Number 10135, 10203, 10284, 11010 IM528-B March, 2005 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 IN[...]

TIG MODULE - i - i SAFETY i 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 c[...]

TIG MODULE - ii - 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[...]

TIG MODULE - 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 manufacturer ’ s recommendations. 8.c. Ground the equipment in accordance with the U.S. [...]

TIG MODULE - iv - iv SAFETY iv PR É CAUTIONS DE S Û RET É Pour votre propre protection lire et observer toutes les instructions et les pr é cautions de s û ret é specifiques qui parraissent dans ce manuel aussi bien que les pr é cautions de s û ret é g é n é rales suivantes: S û ret é Pour Soudage A L ’ Arc 1. Protegez-vous contre la[...]

TIG MODULE - v - v v 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 qui[...]

T ABLE OF CONTENTS Page Safety .....................................................................................................................i-iv Installation ................................................................................................................1-1 7 Technical Specifications .........................................[...]

INST ALLA TION TECHNICAL SPECIFICA TIONS - TIG MODULE Code Number 10135 10203 10284 11010 Total Capacity Range 15 - 400 amps AC/DC Input Current 1.3 amperes Amps 200 amps AC/DC 300 amps AC/DC 400 amps AC/DC Standard Voltage 115 VAC 50/60 (60VAC TO 130 VAC) 50/60 HZ. (MIN. TO MAX.) Duty Cycle 100% 60% 20% Duty Cycle 100% 60% 20% Amps 200 amps AC/DC [...]

– 2 – INST ALLA TION TIG MODULE Read entire installation section before starting installation. Safety Precautions Users should familiarize themselves with Figure 8, Rear Connections, in the Operating Section of this manual before proceeding. LOCA TION The TIG Module can be mounted in or carried to any convenient location. It is designed to be p[...]

INST ALLA TION – 3 – TIG MODULE 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 meta[...]

– 4 – INST ALLA TION TIG MODULE 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. INST ALLA TION OF FIELD INST ALLED ACCESSORIES Ins[...]

INST ALLA TION 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 c[...]

INST ALLA TION – 6 – TIG MODULE FIGURE 1: RANGER 8 / TIG MODULE CONNECTION DIAGRAM 5 10 15 20 25 30 35 40 45 50 55 S CONTINUOUS OFF POWER 2 AFTERFLOW MODEL CODE SERIAL NO. THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. INPUT PORTABLE HI-FREQ WARNING OFF O ON L9 4 40 1 HIGH FREQUENCY LOCAL 115 V 1.3 A 50/60 Hz LINCOLN R ELECTRIC 0 1 2 3 4 5 6 7[...]

TIG MODULE – 7 – INST ALLA TION RANGER 8 (WITH THE OPTIONAL K892-1 REMOTE KIT INST ALLED) AND THE TIG MODULE REQUIRED EQUIPMENT Control Cable Contactor Kit Work and Electrode Leads from Ranger 8 to TIG Module TIG Torch Work Lead Shielding Gas, Regulator, Flowmeter Arc Start Switch K936-3 9-pin to 6-pin plus 115V Plug K938-1 Field Installed User[...]

INST ALLA TION – 8 – FIGURE 2: RANGER 8 / K892-1 REMOTE KIT / TIG MODULE CONNECTION DIAGRAM 5 10 15 20 25 30 35 40 45 50 55 S CONTINUOUS OFF POWER 2 AFTERFLOW MODEL CODE SERIAL NO. THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. INPUT PORTABLE HI-FREQ WARNING OFF O ON L9 4 40 1 HIGH FREQUENCY LOCAL 115 V 1.3 A 50/60 Hz LINCOLN R ELECTRIC 0 1 2 [...]

TIG MODULE – 9 – INST ALLA TION 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[...]

INST ALLA TION – 10 – FIGURE 3: RANGER 9 / TIG MODULE CONNECTION DIAGRAM 5 10 15 20 25 30 35 40 45 50 55 S CONTINUOUS OFF POWER 2 AFTERFLOW MODEL CODE SERIAL NO. THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. INPUT PORTABLE HI-FREQ WARNING OFF O ON L9440 1 HIGH FREQUENCY LOCAL 115 V 1.3 A 50/60 Hz LINCOLN R ELECTRIC 0 1 2 3 4 5 6 7 8 9 10 CURR[...]

TIG MODULE – 11 – INST ALLA TION Ranger 10 and Ranger 300 D Installation Table 4 lists the required and optional equipment for installing and operating the TIG Module with a Ranger 10 or Ranger 300 D. Refer to Figure 4 for the TIG Module/Ranger 10 connection diagram and to Figure 4A for the TIG Module/Ranger 300 D connection diagram. Make sure [...]

INST ALLA TION – 12 – FIGURE 4: RANGER 10 / TIG MODULE CONNECTION DIAGRAM 5 10 15 20 25 30 35 40 45 50 55 S CONTINUOUS OFF POWER 2 AFTERFLOW MODEL CODE SERIAL NO. THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. INPUT PORTABLE HI-FREQ WARNING OFF O ON L 9 44 0 1 HIGH FREQUENCY LOCAL 115 V 1.3 A 50/60 Hz LINCOLN R ELECTRIC 0 1 2 3 4 5 6 7 8 9 10 [...]

INST ALLA TION – 12a – FIGURE 4A: RANGER 300 D / TIG MODULE CONNECTION DIAGRAM ELECTRODE -OR- 6 PIN AMPHENOL K814 ARC START SWITCH S23732-10 K870 FOOT AMPTROL -OR- K963-1 HAND AMPTROL 1/03 CAUTION : AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE ANY INCREASE OF THE HIGH IDLE[...]

NOTES – 12b – TIG MODULE[...]

TIG MODULE – 13 – INST ALLA TION T ABLE 5 RANGER 10LX / RANGER 300D-LX AND THE TIG MODULE REQUIRED EQUIPMENT Control Cable Contactor Kit Work and Electrode Leads from Ranger 10LX to TIG Module TIG Torch Work Lead Shielding Gas, Regulator, Flowmeter Arc Start Switch - OR - Amptrol K936-1 9-pin to 14-pin Plug K938-1 Field Installed User Supplied;[...]

INST ALLA TION – 14 – FIGURE 5: RANGER 10-LX / TIG MODULE CONNECTION DIAGRAM 5 10 15 20 25 30 35 40 45 50 55 S CONTINUOUS OFF POWER 2 AFTERFLOW MODEL CODE SERIAL NO. THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. INPUT PORTABLE HI-FREQ WARNING OFF O ON L9 440 1 HIGH FREQUENCY LOCAL 115 V 1.3 A 50/60 Hz LINCOLN R ELECTRIC 0 1 2 3 4 5 6 7 8 9 10[...]

INST ALLA TION – 14a – FIGURE 5A: RANGER 300D-LX / TIG MODULE CONNECTION DIAGRAM 14 PIN AMPHENOL ELECTRODE K963-1 HAND AMPTROL -OR- S23732-9 K814 ARC START SWITCH K870 FOOT AMPTROL -OR- B-UF CAUTION : AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE ANY INCREASE OF THE HIGH ID[...]

NOTES – 14 b – TIG MODULE[...]

TIG MODULE – 15 – INST ALLA TION Installation with other Lincoln Power Sources Installation consists of connecting the input work and electrode cables, TIG torch, work lead, the proper control cable, and an Arc Start Switch or Amptrol. Tables 6 and 7 list the equipment required for installing and operating the TIG Module on various Lincoln powe[...]

INST ALLA TION – 16 – T ABLE 7 LINCOLN POWER SOURCES AND THE TIG MODULE OPTIONAL EQUIPMENT T ABLE Control Cable Extension K937-[ ] K937-[ ]* K937- [ ] K937-[ ]* Power Sources DC-250 R3R-All DC-400 DC-600 DC-650 PRO/DC-750 G8000 (w/oK892 Remote Kit) G8000 (w/ K892 Remote Kit) Weldanpower 150 Weldanpower 150 AC/DC SA-250 Perkins SAE-350 Deutz Cla[...]

TIG MODULE – 17 – INST ALLA TION FIGURE 6: TIG MODULE ON A LINCOLN POWER SOURCE - CONNECTION DIAGRAM 5 10 15 20 25 30 35 40 45 50 55 S CONTINUOUS OFF POWER 2 AFTERFLOW MODEL CODE SERIAL NO. THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. INPUT PORTABLE HI-FREQ WARNING OFF O ON L9 4 40 1 HIGH FREQUENCY LOCAL 115 V 1.3 A 50/60 Hz LINCOLN R ELECTR[...]

OPERA TION – 18 – ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone. WELD[...]

TIG MODULE – 19 – OPERA TION ON OFF INPUT HIGH FREQUENCY CONTINUOUS HIGH FREQUENCY ST ART ONL Y AFTERFLOW CURRENT CONTROL (OUTPUT) LOCAL CURRENT CONTROL REMOTE CURRENT CONTROL GAS INPUT GAS OUTPUT W A TER INPUT W A TER OUTPUT INPUT TIG TORCH CONNECTION WORK CONNECTION REMOTE CONTROL CONNECTION INSTRUCTION MANUAL GRAPHIC SYMBOLS USED ON THIS EQU[...]

OPERA TION – 20 – PRODUCT DESCRIPTION The TIG Module is an accessory for constant current power sources. It provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding applications, and easy connection of Amptrol remote controls to power sources having remote control capability. It also provides contactor control of the w[...]

TIG MODULE – 21 – OPERA TION OPERA TION Users should familiarize themselves with Figure 7, Control Panel, before proceeding. 1 INPUT POWER SWITCH AND PILOT LIGHT - Turns the input power to the TIG Module on and off. Red pilot light indicates that input power is “ on ” . 2 HIGH FREQUENCY SWITCH - Used to select Continuous High Frequency, Sta[...]

OPERA TION – 22 – WARNING ELECTRODE WORK V 1 2 3 4 4 5 6 7 REAR CONNECTIONS FIGURE 8 1 WARNING INFORMATION - Important information regarding the safe installation, operation, and servicing of the TIG Module. 2 INPUT RECEPTACLE - For connecting the Control Cable from the power source. This receptacle contains the following circuits: Input power,[...]

TIG MODULE – 23 – OPERA TION RANGER 8 OPERA TION The tables (Table 8 & 9) list the recommended switch and control settings for the TIG Module/Ranger 8 combination. The first table is for the Ranger 8, and the second for the Ranger 8 with the K892-1 Remote Kit installed. Operate the Ranger 8 in accordance with the Ranger 8 Manual. Note: For [...]

OPERA TION – 24 – T ABLE 9: K930-[ ] / RANGER 8 (WITH THE K892-1) SETTINGS K930-[ ] SETTINGS POWER HIGH FREQUENCY AFTERFLOW CURRENT CONTROL CURRENT CONTROL SWITCH ON START - OR - CONTINUOUS ADJUST TO SUIT, 5 - 55 SECONDS ADJUST TO SUIT 0-10 REMOTE (WITH AN AMPTROL) LOCAL (WITH AN ARC START SWITCH) 2 A RANGER 8 (WITH THE K892-1 REMOTE KIT INST A[...]

TIG MODULE – 25 – OPERA TION AMPTROL POSITION HAS NO EFFECT ON THE OUTPUT CURRENT. LIGHT PRESSURE - LOW OUTPUT CURRENT HEAVY PRESSURE - LOCAL REMOTE 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10 OUTPUT HIGH MED LOW 45 90 120 160 200 250 RANGE RANGE SETTING. OUTPUT CONTROL AT WELDER OUTPUT CONTROL REMOTE CHOOSE REMOTE OUTPUT CONTROL. TIG MODULE SE[...]

OPERA TION – 26 – RANGER 9 OPERA TION The table (Table 10) lists the recommended switch and control settings for the TIG Module/Ranger 9 combination. Operate the Ranger 9 in accordance with the Ranger 9 Manual. Note that for AC TIG welding, the maximum TIG welding output currents on each range setting will be approximately 50% higher that those[...]

TIG MODULE – 27 – OPERA TION RANGER 10 / RANGER 300 D OPERA TION The table (Table 11) lists the recommended switch and control settings for the TIG Module/Ranger 10 or TIG Module/Ranger 300 D combination. Make sure all connections are tight before proceeding. Operate the Ranger 10 or Ranger 300 D in accordance with the proper Operator ’ s Man[...]

OPERA TION – 28 – T ABLE 12: K930-[ ] / RANGER 10-LX or RANGER 300 DLX SETTINGS K930-[ ] SETTINGS POWER HIGH FREQUENCY AFTERFLOW CURRENT CONTROL CURRENT CONTROL SWITCH ON START - OR - CONTINUOUS ADJUST TO SUIT, 5 - 55 SECONDS ADJUST TO SUIT 0-10 REMOTE (WITH AN AMPTROL) LOCAL (WITH AN ARC START SWITCH) 2 A RANGER 10-LX SETTINGS IDLER SWITCH STI[...]

TIG MODULE – 29 – OPERA TION OPERA TION ON OTHER LINCOLN POWER SOURCES The table (Table 13) lists the recommended switch and control settings for the TIG Module when used with various Lincoln power sources. Operate the power source in accordance with its Manual. Note that AC power sources must be derated approximately 50% when used for AC TIG w[...]

OPERA TION – 30 – TIG WELDING INFORMA TION .010 (.25) 0.020 (.50) 0.040 (1.0) 1/16 (1.6) 3/32 (2.4) 1/8 (3.2) 5/32 (4.0) 3/16 (4.8) 1/4 (6.4) 2-15 5-20 15-80 70-150 150-250 250-400 400-500 500-750 750-1000 (3) (3) (3) 10-20 15-30 25-40 40-55 55-80 80-125 2-15 5-15 10-60 50-100 100-160 150-210 200-275 250-350 325-450 2-15 5-20 15-80 70-150 140-2[...]

TIG MODULE – 31 – ACCESSORIES OPTIONS / ACCESSORIES The following field installed Kits and accessories may be used dependingon the application: K936 Control Cables At least one of the following control cables is needed to connect the TIG Module to the power source. Four different cables are available. The proper choice of cable depends on the p[...]

SAFETY PRECAUTIONS PERIODIC MAINTENANCE Very little maintenance is required to keep your TIG Module in top operating condition. No specific schedule can be set for performing the following items; factors such as hours of usage and the machine environment should be considered when establishing a maintenance schedule. 1 . Periodically blow off dust a[...]

TIG MODULE How T o Use T roubleshooting Guide This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety, please observe all safety notes and precautions detail[...]

TROUBLESHOOTING – 34 – T roubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. High frequency “ jumps ” from the electrode to work but welding arc does not establish POSSIBLE CAUSE 1. Contact your local Lincoln Authorized Field Service Fac[...]

TIG MODULE – 35 – TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide PROBLEMS (SYMPTOMS) No weld output, no gas flow and no high frequency at spark gap Low weld output current when operating in remote control POSSIBLE CAUSE 1. Check arc start switch or remote control unit 2. Make certain b[...]

TROUBLESHOOTING – 36 – T roubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) High frequency not present or intermittent at torch electrode High frequency not present at spark gap High Frequency stays on after the arc is established POSSIBLE CAUSE 1. Check for correct gas and gas flow 2. C[...]

WIRING DIAGRAM – 37 – TIG MODULE TIG MODULE 232 231 2 4 J2 302 I 403 76 403 404 301 H 231 232 S1 CONTROL BOARD OFF ONLY START 404 75 206 + 205 210 CONTINUOUS F E CURRENT SENSOR G 77 G 311A 307 308 L9580 PROTECTION BOARD 75 75A 76 209 LOCAL 208 CURRENT CONTROL 207 209 206 208 204 205 202 HIGH VOLTAGE TRANSFORMER T1 OPTIONAL WATER SOLENOID VALVE [...]

WIRING DIAGRAM – 38 – TIG MODULE 232 231 2 4 J2 302 I 403 76 403 404 301 H 231 232 S1 CONTROL BOAR D OFF ONLY START 404 75 206 + 205 210 CONTINUOUS F E CURRENT SENSOR G 77 G 311A 307 308 L12065 PROTECT ION BOARD 75 75A 76 209 LOCAL 208 CURRENT CO NTROL 207 209 206 208 204 205 202 HIGH VOLTAGE TR ANSFORME R T1 OPTIONAL WATER SOLENOID VALVE 5 EXA[...]

NOTES[...]

NOTES[...]

– 52 – W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O 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 ABRICA[...]

– 53 – W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO 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 rem[...]

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