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Lincoln Electric TIG MODULE IM528-B, Operator'S Manual, Page: 1 / 54

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TIG Module

OPERATOR’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 INSTALL, OPERATE
OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.

And, most

importantly, think before you act
and be careful.

R

• 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 •

Copyright © 2005 Lincoln Global Inc.

Summary of Contents for TIG MODULE IM528-B

Page 1: ...stallation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think...

Page 2: ...ne exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm The engine exhaust from this product contains chemicals known to...

Page 3: ...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...

Page 4: ...m 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 hy...

Page 5: ...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 paiss...

Page 6: ...formation below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ____...

Page 7: ...anger 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 Equipmen...

Page 8: ...0 VAC 50 60 HZ MIN TO MAX Duty Cycle 100 60 20 Duty Cycle 100 60 20 Amps 200 amps AC DC 300 amps AC DC 400 amps AC DC Cable sizes mm2 2 AWG 30 1 AWG 35 1 0 AWG 50 INPUT SINGLE PHASE ONLY RATED CAPACIT...

Page 9: ...om 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 mi...

Page 10: ...nd 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 m...

Page 11: ...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 Ca...

Page 12: ...Make sure all connections are tight before proceeding INSTALLATION 5 TIG MODULE RANGER 8 WITH NO K892 1 REMOTE KIT AND THE TIG MODULE REQUIRED EQUIPMENT Control Cable Contactor Kit Work and Electrode...

Page 13: ...hould install use or service this equipment 5 10 15 20 25 30 35 40 45 50 55 S CONTINUOUS OFF 2 MODEL CODE SERIAL NO THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A INPUT PORTABLE HI FREQ WARNING OFF O ON...

Page 14: ...Plug 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 Supp...

Page 15: ...5 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...

Page 16: ...r 9 to TIG Module TIG Torch Work Lead Shielding Gas Regulator Flowmeter Arc Start Switch OR Amptrol K936 1 9 pin to 14 pin User Supplied Length as Req d Cable Sized to Match Current and Duty Cycle Use...

Page 17: ...0 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 5...

Page 18: ...Cable Contactor Kit Work and Electrode Leads from Ranger 10 to TIG Module TIG Torch Work Lead Shielding Gas Regulator Flowmeter Arc Start Switch OR Amptrol K936 3 9 pin to 6 pin plus 115V Plug K938 1...

Page 19: ...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 CU...

Page 20: ...MAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN N E PLACE IDLER SWITCH IN HIGH IDLE POSITION N B USE POLARITY SWITCH TO SELECT DESIRED ELEC...

Page 21: ...NOTES 12b TIG MODULE...

Page 22: ...nd Duty Cycle User Supplied See Optional Equipment Below RANGER 10LX RANGER 300D LX AND THE TIG MODULE OPTIONAL EQUIPMENT Control Cable Extension Water Valve Arc Start Switch Hand Amptrol Foot Amptrol...

Page 23: ...W 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...

Page 24: ...AMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN N E PLACE IDLER SWITCH IN HIGH IDLE POSITION N B USE POLARITY SWITCH TO SELECT DESIRED ELE...

Page 25: ...NOTES 14b TIG MODULE...

Page 26: ...o Figure 6 for the connection diagram for the TIG Module when used with various Lincoln power sources Make sure all connections are tight before proceeding If using the K936 2 Input Cable 9 socket to...

Page 27: ...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 Classic II Classic III IIID Idealarc 250 AC DC Water Valve K844 1 Arc Sta...

Page 28: ...BLE 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 CURRENT CONTROL SWITCH TM CURRENT CONTROL REMOTE AMPTROL HF START ONLY 20 350A...

Page 29: ...s Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have...

Page 30: ...ART ONLY AFTERFLOW CURRENT CONTROL OUTPUT LOCAL CURRENT CONTROL REMOTE CURRENT CONTROL GAS INPUT GAS OUTPUT WATER INPUT WATER OUTPUT INPUT TIG TORCH CONNECTION WORK CONNECTION REMOTE CONTROL CONNECTIO...

Page 31: ...s adjustable cooling period for gas and water optional flow after the weld is stopped Current Control functions as an adjustable limit control when using a remotely controllable power source Allows op...

Page 32: ...aving remote control capability It controls the welding current and is used in conjunction with the Local Remote Switch 5 LOCAL REMOTE SWITCH This switch functions only when the TIG module is used wit...

Page 33: ...utlet fittings 5 8 18 left hand threads For connection of cooling water to and from the TIG torch Supplied as part of the optional K844 1 Water Valve Kit 4 POWER INPUT CONNECTIONS Connections for the...

Page 34: ...that those marked on the nameplate This is due to the special nature of the AC TIG welding arc Do not AC TIG weld on the 225AC range setting The output current may exceed the rating of the Ranger 8 K...

Page 35: ...art Switch and Amptrols Once the TIG Module and Ranger 8 are properly set up TIG welding is very easy Position the torch in place lower your helmet and press the Arc Start Switch or Amptrol The power...

Page 36: ...ABLE WELDING CURRENT THE CURRENT CAN BE VARIED FROM MINIMUM TO HALF OF THE RANGER SETTING BECAUSE THE CURRENT CONTROL IS SET TO THE HALF WAY POINT THE CURRENT CAN BE VARIED FROM B A A B LOCAL REMOTE 1...

Page 37: ...ntactor will close the engine will go to high idle gas will flow and after a one half second preflow time the high frequency will come on The arc should strike and welding should begin At the end of t...

Page 38: ...set up TIG welding is very easy Position the torch in place lower your helmet and press the Arc Start Switch or Amptrol The TIG Module s optional contactor will close gas will flow for a one half sec...

Page 39: ...of the AC TIG welding arc Do not AC TIG weld on the 200 or 250 amp range settings The output current may exceed the rating of the Ranger 10 LX or Ranger 300 DLX Because your Ranger 10 LX or Ranger 30...

Page 40: ...for a one half second preflow time and the high frequency will come on The arc should strike and welding should begin At the end of the weld simply release the Arc Start Switch or Amptrol and the cont...

Page 41: ...less Steel Tungsten Electrode Diameter in mm TIG Torch Nozzle Size 4 5 DCEN DCEP Unbalanced Wave Balanced Wave AC Approximate Argon Gas Flow Rate C F H 1 min 1 When used with argon gas The current ran...

Page 42: ...to 9 pin K938 1 Contactor Kit This field installed kit must be installed in the TIG Module whenever it is used with a power source which does not have a built in contactor for constant current stick T...

Page 43: ...t the top right hand side of the internal compartment Check the spark gap setting with a feeler gauge If adjustment is required loosen one of the Allen head screws which secure the spark gap electrode...

Page 44: ...under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that your machine may exhibit Find the listing that best describes the symptom that your machine is exhibiting Step 2...

Page 45: ...circuit voltage at welding power source 2 Make certain that the tungsten type and size is correct for the process 3 The tungsten may be contaminated clean or replace RECOMMENDED COURSE OF ACTION If a...

Page 46: ...rce are powered up 1 Make certain the welder power source is in the remote control mode 2 The current control R4 may be set too low for the process RECOMMENDED COURSE OF ACTION If all recommended poss...

Page 47: ...1 Make certain that the High Frequency switch S2 is NOT in the OFF position 2 Check spark gap for correct setting 0 015in 25mm 1 High frequency switch S2 is in the continuous position iRECOMMENDED COU...

Page 48: ...CONTACTOR IS CONNECTED T2 TO TIG TORCH 311B TO WORK J3 PRI CR1 REMOTE RECEPTACLE ELECTRODE TERMINAL HIGH VOLTAGE CAPACITOR 0025 10KV J1 2 PILOT LIGHT HI FREQ INDUCTOR AFTERFLOW TIME POTENTIOMETER 500K...

Page 49: ...IS CONNECTED T2 TO TIG TORCH 311B TO WORK J3 PRI CR1 REMOTE RECEPTACLE ELECTRODE TERMINAL HIGH VOLTAGE CAPACITOR 0025 10KV J1 WIRING DIAGRAM FOR CODE 11010 2 PILOT LIGHT HI FREQ INDUCTOR AFTERFLOW TI...

Page 50: ...NOTES...

Page 51: ...NOTES...

Page 52: ...ouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa mojada Aislese del trabajo...

Page 53: ...gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de alimenta...

Page 54: ...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 Pr...

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