NOTE:
The welding electrode is energized at all
times, unless an LN-25 with built-in contactor is used.
If the output “CONTROL” is set below “3”, the LN-25
contactor may not pull in.
CONNECTION OF K930-2 TIG MODULE TO THE
ZR-8.
The TIG Module is an accessory that provides high
frequency and shielding gas control for AC and DC
GTAW (TIG) welding. See IM528 supplied with the
TIG Module for installation instructions.
Note: The TIG Module does not require the use of a
high frequency bypass capacitor. However, if the ZR-
8 is used with any other high frequency equipment,
the bypass capacitor must be installed, order kit
T12246.
INSTRUCTIONS
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the roof and case
sides in place as this provides maximum protection
from moving parts and assures proper cooling air
flow.
Read and understand all Safety Precautions before
operating this machine. Always follow these and any
other safety procedures included in this manual and in
the Engine Owner’s Manual.
WELDER OPERATION
WELDER OUTPUT
• Maximum Open Circuit Voltage at 3700 RPM is
80 Volts RMS.
• Duty Cycle is the percentage of time the load is
being applied in a 10 minute period. For example, a
60% duty cycle represents 6 minutes of load and 4
minutes of no load in a 10 minute period. Duty
Cycle for the ZR-8 is 100%.
A-5
INSTALLATION
ZR-8
A-5
LOCATION / VENTILATION
The welder should be located to provide an unrestricted flow
of clean, cool air to the cooling air inlets and to avoid heated
air coming out of the welder recirculating
back to the cooling air inlet. Also, locate the welder so that
engine exhaust fumes are properly vented to an outside
area.
STACKING
ZR-8 machines cannot be stacked.
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
Shut off welder before making any electrical connec-
tions.
-------------------------------------------------------------------------------
WIRE FEED (CONSTANT VOLTAGE)
CONNECTION OF LN-15 ACROSS-THE-ARC WIRE
FEEDER
The LN-15 has an internal contactor and the electrode is not
energized until the gun trigger is closed. When the gun trig-
ger is closed the wire will begin to feed and the welding
process is started.
a. Shut the welder off.
b. Set the Polarity switch to the desired polarity, either DC
(-) or DC (+).
c. Attach the single lead from the front of the LN-15 to work
using the spring clip at the end of the lead. This is a con-
trol lead to supply current to the wire feeder motor; it
does not carry welding current.
d. Set the “RANGE” switch to the “WIRE FEED-CV” posi-
tion
e. Place the Engine switch in the “Auto Idle” position.
f. Adjust the wire feed speed at the LN-15 and adjust the
welding voltage with the output “CONTROL” at the
welder. Output “CONTROL” must be set above 3.
Note:
LN-15 Control Cable model will not work with
the ZR-8.
CONNECTION OF THE LN-25 TO THE
ZR-8
•
Shut the welder off.
•
Connect the electrode cable from the LN-25 to
the“ELECTRODE” terminal of the welder.
Connect the work cable to the “TO WORK” termi-
nal of the welder.
•
Position the welder “Polarity” switch to the desired
polarity, either DC (-) or DC (+).
•
Position the “RANGE” switch to the “WIRE FEED”
position.
•
Attach the single lead from the LN-25 control box
to the work using the spring clip on the end of the
lead - it carries no welding current.
•
Place the engine switch in the “AUTO” position.
•
Adjust wire feed speed at the LN-25 and adjust
the welding voltage with the output “CONTROL”
at the welder.
WARNING
ZR-8
Constant Current
225 Amps AC @ 25 Volts
210 Amps DC @ 25 Volts
Constant Voltage
200 Amps DC @ 20 Volts
