B-4
OPERATION
B-4
WELDING PROCESS
For any electrodes the procedures should be kept
within the rating of the machine. For electrode infor-
mation see the appropriate Lincoln publication.
STICK (CONSTANT CURRENT) WELDING
Connect welding cables to the "TO WORK
”
and
"ELECTRODE
”
studs. Start the engine. Set the
"Polarity
”
switch to the desired polarity. The
“
RANGE
”
switch markings indicate the maximum current for that
range as well as the typical electrode size for that
range. The
“
OUTPUT
”
Control provides fine adjust-
ment of the welding current within the select range.
For maximum output within a selected range set the
“
OUTPUT
”
Control at 10. For minimum output within a
selected range set the
“
OUTPUT
”
Control at 5. (
“
OUT-
PUT
”
Control settings below 5 may reduce arc stabili-
ty) For best overall welding performance set the
“
RANGE
”
Switch to the lowest setting and the OUT-
PUT
”
Control near the maximum to achieve the
desired welding current.
RANGE SETTING
TYPICAL
CURRENT RANGE
ELECTRODE SIZE
The ZR-8 can be used with a broad range of AC and
DC stick electrodes. See
“
Welding Tips 1
”
included
with the ZR-8 for electrodes within the rating of this
unit and recommended welding currents of each.
TIG (CONSTANT CURRENT) WELDING
The K930-[ ] TIG Module installed on a ZR-8 provides
high frequency and shielding gas control for AC and
DC GTAW (TIG) welding processes. The TIG Module
allows full range output control. After flow time is
adjustable from 0 to 55 seconds.
When using the ZR-8 for AC TIG welding of alu-
minum, the following settings and electrodes are
recommended:
The K930-[ ] TIG Module should be used with the ZR-
8 on high idle to maintain satisfactory operation. It can
be used in the AUTO position but the delay going to
flow idle after welding is ceased will be increased if
the AFTER FLOW CONTROL is set above 10 sec-
onds.
WIRE FEED WELDING PROCESSES
(CONSTANT VOLTAGE)
The Innershield
®
electrode recommended for use with
the ZR-8 is NR
®
-211-MP. The electrode sizes and
welding ranges that can be used with the ZR-8 are
shown in the following table:
The ZR-8 is recommended for limited
“
MIG
”
welding
(GMAW - gas metal arc welding). The recommended
electrodes are .030
”
and .035
”
L-50 and L-56. They
must be used with a blended shielding gas such as
C25 (75% Argon - 25% CO
2
). The welding ranges that
can be used with the ZR-8 are shown in the following
table:
ARC GOUGING
The ZR-8 can be used for limited arc gouging.
Set the Range switch to adjust output current to the
desired level for the gouging electrode being used
according to the ratings in the following table:
ZR-8
Diameter Wire Speed Approximate
(in.) Range In./Min. Current Range
.035
80 - 110
75A to 120A
.045
70 - 130
120A to 170A
.068
40 - 90
125A to 210A
Diameter Wire Speed Approximate
(in.) Range In./Min. Current Range
.030
80 - 110
75A to 120A
.035
70 - 130
120A to 170A
SETTINGS FOR PURE TUNGSTEN
TUNGSTEN RANGE SWITCH
APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE
1/8 90 or 145 80 - 150 Amps
3/32 90 or 145 45 - 130 Amps
1/16 90
40 - 80 Amps
SETTINGS FOR 1% THORIATED TUNGSTEN
TUNGSTEN RANGE SWITCH
APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE
1/8 90, 145, or 210 80 - 225 Amps
3/32 90 or 145 50 - 180 Amps
1/16 90 or 145 45 - 120 Amps
ELECTRODE SETTING CURRENT RANGE (DC, electrode positive)
1/8 30 - 60 Amps
5/32 90 - 150 Amps
3/16 200 - 250 Amps
90 MAX.
125 MAX.
210(DC)/225(AC)
MAX.
3/32
”
Dia.
1/8
”
Dia.
5/32
”
Dia.
40 TO 90 AMPS
70 TO 145 AMPS
120 TO 210(DC),
225(AC) AMPS
