Page 2 - TIG MODULE; SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
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,...
Page 3 - ii
TIG MODULE - ii - ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing...
Page 4 - iii
TIG MODULE - iii - FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’ s recommendations. 8.c. Grou...
Page 5 - iv
TIG MODULE - iv - iv SAFETY iv PR É CAUTIONS DE S Û RET É P o u r v o t r e p r o p r e p r o t e c t i o n l i r e e t o b s e r v e r t o u t e s l e s i n s t r u c t i o n s e t l e s p r é c a u t i o n s d e s û r e t é s p e c i f i q u e s q u i parraissent dans ce manuel aussi bien que les ...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
TIG MODULE - v - v v Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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....
Page 7 - TABLE OF CONTENTS; Safety
TABLE OF CONTENTS Page Safety .....................................................................................................................i-iv Installation ................................................................................................................1-17 Technical Specific...
Page 8 - INSTALLATION; T E C H N I C A L S P E C I F I C AT I O N S - T I G M O D U L E
INSTALLATION T E C H N I C A L S P E C I F I C AT I O N S - T I G M O D U L E Code Number 10135102031028411010 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...
Page 9 - Safety Precautions; LOCATION; ELECTRIC SHOCK can kill.; NOTE: The welder frame MUST also be grounded.
– 2 – INSTALLATION TIG MODULE Read entire installation section before startinginstallation. Safety Precautions Users should familiarize themselves with Figure 8,Rear Connections, in the Operating Section of thismanual before proceeding. LOCATION The TIG Module can be mounted in or carried to anyconv...
Page 10 - SUPPLY CONNECTIONS; Input Connections
INSTALLATION – 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 rigidmetallic conduit or equivalent shielding. Flexiblehelically-wrapped metallic conduit is generally notsuitable. ...
Page 12 - INSTALLATION WITH A POWER SOURCE; Ranger 8 Installation; REQUIRED EQUIPMENT
INSTALLATION WITH A POWER SOURCE Ranger 8 Installation T a b l e s 1 a n d 2 l i s t t h e r e q u i r e d a n d o p t i o n a lequipment for installing and operating the TIGM o d u l e w i t h a R a n g e r 8 . T a b l e 1 i s f o r t h eRanger 8, and table 2 is for the Ranger 8 with theK892-1 Remo...
Page 13 - FIGURE
INSTALLATION – 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 L9440 1 HIGH FREQUENCY LOCAL 115 V 1.3 A 5...
Page 21 - NOTES
Page 26 - LINCOLN POWER SOURCES AND THE TIG MODULE
TIG MODULE – 15 – INSTALLATION Installation with other Lincoln PowerSources Installation consists of connecting the input workand electrode cables, TIG torch, work lead, theproper control cable, and an Arc Start Switch orA m p t r o l . T a b l e s 6 a n d 7 l i s t t h e e q u i p m e n tr e q u i ...
Page 27 - TABLE 7
INSTALLATION – 16 – TABLE 7 LINCOLN POWER SOURCES AND THE TIG MODULE OPTIONAL EQUIPMENT TABLE Control Cable Extension K937-[ ] K937-[ ]* K937- [ ] K937-[ ]* Power Sources DC-250R3R-AllDC-400DC-600 DC-650 PRO/DC-750 G8000 (w/oK892 Remote Kit) G8000 (w/ K892 Remote Kit) Weldanpower 150 Weldanpower 150...
Page 29 - OPERATION; OPERATING INSTRUCTIONS; General Warnings; SAFETY INSTRUCTIONS
OPERATION – 18 – ELECTRIC SHOCKcan kill. • Do not touch electrically live partsor electrode with skin or wetclothing. • Insulate yourself from work andground. • Always wear dry insulating gloves. FUMES AND GASEScan be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust toremove fu...
Page 30 - GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL
TIG MODULE – 19 – OPERATION ON OFF INPUT HIGH FREQUENCY CONTINUOUS HIGH FREQUENCY START 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 CONNECTION INSTRUCTION ...
Page 31 - PRODUCT DESCRIPTION; Operational Features and Controls; Welding Capability
OPERATION – 20 – PRODUCT DESCRIPTION The TIG Module is an accessory for constant currentp o w e r s o u r c e s . I t p r o v i d e s h i g h f r e q u e n c y a n dshielding gas control for AC and DC GTAW (TIG)welding applications, and easy connection of Amptrolremote controls to power sources havi...
Page 32 - CONTROL PANEL; FIGURE 7
TIG MODULE – 21 – OPERATION OPERATION 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 andoff. Red pilot light indicates that input power is “ on ” . 2 H I G H F R E Q U E N C Y S W ...
Page 33 - REAR CONNECTIONS; FIGURE 8
OPERATION – 22 – WARNING ELECTRODE WORK V 1 2 3 4 4 5 6 7 REAR CONNECTIONS FIGURE 8 1 WARNING INFORMATION - Important information r e g a r d i n g t h e s a f e i n s t a l l a t i o n , o p e r a t i o n , a n dservicing of the TIG Module. 2 I N P U T R E C E P T A C L E - F o r c o n n e c t i n ...
Page 34 - RANGER 8 OPERATION; Note: For AC TIG welding, the maximum TIG welding; HF
TIG MODULE – 23 – OPERATION RANGER 8 OPERATION The tables (Table 8 & 9) list the recommended switchand control settings for the TIG Module/Ranger 8combination. The first table is for the Ranger 8, andthe second for the Ranger 8 with the K892-1 RemoteKit installed. Operate the Ranger 8 in accorda...
Page 36 - FIGURE 9
TIG MODULE – 25 – OPERATION 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 REMOT...
Page 37 - RANGER 9 OPERATION; RANGER 9 SETTINGS
OPERATION – 26 – RANGER 9 OPERATION The table (Table 10) lists the recommended switchand control settings for the TIG Module/Ranger 9combination. Operate the Ranger 9 in accordance with the Ranger9 Manual. Note that for AC TIG welding, the maximum TIGwelding output currents on each range setting wil...
Page 38 - RANGER 10 / RANGER 300 D OPERATION; RANGER 10 SETTINGS
TIG MODULE – 27 – OPERATION RANGER 10 / RANGER 300 D OPERATION The table (Table 11) lists the recommended switch and control settingsf o r t h e T I G M o d u l e / R a n g e r 1 0 o r T I G M o d u l e / R a n g e r 3 0 0 Dcombination. Make sure all connections are tight before proceeding. Operate ...
Page 39 - RANGER 10-LX SETTINGS
OPERATION – 28 – TABLE 12: K930-[ ] / RANGER 10-LX or RANGER 300 DLX SETTINGS K930-[ ] SETTINGS POWER HIGH FREQUENCY AFTERFLOW CURRENTCONTROL CURRENTCONTROL 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) ...
Page 40 - LINCOLN POWER SOURCE SETTINGS
TIG MODULE – 29 – OPERATION OPERATION ON OTHER LINCOLNPOWER SOURCES The table (Table 13) lists the recommended switchand control settings for the TIG Module when usedwith various Lincoln power sources. Operate the power source in accordance with itsManual. N o t e t h a t A C p o w e r s o u r c e s...
Page 41 - TIG WELDING INFORMATION; TYPICAL CURRENT RANGES
OPERATION – 30 – TIG WELDING INFORMATION .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) 2-155-20 15-80 70-150 150-250250-400 400-500500-750 750-1000 (3) (3) (3) 10-20 15-3025-40 40-5555-80 80-125 2-155-15 10-60 50-100 100-160150-210 200-275250-350325-45...
Page 42 - ACCESSORIES; OPTIONS / ACCESSORIES; K937 Control Cables Extensions
TIG MODULE – 31 – ACCESSORIES OPTIONS / ACCESSORIES The following field installed Kits and accessories maybe used dependingon the application: K936 Control Cables At least one of the following control cables isneeded to connect the TIG Module to the powersource. Four different cables are available. ...
Page 43 - MAINTENANCE
SAFETY PRECAUTIONS PERIODIC MAINTENANCE Very little maintenance is required to keep your TIGM o d u l e i n t o p o p e r a t i n g c o n d i t i o n . N o s p e c i f i cschedule can be set for performing the followingi t e m s ; f a c t o r s s u c h a s h o u r s o f u s a g e a n d t h emachine ...
Page 44 - How To Use Troubleshooting Guide; CAUTION; TROUBLESHOOTING
TIG MODULE How To Use Troubleshooting Guide This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairsperformed on this equipment may result in danger to the technician and machine operator and will invalidate yourfactory warranty. For your safety, please o...
Page 45 - Troubleshooting Guide; OUTPUT PROBLEMS
TROUBLESHOOTING – 34 – Troubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS(SYMPTOMS) Major Physical or ElectricalDamage is Evident. High frequency “ jumps ” from the electrode to work but welding arcdoes not establish POSSIBLECAUSE 1. Contact your local...
Page 47 - NOT; HIGH FREQUENCY PROBLEMS
TROUBLESHOOTING – 36 – Troubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS(SYMPTOMS) High frequency not present orintermittent at torch electrode High frequency not present at sparkgap High Frequency stays on after thearc is established POSSIBLECAUSE 1....
Page 48 - WIRING DIAGRAM
WIRING DIAGRAM – 37 – TIG MODULE TIG MODULE 232 231 2 4 J 2 302 I 4 0 3 7 6 403 404 301 H 231 232 S 1 C O N T R O L B O A R D O F F O N L Y S T A R T 4 0 4 7 5 206 + 205 210 C O N T I N U O U S F E C U R R E N T S E N S O R G 7 7 G 311A 307 308 L9580 P R O T E C T I O N B O A R D 7 5 75A 7 6 209 L O...
Page 52 - ÇÃ
– 52 – WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDE...
