Lincoln Electric Red-D-Arc ZR-8 Mode d'emploi

Marque: Lincoln Electric

Modèle: Red-D-Arc ZR-8

Catégorie: Système de soudage

Taper: Mode d'emploi

RED-D-ARC

ZR-8

IM858

July, 2004

Red-D-Arc Spec-Built Welding Equipment

This RED-D-ARC welder is built to RED-D-ARC Extreme Duty

design specifications by Lincoln Electric.

Safety Depends on You

This welder 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.

For use with machines having Code Numbers:

11170

North America’s Largest Fleet of Welding Equipment

1-800-245-3660

OPERATOR’S MANUAL

FOR ENGINE

powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes

outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.

Stop the engine and allow it to cool before

refueling to prevent spilled fuel from vaporiz-

ing on contact with hot engine parts and

igniting. Do not spill fuel when filling tank. If

fuel is spilled, wipe it up and do not start

engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing and

tools away from V-belts, gears, fans and all other moving

parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove

guards only when necessary and replace them when the

maintenance requiring their removal is complete.

Always use the greatest care when working near moving

parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or

idler by pushing on the throttle control rods

while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance

work, disconnect the spark plug wires, distributor cap or

magneto wire as appropriate.

SAFETY

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 copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box

351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available

from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND

MAGNETIC FIELDS

may be dangerous

2.a. Electric current flowing through any conductor causes

localized Electric and Magnetic Fields (EMF). Welding

current creates EMF fields around welding cables and

welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right

side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is

hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

are known to the State of California to cause can-

cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

SAFETY

ARC RAYS 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 protect your skin and that of your helpers from

the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK can

kill.

3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.

Do not touch these “hot” parts with your bare

skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good 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 for cooling.

3.h. Never simultaneously touch electrically “hot” parts of

electrode holders connected to two welders because voltage

between the two can be the total of the open circuit voltage

of both welders.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASES

can be dangerous.

5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases.When welding, keep

your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) or on lead or

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon

vapors

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors

form phosgene, a highly toxic gas, and other irritating prod-

ucts.

5.c. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,

especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

FOR ELECTRICALLY

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. National

Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the

process used and properly operating

regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

iii

SAFETY

iii

Mar ‘95

WELDING SPARKS can

cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them 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

hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,

special precautions should be used to prevent hazardous

situations. Refer to “Safety in Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the

equipment being used.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact

can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances

inside. They can cause an explosion even

though

they have

been “cleaned”. For information, purchase “Recommended

Safe Practices for the

Preparation

for Welding and Cutting of

Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil

free protective garments such as leather gloves, heavy shirt,

cuffless trousers, high shoes and a cap over your hair. Wear

ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a

welding area.

6.g. Connect the work cable to the work as close to the welding

area as practical. Work cables connected to the building

framework or other locations away from the welding area

increase the possibility of the welding current passing

through lifting chains, crane cables or other alternate cir-

cuits. This can create fire hazards or overheat lifting chains

or cables until they fail.

6.h. Also see item 1.c.

Mar. ‘93

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions

et les précautions de sûreté specifiques qui parraissent dans ce

manuel aussi bien que les précautions de sûreté générales suiv-

antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher

metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état

defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder

parce que la tension entre les deux pinces peut être le

total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-électrode s’applicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie

du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray-

onnement de l’arc et des projections quand on soude ou

quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de

soudage. Se protéger avec des vêtements de protection libres

de l’huile, tels que les gants en cuir, chemise épaisse, pan-

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible

de la zone de travail qu’il est pratique de le faire. Si on place

la masse sur la charpente de la construction ou d’autres

endroits éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,

voir le code “Code for safety in welding and cutting” CSA

Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de

l’électricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branché à une

bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-

er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

place.

Thank You

for selecting a QUALITY product. We want you to take pride in

operating this 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 quick reference. Pay particular attention to the safety instructions we have provided for your protection.

The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or

loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to

this equipment.

CAUTION

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims

for material damaged in shipment must be made by the purchaser against the transportation company at the

time the shipment is received.

Please record your equipment identification information below for future reference. This information can be

found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you

have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet

accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

“Product Registration”. Please complete the form and submit your registration.

vivi

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions ........................................................................................................A-2

Machine Grounding.......................................................................................................A-2

Spark Arrester ...............................................................................................................A-2

Towing...........................................................................................................................A-2

Vehicle Mounting...........................................................................................................A-3

Pre-Operation Engine Service..............................................................................................A-3

Fuel ...............................................................................................................................A-3

Oil..................................................................................................................................A-3

Battery Connections......................................................................................................A-3

Welding Cable Connections..........................................................................................A-4

Angle of Operation ........................................................................................................A-4

Lifting.............................................................................................................................A-4

High Altitude Operation .................................................................................................A-4

Location and Ventilation................................................................................................A-5

Stacking ........................................................................................................................A-5

Connection of Wire Feeders .........................................................................................A-5

Connection of Tig Module .............................................................................................A-5

Additional Safety Precautions,Welding Operation Output.............................................A-5

Auxiliary Power Receptacles, and Plugs .............................................................................A-6

Motor Starting and Extension Cord Length Table ................................................................A-6

Electrical Device Used with the ZR-8 ...................................................................................A-7

Auxiliary Power While Welding, Standby Power Connections ............................................A-8

Premises Wiring ...................................................................................................................A-9

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

General Description..............................................................................................................B-1

Welder Controls Function and Operation .............................................................................B-1

Polarity, Range and Control Switch......................................................................................B-2

Approximate Fuel Consumption ...........................................................................................B-2

Starting/Shutdown Instructions....................................................................................................B-3

Starting the Engine........................................................................................................B-3

Safety Precautions ........................................................................................................B-3

Stopping the Engine......................................................................................................B-3

Break-In Period .............................................................................................................B-3

Welding Process ..................................................................................................................B-4

Stick (Constant Current) Welding..................................................................................B-4

TIG (Constant Current) Welding ..................................................................................B-4

Wire Feed Welding Processes (Constant Voltage)......................................................B-4

Arc Gouging ..................................................................................................................B-5

Summary of Welding Processes ...................................................................................B-5

________________________________________________________________________________

Accessories ........................................................................................................Section C

Optional Equipment...............................................................................................C-1

Recommended Equipment....................................................................................C-2

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Engine Maintenance ..........................................................................D-1,D2

Engine Adjustments...............................................................................................D-3

Slip Rings, Battery and Engine Maintenance Parts...............................................D-3

________________________________________________________________________

Troubleshooting..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide...................................................................................E-2, E-3

________________________________________________________________________

Wiring Diagrams & Dimension Print..............................................................Section F

Wiring and Connection Diagrams....................................................................F-1,F-2

Dimension Print......................................................................................................F-3

________________________________________________________________________

Parts List..................................................................................................................P502

________________________________________________________________________

A-1

INSTALLATION

ZR-8

A-1

TECHNICAL SPECIFICATIONS ZR-8 (K2392-1)

INPUT - GASOLINE ENGINE

RATED OUTPUT @ 104°F (40°C)- WELDER

HEIGHT WIDTH DEPTH WEIGHT

30.3 in. 19.1 in. 42.0 in. 502 lbs. (228kg)

770 mm 485 mm 1067 mm

RATED OUTPUT @ 104°F (40°C)- GENERATOR

Welding Output

AC Constant Current 225A / 25V / 100%

DC Constant Current 210A / 25V / 100%

DC Constant Voltage 200A / 20V / 100%

Auxiliary Power

9,000 Watts Continuous, 60 Hz AC

10,000 Watts Peak, 60 Hz AC

120/240 Volts

PHYSICAL DIMENSIONS

Make/Model

Kohler

CH20S

Description

2 cylinder

4 Cycle

Air-Cooled

Gasoline

Engine.

Aluminum Alloy

with Cast Iron

Liners,

Electronic

Ignition

Operating

Speed (RPM)

High Idle 3700

Full Load 3500

Low Idle 2200

Displacement

cu. in.

(cu.cm.)

38(624)

Kohler

Capacities

Fuel:

9 Gal (34 L)

Lubricating Oil:

2.0 Qts. (1.9 L)

Horsepower

20 HP @

3600 RPM

(Kohler)

Starting

System

12VDC

Battery

Electric Start

Group 58

Battery

(435 cold

Cranking

Amps)

1. Output rating in watts is equivalent to volt - amperes at unity factor. Output voltage is within +/-10% at all loads up to rated capacity.

When welding available auxiliary power will be reduced.

A-2

INSTALLATION

ZR-8

A-2

SAFETY PRECAUTIONS

MACHINE GROUNDING

Because this portable engine driven welder or genera-

tor creates its own power, it is not necessary to con-

nect its frame to an earth ground, unless the machine

is connected to premises wiring (your home, shop,

etc.).

To prevent dangerous electric shock, other equip-

ment to which this engine driven welder supplies

power must:

• be grounded to the frame of the welder using a

grounded type plug, or be double insulated.

Do not ground the machine to a pipe that carries

explosive or combustible material.

------------------------------------------------------------------------

When this welder is mounted on a truck or trailer, its

frame must be electrically bonded to the metal frame

of the vehicle. Use a #8 or larger copper wire connect-

ed between the machine grounding stud and the

frame of the vehicle.

Where this engine driven welder is connected to

premises wiring such as that in your home or shop, its

frame must be connected to the system earth ground.

See further connection instructions in the section enti-

tled “Standby Power Connections”, as well as the arti-

cle on grounding in the latest National Electrical Code

and the local code.

In general, if the machine is to be grounded, it should

be connected with a #8 or larger copper wire to a solid

earth ground such as a metal water pipe going into

the ground for at least ten feet and having no insulat-

ed joints, or to the metal framework of a building

which has been effectively grounded. The National

Electrical Code lists a number of alternate means of

grounding electrical equipment. A machine grounding

stud marked with the symbol is provided on the

front of the welder.

SPARK ARRESTER

Some federal, state, or local laws may require that

gasoline engines be equipped with exhaust spark

arresters when they are operated in certain locations

where unarrested sparks may present a fire hazard.

The standard muffler included with this welder does

not qualify as a spark arrester. When required by local

regulations, the K894-1 spark arrester must be

installed and properly maintained.

An incorrect arrester may lead to damage to the

engine or adversely affect performance.

------------------------------------------------------------------------

TOWING

The recommended trailer for use with this equipment

for road, in-plant and yard towing by a vehicle

(1)

Lincoln’s K957-1. If the user adapts a non-Lincoln

trailer, he must assume responsibility that the method

of attachment and usage does not result in a safety

hazard nor damage the welding equipment. Some of

the factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln

equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of

the welding equipment so there will be no undue

stress to the framework.

CAUTION

Do not attempt to use this equipment until you

have thoroughly read the engine manufacturer’s

manual supplied with your welder. It includes

important safety precautions, detailed engine

starting, operating and maintenance instructions,

and parts lists.

------------------------------------------------------------------------

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.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

WARNING

3. Proper placement of the equipment on the trailer to

insure stability side to side and front to back when

being moved and when standing by itself while

being operated or serviced.

4. Typical conditions of use, i.e., travel speed; rough-

ness of surface on which the trailer will be operated;

environmental conditions.

5. Conformance with federal, state and local laws

(1)

(1) Consult applicable federal, state and local laws regarding specific

requirements for use on public highways.

PRE-OPERATION SERVICE

READ the engine operating and maintenance

instructions supplied with this machine.

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away

from tank.

• Do not leave unattended while

fueling.

• Wipe up spilled fuel and allow

fumes to clear before starting

engine.

• Do not overfill tank, fuel expan-

sion may cause overflow.

GASOLINE FUEL ONLY

------------------------------------------------------------------------

WARNING

A-3

INSTALLATION

ZR-8

A-3

FUEL

Fill the fuel tank with clean, fresh, lead-free gasoline.

Observe fuel gauge while filling to prevent overfilling.

OIL

The ZR-8 is shipped with the engine crankcase filled

with SAE 10W-30 oil. Check the oil level before start-

ing the engine. If it is not up to the full mark on the dip

stick, add oil as required. Make certain that the oil filler

cap is tightened securely. Refer to the engine Owner’s

Manual for specific oil recommendations.

BATTERY CONNECTIONS

Use caution as the electrolyte is a strong

acid that can burn skin and damage eyes.

-----------------------------------------------------------------------

This welder is shipped with the negative battery cable

disconnected. Make sure that the Engine Switch is in

the “STOP” position and attach the disconnected

cable securely to the negative battery terminal before

attempting to operate the machine. If the battery is

discharged and does not have enough power to start

the engine, see the battery charging instructions in the

Battery section.

NOTE: This machine is furnished with a wet charged

battery; if unused for several months, the battery may

require a booster charge. Be careful to charge the bat-

tery with the correct polarity.

CAUTION

LUBRICATION SYSTEM CAPACITY

(INCLUDING FILTER)

Kohler CH20S - 2.0 Quarts (1.9 Liters)

• Damage to the fuel tank may cause

fire or explosion. Do not drill holes

in the ZR-8 base or weld to

the ZR-8 base.

WARNING

CAUTION

GASOLINE

can cause fire

or explosion.

VEHICLE MOUNTING

Improperly mounted concentrated loads may

cause unstable vehicle handling and tires or other

components to fail.

• Only transport this Equipment on serviceable

vehicles which are rated and designed for such

loads.

• Distribute, balance and secure loads so vehicle

is stable under conditions of use.

• Do not exceed maximum rated loads for compo-

nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of

vehicle.

• Follow vehicle manufacture’s instructions.

------------------------------------------------------------------------

WARNING

A-4

INSTALLATION

ZR-8

A-4

WELDING OUTPUT CABLES

With the engine off, connect the electrode and work

cables to the studs provided. These connections

should be checked periodically and tightened if neces-

sary. Loose connections will result in overheating of

the output studs.

When welding at a considerable distance from the

welder, be sure you use ample size welding cables.

Listed below are copper cable sizes recommended for

the rated current and duty cycle. Lengths stipulated

are the distance from the welder to work and back to

the welder again. Cable sizes are increased for

greater lengths primarily for the purpose of minimizing

cable voltage drop.

ANGLE OF OPERATION

Internal combustion engines are designed to run in a

level condition which is where the optimum perfor-

mance is achieved. The maximum angle of operation

for the engine is 15 degrees from horizontal in any

direction. If the engine is to be operated at an angle,

provisions must be made for checking and maintain-

ing the oil at the normal (FULL) oil capacity in the

crankcase in a level condition.

When operating at an angle, the effective fuel capacity

will be slightly less than the specified 9 gallons.

LIFTING

The ZR-8 weighs approximately 575 lbs.(260Kg) with

a full tank of gasoline. A lift bail is mounted to the

machine and should always be used when lifting the

machine.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

0-100 Ft.

(0-30.5 M)

100-200 Ft.

(30.5-61.0 M)

200-255 Ft.

(61.0-76.2 M)

225 Amps

100% Duty Cycle

1 AWG

1/0 AWG

HIGH ALTITUDE OPERATION

If the ZR-8 will be consistently operated at altitudes

above 5000 ft. (1524m), a carburetor jet designed for

high altitudes should be installed. This will result in

better fuel economy, cleaner exhaust, and longer

spark plug life. It will not

give increased power which

is decreased at higher altitudes. Engine horsepower

is reduced by 3.5% per 1000 ft. (305m) for altitudes

above 377 ft. (115m)

Do not operate a ZR-8 with a high altitude jet

installed at altitudes below 5000 ft. (1524m). This

will result in the engine running too lean and

result in higher engine operating temperatures

which can shorten engine life.

-----------------------------------------------------------------------

Contact your local Kohler Authorized Dealer for high alti-

tude jet kits that are available from the engine manufactur-

er.

• Lift only with equipment of

adequate lifting capacity.

• Be sure machine is stable

when lifting.

• Do not lift this machine using

lift bale if it is equipped with a

heavy accessory such as trail-

er or gas cylinder.

FALLING • Do not lift machine if lift bale is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bale.

------------------------------------------------------------------------

WARNING

VEHICLE MOUNTING

Improperly mounted concentrated loads may

cause unstable vehicle handling and tires or other

components to fail.

• Only transport this Equipment on serviceable

vehicles which are rated and designed for such

loads.

• Distribute, balance and secure loads so vehicle

is stable under conditions of use.

• Do not exceed maximum rated loads for compo-

nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of

vehicle.

• Follow vehicle manufacturer’s instructions.

------------------------------------------------------------------------

WARNING

• 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.

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

Muffler Relocation

•

Shut off welder and allow muffler to cool before touch-

ing muffler.

-------------------------------------------------------------------------------

The ZR-8 is shipped with the exhaust coming out on the left

side. The exhaust can be changed to the opposite side by

removing the two screws that hold the exhaust port cover in

place and installing the cover on the opposite side.

(Operating the ZR-8 without the cover in place will result in

a higher noise level and no increase in machine output.)

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 “High 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.

WARNING

ZR-8

Constant Current 225 Amps AC @ 25 Volts

210 Amps DC @ 25 Volts

Constant Voltage 200 Amps DC @ 20 Volts

120 V DUPLEX RECEPTACLES

The 120V auxiliary power receptacles should only be

used with three wire grounded type plugs or approved

double insulated tools with two wire plugs.

The current rating of any plug used with the system

must be at least equal to the current load through the

associated receptacle.

MOTOR STARTING

Most 1.5 hp AC single phase motors can be started if

there is no load on the motor or other load connected

to the machine, since the full load current rating of a

1.5 hp motor is approximately 20 amperes (10

amperes for 240 volt motors). The motor may be run

at full load when plugged into only one side of the

duplex receptacle. Larger motors through 2 hp can be

run provided the receptacle rating as previously stat-

ed is not exceeded. This may necessitate 240V oper-

ation only.

GND

120 V

120 V*

240 V

*Current Sensing for Automatic Idle.

(Receptacle viewed from front of Machine)

ZR-8 Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

Current

(Amps)

Voltage

Volts

120

240

Load

(Watts)

1800

2400

3600

4800

9000

(9)

(18)

(12)

(9)

(23)

(18)

150

100

(23)

(15)

(46)

(30)

(15)

125

225

175

(38)

(27)

(69)

(53)

(27)

175

138

350

275

150

(53)

(42)

(107)

(84)

(46)

300

225

600

450

225

(91)

(69)

(183)

(137)

(69)

Maximum Allowable Cord Length in ft. (m) for Conductor Size

Conductor size is based on maximum 2.0% voltage drop.

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

A-6

INSTALLATION

ZR-8

A-6

AUXILIARY POWER

The ZR-8 can provide up to 9,000 watts of 120/240

volts AC, single phase 60Hz power for continuous

use, and up to 10,000 watts of 120/240 volts AC, sin-

gle phase 60Hz power peak use. The front of the

machine includes three receptacles for connecting the

AC power plugs; one 50 amp 120/240 volt NEMA 14-

50R receptacle and two 20 amp 120 volt NEMA 5-20R

receptacles. Output voltage is within +/-10% at all

loads up to rated capacity.

Do not connect any plugs that connect to the

power receptacles in parallel.

------------------------------------------------------------------------

Start the engine and set the “IDLER” control switch to

the desired operating mode. Set the “CONTROL” to

10. Voltage is now correct at the receptacles for auxil-

iary power.

120/240 VOLT DUAL VOLTAGE RECEPTACLE

The 120/240 volt receptacle can supply up to 38 amps

of 240 volt power to a two wire circuit, up to 38 amps

of 120 volts power from each side of a three wire cir-

cuit (up to 76 amps total). Do not connect the 120 volt

circuits in parallel. Current sensing for the automatic

idle feature is only in one leg of the three wire circuit

as shown in the following column.

CAUTION

A-7

INSTALLATION

ZR-8

A-7

TABLE lll

ELECTRICAL DEVICE USE WITH THE ZR-8.

Type Common Electrical Devices Possible Concerns

Resistive Heaters, toasters, incandescent NONE

light bulbs, electric range, hot

pan, skillet, coffee maker.

Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage

appliances with electrical control. regulation can cause the capac-

itative elements to fail. Surge

protection, transient protection,

and additional loading is recom-

mended for 100% fail-safe

operation. DO NOT RUN

THESE DEVICES WITHOUT

ADDITIONAL RESISTIVE TYPE

LOADS.

Inductive Single-phase induction motors, These devices require large

drills, well pumps, grinders, small current inrush for starting.

refrigerators, weed and hedge Some synchronous motors may

trimmers be frequency sensitive to attain

maximum output torque, but

they SHOULD BE SAFE from

any frequency induced failures.

Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-

complicated electrical equipment. er along with transient and

surge protection is required,

and liabilities still exist. DO

NOT USE THESE DEVICES

WITH A ZR-8

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect-

ed to the ZR-8.

A-8

INSTALLATION

ZR-8

A-8

STANDBY POWER CONNECTIONS

The ZR-8 is suitable for temporary, standby, or emer-

gency power using the engine manufacturer’s recom-

mended maintenance schedule.

The ZR-8 can be permanently installed as a standby

power unit for 240V-3 wire, single phase 38 ampere

service.

(Connections must be made by a licensed electri-

cian who can determine how the 120/240V power

can be adapted to the particular installation and

comply with all applicable electrical codes.) The

following information can be used as a guide by

the electrician for most applications (refer also to

the connection diagram shown in Figure 1.)

-------------------------------------------------------------------------

1. Install a double pole, double throw switch between

the power company meter and the premises dis-

connect.

Switch rating must be the same or greater than the

customer’s premises disconnect and service over-

current protection.

2. Take necessary steps to assure load is limited to

the capacity of the ZR-8 by installing a 38 amp

240V double pole circuit breaker. Maximum rated

load for the 240V auxiliary is 38 amperes. Loading

above 38 amperes will reduce output voltage

below the allowable -10% of rated voltage which

may damage appliances or other motor-driven

equipment.

3. Install a 50 amp 120/240V plug (NEMA type 14-50)

to the Double Pole Circuit Breaker using No. 8, 4

conductor cable of the desired length. (The 50 amp

120/240V plug is available in the optional plug kit.)

4. Plug this cable into the 50 amp 120/240V recepta-

cle on the ZR-8 case front.

WARNING

AUXILIARY POWER WHILE WELDING

Simultaneous welding and power loads are permitted

by following Table I. The permissible currents shown

assume that current is being drawn from either the

120V or 240V supply (not both at the same time).

Also, the “Output Control” is set at “10” for maximum

auxiliary power.

TABLE I

SIMULTANEOUS WELDING AND POWER

Output Selector Permissible Power Permissible Auxiliary

Setting Watts (Unity Power Current in Amperes

Factor) @ 120V

*-or- @ 240V

Max. Stick or Wire

Feed Setting None 0 0

145 Stick Setting 3450 32 16

90 Stick Setting 6000 50

** 25

NO WELDING 9000 76

** 38

* Each duplex receptacle is limited to 20 amps.

**Not to exceed 40A per 120VAC branch circuit when

splitting the 240 VAC output.

240 Volt

60 Hz.

3-Wire

Service

POWER

COMPANY

METER

240 VOLT

120 VOLT

LOAD

NEUTRAL

BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

240 VOLT

GROUNDED CONDUCTOR

40 AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

DOUBLE POLE DOUBLE THROW

SWITCH RATING TO BE THE SAME

AS OR GREATER THAN PREMISES

SERVICE OVERCURRENT

PROTECTION.

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT

RECEPTACLE

A-9

INSTALLATION

ZR-8

A-9

Connection of ZR-8 to premises wiring must be

done by a licensed electrician and must comply

with the National Electrical Code and all other

applicable electrical codes.

Figure 1

CONNECTION OF ZR-8 TO PREMISES WIRING

WARNING

WELDER CONTROLS - FUNCTION AND

OPERATION

ENGINE SWITCH

The engine switch is used to Start the Engine, Select

High Idle or Auto Idle while the engine is running, and

stop the Engine.

When placed in the “OFF” position, the ignition

circuit is de-energized to shut down the engine.

When held in the “START” position, the engine

starter motor is energized.

When in “HIGH IDLE” ( ) position, the engine will

run continuously at high idle.

When in “AUTO IDLE” ( / ) position, the

engine will run continuously and the idler operates as

follows:

• Welding

When the electrode touches the work, the welding

arc is initiated and the engine accelerates to full

speed.

After welding ceases (and no auxiliary power is

being drawn), the engine will return to low idle

after approximately 10 to 14 seconds.

• Auxiliary Power

With the engine running at low idle and auxiliary

power for lights or tools is drawn (approximately

100-150 watts or greater) from the receptacles,

the engine will accelerate to high speed. If no

power is being drawn from the receptacles (and

not welding) for 10-14 seconds, the idler reduces

the engine speed to low idle.

B-1

OPERATION

ZR-8

B-1

SAFETY PRECAUTIONS

Do not attempt to use this equipment until you

have thoroughly read the engine manufacturer’s

manual supplied with your welder. It includes

important safety precautions, detailed engine

starting, operating and maintenance instructions,

and parts lists.

------------------------------------------------------------------------

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.

• Always operate the welder with the hinged door

closed and the side panels in place.

• Read carefully the Safety Precautions page

before operating this machine. Always follow

these and any other safety procedures included

in this manual and in the Engine Instruction

Manual.

------------------------------------------------------------------------

GENERAL DESCRIPTION

The ZR-8 is a twin-cylinder, gasoline driven, multi-

process arc welder and AC power generator. It is built

in a heavy gauge steel case for durability on the job

site.

“ RANGE” SWITCH

The “Range” switch is used to select one of three

amperage ranges with generous overlap for Stick/TIG

welding, or one Wire Feed welding range.

Never change the “RANGE” Switch setting while

welding. This will damage the switch.

------------------------------------------------------------------------

“ CONTROL” DIAL

Provides a fine welding current adjustment within the

Range Switch settings in the STICK mode and weld-

ing voltage control with the Range switch set in the

wire feed mode.

Process Range Setting Current Range

POLARITY SWITCH

Provides three selectable welding polarities:

AC, DC+ & DC-

Never change the Polarity switch setting while

welding. This will damage the switch.

------------------------------------------------------------------------

B-2

OPERATION

B-2

ZR-8

CAUTION

KOHLER

20 H.P. COMMAND

.4 Gallons/Hour

(1.5 Liters/Hour)

.7 Gallons/Hour

(2.8 Liters/Hour)

1.2 Gallons/Hour

(4.6 Liters/Hour)

1.3 Gallons/Hour

(4.9 Liters/Hour)

1.2 Gallons/Hour

(4.5 Liters/Hour)

1.4 Gallons/Hour)

(5.3 Liters/Hour)

Low Idle - No Load

2200 RPM

High Idle - No Load

3700 RPM

AC CC Weld Output

225 Amps @ 25 Volts

DC CC Weld Output

210 Amps @ 25 Volts

DC CV Weld Output

200 Amps @ 20 Volts

Auxiliary Power

9000 Watts

ZR-8 APPROXIMATE FUEL CONSUMPTION

STICK/TIG

(constant current)

(3 range settings)

WIRE FEED

(constant voltage)

(one range setting)

90 Max.

145 Max.

210DC/225AC Max.

15 to 25V

40 to 90 Amps

70 to 145 Amps

120 to 210 (DC) 225(AC)

Up to 200 Amps

B-3

OPERATION

B-3

STARTING/SHUTDOWN INSTRUCTIONS

STARTING THE ENGINE

Be sure all Pre-Operation Maintenance has been per-

formed. Also, read the Engine Owner’s Manual before

starting for the first time.

Remove all loads connected to the AC power recepta-

cles. Use the choke control as follows:

KOHLER ENGINE - Always pull the choke control out

when starting the engine; cold, warm or hot.

Turn the engine switch to the “start” position and

crank the engine until it starts. Release the switch as

soon as the engine starts, slowly return the choke

control to the full “in” position (choke open),

and turn the switch to the Auto Idle( / )

position. Do not turn the switch to the “start” position

while the engine is running because this will cause

damage to the ring gear and/or starter motor

After running at high engine speed for 10-14 seconds,

the engine will go to low idle.

Allow the engine to warm up by letting it run at low idle

for a few minutes.

STOPPING THE ENGINE

Remove all welding and auxiliary power loads and

allow engine to run at low idle speed for a few minutes

to cool the engine.

Stop the engine by placing the Engine switch in the

“OFF” position.

A fuel shut off valve is not required on the ZR-8

because the fuel tank is mounted below the engine.

BREAK-IN PERIOD

It is normal for any engine to use a greater amount of

oil until the break-in is accomplished. Check the oil

level twice a day during the break-in period (approxi-

mately 50 running hours).

IMPORTANT: IN ORDER TO ACCOMPLISH THIS

BREAK-IN, THE UNIT SHOULD BE

SUBJECTED TO MODERATE

LOADS, WITHIN THE RATING OF

THE MACHINE. AVOID LONG IDLE

RUNNING PERIODS. REMOVE

LOADS AND ALLOW ENGINE TO

COOL BEFORE SHUTDOWN.

The engine manufacturer’s recommendation for the

running time until the first oil change is as follows:

The oil filter is to be changed at the second oil

change. Refer to the Engine Owner’s Manual for more

information.

ZR-8

• Do not touch electrically live parts

of electrode with skin or wet

clothing.

• Keep flammable material away.

• Insulate yourself from work and

ground. Wear eye, ear, and body

protection.

• Keep your head out of the fumes.

• Use ventilation or exhaust to

remove fumes from breathing zone.

WARNING

KOHLER

CH20S

5 HRS

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. Output control is

from the ZR-8.The output control on the TIG Module is

not functional. 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

low idle after welding is ceased will be increased if the

AFTER FLOW CONTROL is set above 10 seconds.

Note: For AC TIG Welding, the maximum TIG welding

output currents on each range setting will be approxi-

mately 50% higher than those marked on the name-

plate. 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 ZR-8.

WIRE FEED WELDING PROCESSES

(CONSTANT VOLTAGE)

The Innershield

electrode suitable for use with the

ZR-8 is NR

-211-MP. The electrode sizes and weld-

ing 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

). The welding ranges that

can be used with the ZR-8 are shown 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 75 - 300 50A to 130A

.035 100 - 250 80A to 175A

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

90 MAX.

145 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

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