Lincoln Electric IM858 RED-D-ARC ZR-8 - Manual (Page 20)

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
2
). 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