Instruction/ maintenance manual of the product TIG MODULE IM528-B Lincoln Electric
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TIG M odule OPERA TOR’S MANUAL For use with Equipment having Code Number 10135, 10203, 10284, 11010 IM528-B March, 2005 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation .
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.
TIG MODULE - ii - ii SAFETY ii ARC RA YS 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.
TIG MODULE - iii - FOR ELECTRICALL Y 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.
TIG MODULE - iv - iv SAFETY iv PR É CAUTIONS DE S Û RET É Pour votre propre protection lire et observer toutes les instructions et les pr é cautions de s û ret é specifiques qui parraissent dans ce manuel aussi bien que les pr é cautions de s û ret é g é n é rales suivantes: S û ret é Pour Soudage A L ’ Arc 1.
TIG MODULE - v - v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to 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.
T ABLE OF CONTENTS Page Safety .....................................................................................................................i-iv Installation .....................................................................................
INST ALLA TION TECHNICAL SPECIFICA TIONS - TIG MODULE Code Number 10135 10203 10284 11010 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.
– 2 – INST ALLA TION TIG MODULE Read entire installation section before starting installation. Safety Precautions Users should familiarize themselves with Figure 8, Rear Connections, in the Operating Section of this manual before proceeding. LOCA TION The TIG Module can be mounted in or carried to any convenient location.
INST ALLA TION – 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 rigid metallic conduit or equivalent shielding. Flexible helically-wrapped metallic conduit is generally not suitable.
– 4 – INST ALLA TION TIG MODULE If using a water cooled torch with a water cooler, do not install the water valve. It will block the water flow, possibly damaging the pump. Magnum water coolers are an exception to this rule. Refer to the manufacturer ’ s instructions provided with the cooler.
INST ALLA TION WITH A POWER SOURCE Ranger 8 Installation Tables 1 and 2 list the required and optional equipment for installing and operating the TIG Module with a Ranger 8. Table 1 is for the Ranger 8, and table 2 is for the Ranger 8 with the K892-1 Remote Kit installed.
INST ALLA TION – 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 L9 4 40 1 HIGH FREQUENCY LOCAL 115 V 1.
TIG MODULE – 7 – INST ALLA TION RANGER 8 (WITH THE OPTIONAL K892-1 REMOTE KIT INST ALLED) AND THE TIG MODULE REQUIRED EQUIPMENT Control Cable Contactor Kit Work and Electrode Leads from Ranger 8 t.
INST ALLA TION – 8 – FIGURE 2: RANGER 8 / K892-1 REMOTE KIT / 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 L9 4 40 1 HIGH FREQUENCY LOCAL 115 V 1.
TIG MODULE – 9 – INST ALLA TION Ranger 9 Installation Table 3 lists the required and optional equipment for installing and operating the TIG Module with a Ranger 9. Refer to Figure 3 for the TIG Module/Ranger 9 connection diagram. Make sure all connections are tight before proceeding.
INST ALLA TION – 10 – FIGURE 3: RANGER 9 / 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.
TIG MODULE – 11 – INST ALLA TION Ranger 10 and Ranger 300 D Installation Table 4 lists the required and optional equipment for installing and operating the TIG Module with a Ranger 10 or Ranger 300 D. Refer to Figure 4 for the TIG Module/Ranger 10 connection diagram and to Figure 4A for the TIG Module/Ranger 300 D connection diagram.
INST ALLA TION – 12 – FIGURE 4: RANGER 10 / 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 L 9 44 0 1 HIGH FREQUENCY LOCAL 115 V 1.
INST ALLA TION – 12a – FIGURE 4A: RANGER 300 D / TIG MODULE CONNECTION DIAGRAM ELECTRODE -OR- 6 PIN AMPHENOL K814 ARC START SWITCH S23732-10 K870 FOOT AMPTROL -OR- K963-1 HAND AMPTROL 1/03 CAUTION : AN INCREASE IN THE THE AC AUXILIARY VOLTAGE.
NOTES – 12b – TIG MODULE.
TIG MODULE – 13 – INST ALLA TION T ABLE 5 RANGER 10LX / RANGER 300D-LX AND THE TIG MODULE REQUIRED EQUIPMENT Control Cable Contactor Kit Work and Electrode Leads from Ranger 10LX to TIG Module TIG.
INST ALLA TION – 14 – FIGURE 5: RANGER 10-LX / 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 L9 440 1 HIGH FREQUENCY LOCAL 115 V 1.
INST ALLA TION – 14a – FIGURE 5A: RANGER 300D-LX / TIG MODULE CONNECTION DIAGRAM 14 PIN AMPHENOL ELECTRODE K963-1 HAND AMPTROL -OR- S23732-9 K814 ARC START SWITCH K870 FOOT AMPTROL -OR- B-UF CAUTION : AN INCREASE IN THE THE AC AUXILIARY VOLTAGE.
NOTES – 14 b – TIG MODULE.
TIG MODULE – 15 – INST ALLA TION Installation with other Lincoln Power Sources Installation consists of connecting the input work and electrode cables, TIG torch, work lead, the proper control cable, and an Arc Start Switch or Amptrol.
INST ALLA TION – 16 – T ABLE 7 LINCOLN POWER SOURCES AND THE TIG MODULE OPTIONAL EQUIPMENT T ABLE Control Cable Extension K937-[ ] K937-[ ]* K937- [ ] K937-[ ]* Power Sources DC-250 R3R-All DC-400.
TIG MODULE – 17 – INST ALLA TION FIGURE 6: TIG MODULE ON A LINCOLN POWER SOURCE - 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 L9 4 40 1 HIGH FREQUENCY LOCAL 115 V 1.
OPERA TION – 18 – 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. FUMES AND GASES can be dangerous. • Keep your head out of fumes.
TIG MODULE – 19 – OPERA TION ON OFF INPUT HIGH FREQUENCY CONTINUOUS HIGH FREQUENCY ST ART ONL Y AFTERFLOW CURRENT CONTROL (OUTPUT) LOCAL CURRENT CONTROL REMOTE CURRENT CONTROL GAS INPUT GAS OUTPUT.
OPERA TION – 20 – PRODUCT DESCRIPTION The TIG Module is an accessory for constant current power sources. It provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding applications, and easy connection of Amptrol remote controls to power sources having remote control capability.
TIG MODULE – 21 – OPERA TION OPERA TION 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 and off. Red pilot light indicates that input power is “ on ” .
OPERA TION – 22 – WARNING ELECTRODE WORK V 1 2 3 4 4 5 6 7 REAR CONNECTIONS FIGURE 8 1 WARNING INFORMATION - Important information regarding the safe installation, operation, and servicing of the TIG Module. 2 INPUT RECEPTACLE - For connecting the Control Cable from the power source.
TIG MODULE – 23 – OPERA TION RANGER 8 OPERA TION The tables (Table 8 & 9) list the recommended switch and control settings for the TIG Module/Ranger 8 combination. The first table is for the Ranger 8, and the second for the Ranger 8 with the K892-1 Remote Kit installed.
OPERA TION – 24 – T ABLE 9: K930-[ ] / RANGER 8 (WITH THE K892-1) SETTINGS K930-[ ] SETTINGS POWER HIGH FREQUENCY AFTERFLOW CURRENT CONTROL CURRENT CONTROL SWITCH ON START - OR - CONTINUOUS ADJUST.
TIG MODULE – 25 – OPERA TION 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.
OPERA TION – 26 – RANGER 9 OPERA TION The table (Table 10) lists the recommended switch and control settings for the TIG Module/Ranger 9 combination.
TIG MODULE – 27 – OPERA TION RANGER 10 / RANGER 300 D OPERA TION The table (Table 11) lists the recommended switch and control settings for the TIG Module/Ranger 10 or TIG Module/Ranger 300 D combination. Make sure all connections are tight before proceeding.
OPERA TION – 28 – T ABLE 12: K930-[ ] / RANGER 10-LX or RANGER 300 DLX SETTINGS K930-[ ] SETTINGS POWER HIGH FREQUENCY AFTERFLOW CURRENT CONTROL CURRENT CONTROL SWITCH ON START - OR - CONTINUOUS A.
TIG MODULE – 29 – OPERA TION OPERA TION ON OTHER LINCOLN POWER SOURCES The table (Table 13) lists the recommended switch and control settings for the TIG Module when used with various Lincoln power sources. Operate the power source in accordance with its Manual.
OPERA TION – 30 – TIG WELDING INFORMA TION .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) 2-15 5-20 15-80 70-150 150-250 250-400 400-500 500-750.
TIG MODULE – 31 – ACCESSORIES OPTIONS / ACCESSORIES The following field installed Kits and accessories may be used dependingon the application: K936 Control Cables At least one of the following control cables is needed to connect the TIG Module to the power source.
SAFETY PRECAUTIONS PERIODIC MAINTENANCE Very little maintenance is required to keep your TIG Module in top operating condition. No specific schedule can be set for performing the following items; factors such as hours of usage and the machine environment should be considered when establishing a maintenance schedule.
TIG MODULE How T o Use T roubleshooting Guide This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
TROUBLESHOOTING – 34 – T roubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. High frequency “ jumps ” from the electrode to work but welding arc does not establish POSSIBLE CAUSE 1.
TIG MODULE – 35 – TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide PROBLEMS (SYMPTOMS) No weld output, no gas flow and no high frequency at spark gap Low weld output current when operating in remote control POSSIBLE CAUSE 1.
TROUBLESHOOTING – 36 – T roubleshooting Guide Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) High frequency not present or intermittent at torch electrode High frequency not present at spark gap High Frequency stays on after the arc is established POSSIBLE CAUSE 1.
WIRING DIAGRAM – 37 – TIG MODULE TIG MODULE 232 231 2 4 J2 302 I 403 76 403 404 301 H 231 232 S1 CONTROL BOARD OFF ONLY START 404 75 206 + 205 210 CONTINUOUS F E CURRENT SENSOR G 77 G 311A 307 308.
WIRING DIAGRAM – 38 – TIG MODULE 232 231 2 4 J2 302 I 403 76 403 404 301 H 231 232 S1 CONTROL BOAR D OFF ONLY START 404 75 206 + 205 210 CONTINUOUS F E CURRENT SENSOR G 77 G 311A 307 308 L12065 PR.
NOTES.
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– 52 – W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
– 53 – W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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An important point after buying a device Lincoln Electric TIG MODULE IM528-B (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric TIG MODULE IM528-B yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric TIG MODULE IM528-B - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric TIG MODULE IM528-B you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric TIG MODULE IM528-B will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric TIG MODULE IM528-B, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric TIG MODULE IM528-B.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric TIG MODULE IM528-B. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric TIG MODULE IM528-B along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
