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Red-D-Arc ZR-10 Operation Manual

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IM754
RED-D-ARC
August, 2002
ZR-10
10796
For use with machines having Code Numbers:
OPERATOR'S MANUAL
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.
1-800-245-3660
North America's Largest Fleet of Welding Equipment

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Summary of Contents for Red-D-Arc ZR-10

  • Page 1 For use with machines having Code Numbers: OPERATOR’S MANUAL 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.

  • Page 2: California Proposition 65 Warnings

    1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source. turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate. Mar ‘95 ZR-10...

  • Page 3: Electric Shock Can Kill

    (MSDS) and follow your yourself from a fall should you get a shock. employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 3.j. Also see Items 6.c. and 8. 5.e. Also see item 1.b. Mar ‘95 ZR-10...
  • Page 4 This can create fire hazards or overheat lifting chains Electrical Code, all local codes and the manufacturer’s or cables until they fail. recommendations. 6.h. Also see item 1.c. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. Mar ‘95 ZR-10...
  • Page 5 4. Garder tous les couvercles et dispositifs de sûreté à leur talons sans revers, et chaussures montantes. place. 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les Mar. ‘93 ZR-10...
  • Page 6 for selecting a QUALITY product. We want you to take pride in Thank You operating this product ••• as much pride as we have in bringing this product to you! 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.

  • Page 7: Table Of Contents

    Current Draw from Receptacle-No Welding ..............B-6 Electrical Devices used with the ZR-10.................B-6 Auxiliary Power While Welding ..................B-7 Standby Power Connections ..................B-7 Connection of ZR-10 to Premises Wiring ..............B-8 Accessories .....................Section C Optional Equipment ....................C-1 Maintenance ....................Section D Safety Precautions ....................D-1 Routine Maintenance ....................D-1...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS: ZR-10 (K1786-2) INPUT - GASOLINE ENGINE Make/Model Capacities Description Speed (RPM) Horsepower Displacement cu. in. (cu. cm.) Full Load: 2 Cylinder ZR-10 Fuel: 3500 RPM 4 Cycle (Honda 20HP 9 Gal (34 L) 37.5 cu-in. Air-Cooled GX620-K1)
  • Page 9 AC STICK / TIG (CC) OUTPUT A 225 OUTPUT RANGE B 50 OUTPUT RANGE OUTPUT AMPS DC STICK / TIG (CC) OUTPUT A 210 OUTPUT RANGE B 50 OUTPUT RANGE OUTPUT AMPS DC WIRE FEED (CV) OUTPUT CV OUTPUT RANGE OUTPUT AMPS ZR-10...

  • Page 10: Safety Precautions

    • be grounded to the frame of the welder using a being moved and when standing by itself while grounded type plug, or being operated or serviced. • be double insulated. ZR-10...

  • Page 11: Pre-Operation Engine Service

    ELECTRODE AND WORK CABLES 225 Amps 225 Amps 40% Duty Cycle 100% Duty Cycle The ZR-10 is shipped with the engine crankcase filled 3 AWG 1 AWG 0-50 Ft. 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...

  • Page 12: Angle Of Operation

    377 feet. CAUTION CONNECTION OF THE LN-25 TO THE ZR-10 Do not operate a ZR-10 with a high altitude jet • Shut the welder off. installed at altitudes below 5000 ft. This will result in the engine running too lean and result in •...
  • Page 13 NOTE: If the output “CONTROL” is set below “3” the K240 contactor may not pull in. CONNECTION OF K930-1 TIG MODULE TO THE ZR-10 The TIG Module is an accessory that provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding.

  • Page 14: Operation

    WIRE FEED - CV 1 Range Setting GENERAL DESCRIPTION The ZR-10 is a twin-cylinder, gasoline driven, multi- process arc welder and AC power generator. It is built CAUTION in a heavy gauge steel case for durability on the job site.

  • Page 15: Zr-10 Approximate Fuel Consumption

    If no power is being drawn from the “OFF” position. receptacles (and not welding) for 10-16 seconds, A fuel shut off valve is not required on the ZR-10 the idler reduces the engine speed to low idle. because the fuel tank is mounted below the engine.

  • Page 16: Break-In Period

    10. LOADS AND ALLOW ENGINE TO COOL BEFORE SHUTDOWN. The ZR-10 can be used with a broad range of AC and DC stick electrodes. See “Welding Tips 1” included The engine manufacturer’s recommendation for the with the ZR-10 for electrodes within the rating of this running time until the first oil change is as follows: unit and recommended welding currents of each.

  • Page 17: Wire Feed Welding Processes(Cv

    .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-10 are shown in the following table: Diameter Wire Speed Approximate (in.)

  • Page 18: Auxiliary Power

    The 460 volt 3 phase output of the ZR-10 is capable The current rating of any plug used with the system of running most 460VAC 3 phase motors up to 10HP.
  • Page 19 9.0 KW 9.0 KW *Maximum current draw from each 115V *NEMA 5-20P Plug required for 20Amp Draw GFCI Duplex is 20 amps TABLE lll ELECTRICAL DEVICES USE WITH THE ZR-10 Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent...

  • Page 20: Standby Power Connections

    • Take necessary steps to assure load is limited to AUXILLIARY POWER WHILE WELDING the capacity of the ZR-10 by installing a 35 amp 230V double pole circuit breaker. Maximum rated It must be noted that the above auxiliary power ratings load for the 230V auxiliary is 35 amperes.

  • Page 21: Connection Of Zr-10 To Premises Wiring

    NOTE: No. 8 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. WARNING Connection of ZR-10 to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes. ZR-10...

  • Page 22: Accessories

    If remote control is not used the K936-4 control cable is required. Canvas Cover (K886-1) - To protect the ZR-10 when not in use. Made from attractive red canvas material Foot Amptrol (K870) which is flame retardant, mildew resistant, and water repellent.

  • Page 23: Maintenance

    Lincoln Distributor. (See contacts clean, rotate the switch through its entire Operating Manual Parts List.) range frequently. Good practice is to turn the han- dle from maximum to minimum setting twice each morning before starting to weld. ZR-10...

  • Page 24: Engine Adjustments

    Replace • (3) Fuel Line Check Every 2 Years (3) (Replace if necessary) (1) Service more frequently when used in dusty areas. (2) Replace the paper element only. (3) These items should be services by an authorized engine dealer. ZR-10...

  • Page 25: Troubleshooting

    CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. ZR-10...
  • Page 26 No voltage signal from the current sensor. No open circuit voltage on output studs. Faulty P.C. Board. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your ZR-10...
  • Page 27 Air filter clogged. Engine is hard to start. Spark plugs do not have specified gap. Spark plugs are fouled. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your ZR-10...

  • Page 28: Diagrams

    DIAGRAMS ZR-10...

  • Page 29: Connection Diagram

    M 1 7 4 8 6 CONNECTION OF ZR-10 TO LN-7 & K240 CONTACTOR KIT C O N N E C T I O N O F L N - 7 & K 2 4 0 C O N T A C T O R K I T W I T H 1 1 5 V O L T A C A U X I L I A R Y P O W E R A N D C V O U T P U T...
  • Page 30 DIAGRAMS ZR-10...
  • Page 31 NOTES ZR-10...
  • Page 32 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
  • Page 33 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING ● Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish ● Los humos fuera de la zona de res- ●...
  • Page 34 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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