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Red-D-Arc ZR-8 Operator's Manual

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RED-D-ARC
ZR-8
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
10706, 10938
IM672-A
August, 2002

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Summary of Contents for Red-D-Arc ZR-8

  • 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

    SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm.

  • Page 3: Electric Shock Can Kill

    SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
  • Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
  • Page 5 SAFETY PRÉCAUTIONS DE SÛRETÉ 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les Pour votre propre protection lire et observer toutes les instruc- zones où l’on pique le laitier. tions et les précautions de sûreté...
  • 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

    High Altitude Operation..................15 Muffler Relocation....................15 Location / Ventilation ..................15 Connection of Lincoln Electric Wire Feeders............15 Connection of the LN-25 to the ZR-8 ............15 Connection of the LN-7 to the ZR-8 .............16 High Frequency Generator for TIG Welding Applications........16 OPERATING INSTRUCTIONS .................16 Additional Safety Precautions................16...

  • Page 8: General Description

    • K930-1 TIG Module Available. GENERAL DESCRIPTION • Remote Control Receptacle Kit Available. The ZR-8 is a twin-cylinder, gasoline driven, multi- • Electronic Engine Idler. Engine Automatically Goes to process arc welder and AC power generator. It is built Low Idle in 10 to 14 Seconds after Welding or Use in a heavy gauge steel case for durability on the job of Auxiliary Power.

  • Page 9: Specifications

    Multi-Purpose DC Constant Current K1786-1 70 Amps @ Arc Welder with (765 x 460 x 1073 mm) 210A / 25V / 100% ZR-8 115V 8,000 watts of K1786-4 Auxiliary Power 511 lbs (233 kg) DC Constant Voltage 35 Amps @...
  • Page 10 Engine Product Operating Name Description Horsepower Speeds Displacement Capacities ZR-8 20 HP 38.1 cu in Fuel: 2 Cylinder Full Load: (Kohler Command @ 3600 RPM (624 cc) 9 Gal (34 L) 4 Cycle 3500 RPM CH20S) Air-Cooled Lubricating Oil: Gasoline Engine.

  • Page 11: Specifications

    SPECIFICATIONS 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 –...

  • Page 12: Optional Equipment

    (Contains circuits 2, 4, 31, 32, 75, 76, 77 and ground) Canvas Cover (K886-1) - To protect the ZR-8 when Remote Control Cable (K936-4) - Control cable for not in use. Made from attractive red canvas material...

  • Page 13: Recommended Equipment

    RECOMMENDED EQUIPMENT STICK Accessory Kit (K710) which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield Remote Control Receptacle Kit (K892-1), and Remote Control Kit (K857) are optional for remote current control. Magnum™ TIG Torch Magnum Parts Kit and Argon Gas TIG Module (K930-1) (requires K938-1 Contactor Kit) Control Cable K939-3 or K939-4 (see Optional Equipment)

  • Page 14: Installation Instructions

    INSTALLATION INSTRUCTIONS it’s frame must be connected to the system earth ground. See further connection instructions in the section entitled “Standby Power Connections”, as well Safety Precautions as the article on grounding in the latest U.S. National Electrical Code and the local code. WARNING In general, if the machine is to be grounded, it should Do not attempt to use this equipment until you...

  • Page 15: Pre-Operation Service

    40% Duty Cycle 100% Duty Cycle 3 AWG 1 AWG 0-50 Ft. The ZR-8 is shipped with the engine crankcase filled 3 AWG 1 AWG 50-100 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 16: Angle Of Operation

    Shut off welder before making any electrical connections. CAUTION Do not operate a ZR-8 with a high altitude jet Wire Feed (Constant voltage) installed at altitudes below 5000 ft. This will result in the engine running too lean and result in...

  • Page 17: Connection Of The Ln-7 To The Zr-8

    Connection of the LN-7 to the ZR-8 OPERATING INSTRUCTIONS Shut the welder off. Connect the LN-7 and the K240 contactor kit per Additional Safety Precautions instructions on the connection diagram S17742 (can be found in the back of this manual).

  • Page 18: Welder Controls - Function And Operation

    Welder Controls - Function and Operation Welding Explanation of Symbols that Appear on this Equipment When the electrode touches the work, the welding arc is initiated and the engine accelerates to full speed. Low Idle High Idle After welding ceases (and no auxiliary power is ENGINE “ON-OFF”...

  • Page 19: Break-In Period

    5 through 10. Stop the engine by placing the “Engine” switch in the The ZR-8 can be used with a broad range of AC and “OFF” position. DC stick electrodes. See “Welding Tips 1” included with the ZR-8 for electrodes within the rating of this A fuel shut off valve is not required on the ZR-8 unit and recommended welding currents of each.

  • Page 20: Wire Feed Welding Processes (Constant Voltage)

    C25 (75% Argon - 25% CO ). The welding ranges the AFTERFLOW CONTROL is set above 10 sec- onds that can be used with the ZR-8 are shown in the fol- lowing table: Diameter Wire Speed Approximate Wire Feed Welding Processes (in.)

  • Page 21: Auxiliary Power

    Auxiliary Power The ZR-8 can provide up to 8,000 watts of 115/230 volts AC, single phase 60Hz power for continuous use. The front of the machine includes three recepta- cles for connecting the AC power plugs; one 50 amp 115/230 volt NEMA 14-50R receptacle and two 20 amp 115 volt NEMA 5-20R receptacles.

  • Page 22: Electrical Device Use With The Zr-8

    Duplexes 1.1 KW 3.4 KW 5.7 KW 8.0 KW *Maximum current draw from each 115V GFCI Duplex is 20 amps 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.

  • Page 23: Auxiliary Power While Welding

    “10” for maximum auxiliary power. 2. Take necessary steps to assure load is limited to the capacity of the ZR-8 by installing a 35 amp 230V double pole circuit breaker. Maximum rated load for the 230V auxiliary is 35 amperes.

  • Page 24: Connecting Zr-8 To Premises Wiring

    RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. WARNING 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. – 23 –...

  • Page 25: Maintenance

    MAINTENANCE Kohler CH20S 100 hr Safety Precautions Oil Filter 200 hr WARNING • The above schedule is for normal operating condi- Have qualified personnel do maintenance and tions. More frequent oil changes are required with troubleshooting work. dusty, high temperature and other severe operating conditions.

  • Page 26: Slip Rings

    Slip Rings When replacing, jumping, or otherwise connecting the battery to the battery cables, the proper polarity must be observed. Failure to observe A slight amount of darkening and wear of the slip rings the proper polarity could result in damage to the and brushes is normal.

  • Page 27: Troubleshooting

    TROUBLESHOOTING TROUBLE CAUSE WHAT TO DO Refer to wiring diagram & No welder or output power. Open in miscellaneous leads. check related leads. Open lead in flashing or field Refer to wiring diagram and check all related leads (200, circuit. 224, 200A, 200B, 201, 201A).

  • Page 28: Troubleshooting

    TROUBLESHOOTING TROUBLE CAUSE WHAT TO DO D. Engine will not go to high idle No voltage signal from the Check for disconnected or when using auxiliary power. current sensor. broken leads in idler sensing circuit. Auxiliary power load less than Idler may not function with less 100 to 150 watts.
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  • Page 31: Connection Diagrams

    M 1 7 4 8 6 CONNECTION OF ZR-8 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 32: Dimension Print

    – 31 –...
  • Page 33 Now Available...12th Edition New Lessons in Arc Welding The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques; With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects, since 1933, the Procedure Handbook is considered by many to such as distortion;...
  • Page 34 ● ● ● 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 35 ● ● ● 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 36 • 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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