Lincoln Electric TIG MODULE IM528-B User manual

TIG Module
OPERATOR’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 ... 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.
R
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © 2005 Lincoln Global Inc.

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. 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
cancer, 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
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
vaporizing 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.

TIG MODULE
- ii -
ii
SAFETY
ii
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 to
form phosgene, a highly toxic gas, and other irritating
products.
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

TIG MODULE - iii -
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
circuits. This can create fire hazards or overheat lifting
chains or cables until they fail.
6.h. Also see item 1.c.

TIG MODULE
- iv -
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les
instructions et les précautions de sûretéspecifiques qui
parraissent dans ce manuel aussi bien que les précautions de
sûretégénérales suivantes:
SûretéPour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits àl’électrode et àla piéce sont sous tension
quand la machine àsouder 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 couchépour 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 àsouder en bon et sûrétat
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 connectésàdeux machines à
souder parce que la tension entre les deux pinces peut
être le total de la tension àvide des deux machines.
f. Si on utilise la machine àsouder 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
rayonnement 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 àproximitéau
soudage àl’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,
pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécuritédans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones oùl’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dûaux étincelles.
7. Quand on ne soude pas, poser la pince àune endroit isoléde
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
levage, 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 SÛRETÉPOUR
LES MACHINES ÀSOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier àla terre le chassis du poste conformement au code
de l’électricitéet aux recommendations du fabricant. Le
dispositif de montage ou la piece àsouder doit être branché
àune bonne mise àla terre.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux àl’interieur de poste, la
debrancher àl’interrupteur àla boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûretéàleur
place.
Mar. ‘93

TIG MODULE - v -
vv
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. 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.

TABLE OF CONTENTS
Page
Safety .....................................................................................................................i-iv
Installation................................................................................................................1-17
Technical Specifications ............................................................................................1
Input and Rated Capacities
Recommended Welding Cables
Physical Dimensions
Location .....................................................................................................................2
Environmental Protection...........................................................................................2
High Frequency Interference Protection....................................................................2
Supply Connections...................................................................................................3
Input & Output Connections.......................................................................................3
Installation of Field Installed Accessories..................................................................4
Installation with a Power Source...........................................................................5-17
Ranger 8 Installation...........................................................................................5-8
Ranger 9 Installation.........................................................................................9-10
Ranger 10 & Ranger 300 D Installation..........................................................11-12
Ranger 10-LX & Ranger 300 DLX Installation................................................13-14
Installation with other Lincoln Power Sources ................................................15-17
Operation................................................................................................................18-30
Safety Instructions ...................................................................................................18
Graphic Symbols......................................................................................................19
Product Description..................................................................................................20
Recommended Processes and Equipment..............................................................20
Design Summary .....................................................................................................20
Controls and Settings .........................................................................................21-22
Ranger 8 Operation............................................................................................23-24
Figure 9....................................................................................................................25
Ranger 9 Operation .................................................................................................26
Ranger 10 & Ranger 300 D Operation.....................................................................27
Ranger 10-LX & Ranger 300 DLX Operation...........................................................28
Operation on other Lincoln Power Sources.............................................................29
TIG Welding Information..........................................................................................30
Accessories.................................................................................................................31
Maintenance ................................................................................................................32
Safety Precautions...................................................................................................32
Periodic Maintenance ..............................................................................................32
Troubleshooting ....................................................................................................33-36
How To Use Troubleshooting Guide........................................................................33
Troubleshooting Guide .......................................................................................34-36
Wiring Diagram ...........................................................................................................37
Parts Manual ...................................................................................................Appendix
TIG MODULE
- vi -

INSTALLATION
TECHNICAL SPECIFICATIONS - 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.
(MIN. TO MAX.)
Duty Cycle
100%
60%
20%
Duty Cycle
100%
60%
20%
Amps
200 amps AC/DC
300 amps AC/DC
400 amps AC/DC
Cable sizes* (mm2)
#2 AWG (30)
#1 AWG (35)
#1/0 AWG (50)
INPUT - SINGLE PHASE ONLY
RATED CAPACITIES
RECOMMENDED WELDING CABLES
Height Width Depth Weight
12.0 in. 15.0 in. 10.5 in. 33 lbs
305 mm 381 mm 267 mm (15 kg)
PHYSICAL DIMENSIONS
(*) Correct Cable size if the cable length is 150 feet (45.7 meters) or less.
Insulation Class 155(F)
–1–
TIG MODULE

–2–
INSTALLATION
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.
LOCATION
The TIG Module can be mounted in or carried to any
convenient location. It is designed to be portable. If
placed on the roof of engine welders, it must be
mounted securely. A Docking Kit option is available
for this purpose. See the Accessories section.
ENVIRONMENTAL PROTECTION
This accessory qualifies for an IP23 rating. It is suited
for use in damp, dirty and dusty locations. (In
locations where there are large amounts of conductive
metal or salt particles in the air, additional
maintenance may be required.) It is protected against
rainfall. Excessive moisture can, however, cause
short term operational difficulties. Difficulties can
occur with the spark gap; it may not “spark”when the
unit is first turned on after prolonged exposure to
moisture. Usually, allowing the unit to operate for 5 to
15 minutes will allow the spark gap to dry out, and
return to normal operation.
HIGH FREQUENCY INTERFERENCE
PROTECTION
Since the spark gap oscillator in the TIG Module is
similar to a radio transmitter, improper installation can
result in radio and TV interference or problems with
nearby electronic equipment.
Radiated interference can develop in the following
four ways:
1. Direct interference radiated from the welder and
the TIG Module.
ELECTRIC SHOCK can kill.
•Only qualified personnel should perform
this installation.
•Turn the Power Source input power OFF
at the disconnect switch or stop the
engine before attempting to connect the
TIG Module
•Do not touch electrically hot parts.
2. Direct interference radiated from the welding leads.
3. Direct interference radiated from feedback into the
power lines.
4.Interference from reradiation of “pickup”by
ungrounded metallic objects.
Keeping these contributing factors in mind, installing
equipment per the following instructions should
minimize problems.
1. Keep the power source input supply lines as short
as possible and completely enclose them in rigid
metallic conduit or equivalent shielding for a
minimum distance of 50 feet (15.2 m). There
should be good electrical contact between this
conduit and the welder. Both ends of the conduit
should be connected to a driven ground and the
entire length should be continuous.
2. Keep the work and electrode leads as short as
possible and as close together as possible.
Lengths should not exceed 25 feet (7.6 m). Tape
the leads together when practical.
3. Be sure the torch and work cable rubber coverings
are free of cuts and cracks that allow high
frequency leakage. Cables with high natural
rubber content, such as Lincoln Stable-Arc®better
resist high frequency leakage than neoprene and
other synthetic rubber insulated cables.
4. Keep the torch in good repair and all connections
tight to reduce high frequency leakage.
5. The work terminal must be connected to a ground
within ten feet of the welder, using one of the
following methods:
a) A metal underground water pipe in direct
contact with the earth for ten feet or more.
b) A 3/4”(19 mm) galvanized pipe or conduit
or a 5/8”(16 mm) solid galvanized iron or
steel or copper rod driven at least eight
feet into the ground.
The ground should be securely made and the
grounding cable should be as short as possible using
cable of the same size as the work cable, or larger.
Grounding to the building frame electrical conduit or a
long pipe system can result in reradiation, effectively
making these members radiating antennas.
NOTE: The welder frame MUST also be grounded.
The work terminal ground does not ground
the welder frame.
WARNING

INSTALLATION
–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.
8. When the welder is enclosed in a metal building,
several good earth driven electrical grounds (as in
5 (b)) around the periphery of the building are
recommended.
SUPPLY CONNECTIONS
Control cables are needed to connect the TIG
Module’s 9-pin Input Receptacle to the power source.
Four different cables are available. The proper choice
of cable depends on the power source being used.
Included in this report are charts which specify which
cable is used with a particular power source. The
cables come in standard 5 ft.(1.5m) lengths. 22(6.7m)
and 45(13.7) ft. extensions are available.
Input power should be nominally 115 volts AC, but the
TIG Module will operate properly on any AC voltage
from 60 to 130 volts, 50 or 60 Hz. Input current draw
is 1.3 amps at 115 volts.
INPUT AND OUTPUT CONNECTIONS
Input Connections
The user must provide welding cables for the
connections between the work and electrode
terminals of the power source, and the “FROM
POWER SOURCE WORK”and “FROM POWER
SOURCE ELECTRODE”terminals of the TIG
Module. All connections are made with 1/2-13
threaded stud output terminals. Choose cables
according to the output currents and duty cycles
listed below.
200 Amps 100% Duty Cycle #2 AWG(30mm2)
(minimum) Cable
300 Amps 60% Duty Cycle #1 AWG(35mm2)
(minimum) Cable
400 Amps 20% Duty Cycle #1/0 AWG(50mm2)
(minimum) Cable
These ratings are for cables lengths of 150
ft.(46.0m) or less.
Note that two of the studs are labeled “FROM
POWER SOURCE”; these are to be connected to
the power source work and electrode terminals. If
the power source output terminals are not labeled
“WORK”and “ELECTRODE”, the TIG Module
“FROM POWER SOURCE ELECTRODE”
terminal should go to the power source output
terminal which matches the desired welding
polarity. This is the negative (-) terminal when
welding DC-. The choice of power source
terminal will have no effect when welding AC.
TIG Torch and Workpiece Connections
One terminal is labeled “TO TIG TORCH”. Use
that terminal for the TIG torch connection. TIG
torches come in 12.5ft.(3.8m) and 25ft.(7.6m)
lengths; use the shorter size whenever possible to
minimize the possibility of high frequency
interference.
The last terminal is labeled “TO WORKPIECE”.
Use short lengths whenever possible to minimize
the possibility of high frequency interference.
Shielding Gas Connections
The gas valve connections are labeled “GAS
INPUT”and “GAS OUTPUT”. Any torch and gas
supply conforming to Compressed Gas
Association (CGA) standards can be connected
via the 5/8-18 right hand threaded fittings. The
cylinder of shielding gas must be equipped with a
regulator and flowmeter. Install a hose between
the flowmeter and the input fitting.
Water Valve Connection
The optional K844-1 Water Valve Kit can be
installed in the TIG Module to provide on/off flow
control for cooling water. The water valve opens
and closes at the same time as the gas valve, so
cooling water flows during the afterflow period.
Connections are made via the two 5/8-18 left
hand threaded connections. If using a water-
cooled torch with a free running water supply,
install a water line between the water supply and
the “WATER INPUT”fitting on the TIG Module.
Include a strainer in the supply line to prevent dirt
particles from obstructing the water flow in the
valve and cooling chamber of the TIG torch.
Failure to do so could result in overheating of the
water-cooled torch. Connect the torch water line
to the “WATER OUTPUT”fitting. Use a
nonmetallic drain line from the TIG torch power
block to the drain.

–4–
INSTALLATION
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.
INSTALLATION OF FIELD INSTALLED
ACCESSORIES
Installation of the K963 Hand Amptrol, K870 Foot
Amptrol, and K814 Arc Start Switch is as follows:
Connect the 6-pin MS-type circular connector to
the Remote Receptacle on the TIG Module.
Secure with the threaded collar.
Installation of the K936-[ ] Input Cables and K937-[ ]
Extension Cables is as follows:
Connect the 9-socket MS-type circular connector
on the Input Cable to the Input Receptacle on the
TIG Module. Secure with the threaded collar. If
one or more K937-[ ] Extension Cables are used,
connect them between the TIG Module and the
K936-[ ] Input cable.
Installation instructions for the K938-1 Contactor Kit,
K844-1 Water Valve Kit and the K939-1 Docking Kit
are included with those kits.

INSTALLATION 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. The Remote Kit
installation is identified by the presence of a 6-pin
remote connector located between the output
studs.
Refer to the Connection Diagrams Figures 1 and
2. Figure 1 is for the Ranger 8, and figure 2, for
the Ranger 8 with the K892-1 Remote Kit
installed. Make sure all connections are tight
before proceeding.
INSTALLATION
–5–
TIG MODULE
RANGER 8 (WITH NO K892-1 REMOTE KIT) AND THE TIG MODULE
REQUIRED EQUIPMENT
Control
Cable Contactor Kit Work and Electrode
Leads from
Ranger 8 to
TIG Module
TIG
Torch Work Lead Shielding Gas, Regulator,
Flowmeter
Arc Start
Switch
K936-4
9-pin to
115V Plug
K938-1
Field
Installed
User Supplied;
Length as
Req’d. Cable
Sized to Match
Current and
Duty Cycle
User
Supplied User Supplied; Length as
Req’d. Cable
Sized to Match
Current and
Duty Cycle
User
Supplied K814
RANGER 8 (WITH NO K892-1 REMOTE KIT) AND THE TIG MODULE
OPTIONAL EQUIPMENT
Control
Cable
Extension
Water
Valve Docking Kit
K937 - [ ]
Extension
9-pin to 9-pin
K844-1 K939-1
Mounts to
Ranger 8 Roof
TABLE 1

INSTALLATION
–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 SERIALNO.
THELINCOLN ELECTRIC CO. CLEVELAND,OHIO U.S.A.
INPUT
PORTABLEHI-FREQ
WARNING
OFF
O
ON
L9440
1
HIGH FREQUENCY
LOCAL
115V 1.3 A 50/60Hz
LINCOLN R
ELECTRIC
0
1
2
3
4
56
7
8
9
10
CURRENT
SWITCH
TM
CURRENT CONTROL
REMOTEAMPTROL
HF
STARTONLY
20%
350A
60% 100%
250A 180A
RATEDCAPACITY
20ATO350A
WARNING
Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD before servicing.
Do not touch electrically live parts.
Keep guards in place. Keep away from moving parts.
Only qualified personnel should install,use or service this equipment.
5
10
15
20
25 30 35
40
45
50
55 S
CONTINUOUS
OFF
2
MODEL CODE SERIALNO.
THELINCOLN ELECTRIC CO. CLEVELAND,OHIO U.S.A.
INPUT
PORTABLEHI-FREQ
WARNING
OFF
O
ON
L9440
1
LOCAL
115V 1.3 A 50/60Hz
LINCOLN R
ELECTRIC
0
1
2
3
4
56
7
8
9
10
CONTROL
TM
REMOTEAMPTROL
HF
STARTONLY
20%
350A
60% 100%
250A 180A
RATEDCAPACITY
20ATO350A
TO GAS
INPUT
FITTING
FLOWMETER
ARGON GAS
CYLINDER
K814 ARC START SWITCH
M17530
12-1-94
REGULATOR
WELDING CABLES MUST BE PROPERLY SIZED FOR THE CURRENT AND DUTY CYCLE OF APPLICATION
NOTE: This diagram is for reference only. It was accurate at the time of printing , however Lincoln Electric reserves the right to make improvements and modifications as necessary, if you supect this information to be inaccurate, write to the Service Department for a replacement. Give the equipment code number..

TIG MODULE –7–
INSTALLATION
RANGER 8 (WITH THE OPTIONAL K892-1 REMOTE KIT INSTALLED) AND THE TIG MODULE
REQUIRED EQUIPMENT
Control
Cable Contactor Kit Work and Electrode
Leads from
Ranger 8 to
TIG Module
TIG
Torch Work Lead Shielding Gas, Regulator,
Flowmeter
Arc Start
Switch
K936-3
9-pin to
6-pin
plus
115V Plug
K938-1
Field
Installed
User Supplied;
Length as
Req’d. Cable
Sized to Match
Current and
Duty Cycle
User
Supplied User Supplied; Length as
Req’d. Cable
Sized to Match
Current and
Duty Cycle
User
Supplied See Optional
Equipment
Below
RANGER 8 (WITH THE OPTIONAL REMOTE KIT INSTALLED) AND THE TIG MODULE
OPTIONAL EQUIPMENT
Control
Cable
Extension
Water
Valve Arc Start Switch Hand Amptrol Foot Amptrol Docking Kit
K937 - [ ]
Extension
9-pin to 9-pin
K844-1 K814 K963 K870 K939-1
Mounts to
Ranger 8 Roof
TABLE 2

INSTALLATION
–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 SERIALNO.
THELINCOLN ELECTRIC CO. CLEVELAND,OHIO U.S.A.
INPUT
PORTABLEHI-FREQ
WARNING
OFF
O
ON
L9440
1
HIGH FREQUENCY
LOCAL
115V 1.3 A 50/60Hz
LINCOLN R
ELECTRIC
0
1
2
3
4
56
7
8
9
10
CURRENT
CONTROL
SWITCH
TM
CURRENT CONTROL
REMOTEAMPTROL
HF
STARTONLY
20%
350A
60% 100%
250A 180A
RATEDCAPACITY
20ATO350A
WARNING
Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD before servicing.
Do not touch electrically live parts.
Keep guards in place. Keep away from moving parts.
Only qualified personnel should install,use or service this equipment.
5
10
15
20
25 30 35
40
45
50
55 S
CONTINUOUS
OFF
POWER
2
AFTERFLOW
MODEL CODE SERIALNO.
THELINCOLN ELECTRIC CO. CLEVELAND,OHIO U.S.A.
INPUT
PORTABLEHI-FREQ
WARNING
OFF
O
ON
L9440
1
HIGH FREQUENCY
LOCAL
115V 1.3 A 50/60Hz
LINCOLN R
ELECTRIC
0
1
2
3
4
56
7
8
9
10
CURRENT
CONTROL
SWITCH
TM
CURRENT CONTROL
REMOTEAMPTROL
HF
STARTONLY
20%
350A
60% 100%
250A 180A
RATEDCAPACITY
20ATO350A
TO GAS
INPUT
FITTING
FLOWMETER
ARGON GAS
CYLINDER
K870 FOOT AMPTROL
-OR-
-OR-
K963 HAND AMPTROL
K814 ARC START SWITCH
M17531
4-19-96D
REGULATOR
WELDING CABLES MUST BE PROPERLY SIZED FOR THE CURRENT AND DUTY CYCLE OF APPLICATION
NOTE: This diagram is for reference only. It was accurate at the time of printing , however Lincoln Electric reserves the right to make improvements and modifications as necessary, if you supect this information to be inaccurate, write to the Service Department for a replacement. Give the equipment code number..
TIG MODULE

TIG MODULE –9–
INSTALLATION
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.
RANGER 9 AND THE TIG MODULE
REQUIRED EQUIPMENT
Control
Cable Work and Electrode
Leads from
Ranger 9 to
TIG Module
TIG
Torch Work Lead Shielding Gas, Regulator,
Flowmeter
Arc Start
Switch
- OR -
Amptrol
K936-1
9-pin to 14-pin User Supplied; Length as Req’d.
Cable Sized to
Match Current
and Duty Cycle
User
Supplied User Supplied; Length as Req’d.
Cable Sized to
Match Current
and Duty Cycle
User
Supplied See Optional
Equipment
Below
RANGER 9 AND THE TIG MODULE
OPTIONAL EQUIPMENT
Control Cable
Extension Water Valve Arc Start Switch Hand Amptrol Foot Amptrol Docking Kit
K937 - [ ]
Extension
9-pin to 9-pin
K844-1
Field
Installed
K814 K963 K870 K939-1
Mounts to
Ranger 9 Roof
TABLE 3

INSTALLATION
–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 SERIALNO.
THELINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
INPUT
PORTABLEHI-FREQ
WARNING
OFF
O
ON
L9440
1
HIGH FREQUENCY
LOCAL
115V 1.3 A 50/60Hz
LINCOLN R
ELECTRIC
0
1
2
3
4
56
7
8
9
10
CURRENT
CONTROL
SWITCH
TM
CURRENT CONTROL
REMOTEAMPTROL
HF
STARTONLY
20%
350A
60% 100%
250A 180A
RATEDCAPACITY
20ATO350A
WARNING
Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD before servicing.
Do not touch electrically live parts.
Keep guards in place. Keep away from moving parts.
Only qualified personnel should install,use or service this equipment.
5
10
15
20
25 30 35
40
45
50
55 S
CONTINUOUS
OFF
POWER
2
AFTERFLOW
MODEL CODE SERIALNO.
THELINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
INPUT
PORTABLEHI-FREQ
WARNING
OFF
O
ON
L9440
1
HIGH FREQUENCY
LOCAL
115V 1.3 A 50/60Hz
LINCOLN R
ELECTRIC
0
1
2
3
4
56
7
8
9
10
CURRENT
CONTROL
SWITCH
TM
CURRENT CONTROL
REMOTEAMPTROL
HF
STARTONLY
20%
350A
60% 100%
250A 180A
RATEDCAPACITY
20ATO350A
TO GAS
INPUT
FITTING
FLOWMETER
ARGON GAS
CYLINDER
K870 FOOT AMPTROL
-OR-
-OR-
K963 HAND AMPTROL
K814 ARC START SWITCH
M17532
4-19-96D
REGULATOR
WELDING CABLES MUST BE PROPERLY SIZED FOR THE CURRENT AND DUTY CYCLE OF APPLICATION
NOTE: This diagram is for reference only. It was accurate at the time of printing , however Lincoln Electric reserves the right to make improvements and modifications as necessary, if you supect this information to be inaccurate, write to the Service Department for a replacement. Give the equipment code number..
TIG MODULE

TIG MODULE –11 –
INSTALLATION
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. Make
sure all connections are tight before proceeding.
TABLE 4
RANGER 10 / RANGER 300 D AND THE TIG MODULE
REQUIRED EQUIPMENT
Control
Cable Contactor Kit Work and Electrode
Leads from
Ranger 10 to
TIG Module
TIG
Torch Work Lead Shielding Gas, Regulator,
Flowmeter
Arc Start
Switch
- OR -
Amptrol
K936-3
9-pin to
6-pin
plus
115V Plug
K938-1
Field
Installed
User Supplied;
Length as
Req’d. Cable
Sized to Match
Current and
Duty Cycle
User
Supplied User Supplied; Length as
Req’d. Cable
Sized to Match
Current and
Duty Cycle
User
Supplied See Optional
Equipment
Below
RANGER 10 / RANGER 300 D AND THE TIG MODULE
OPTIONAL EQUIPMENT
Control
Cable
Extension
Water
Valve Arc Start Switch Hand Amptrol Foot Amptrol Docking Kit
K937 - [ ]
Extension
9-pin to 9-pin
K844-1 K814 K963 K870 K939-1
Mounts to
Ranger 10
Roof

INSTALLATION
–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 SERIALNO.
THELINCOLN ELECTRIC CO. CLEVELAND,OHIO U.S.A.
INPUT
PORTABLEHI-FREQ
WARNING
OFF
O
ON
L9440
1
HIGH FREQUENCY
LOCAL
115V 1.3 A 50/60Hz
LINCOLN R
ELECTRIC
0
1
2
3
4
56
7
8
9
10
CURRENT
CONTROL
SWITCH
TM
CURRENT CONTROL
REMOTEAMPTROL
HF
STARTONLY
20%
350A
60% 100%
250A 180A
RATEDCAPACITY
20ATO350A
WARNING
Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD before servicing.
Do not touch electrically live parts.
Keep guards in place. Keep away from moving parts.
Only qualified personnel should install,use or service this equipment.
5
10
15
20
25 30 35
40
45
50
55 S
CONTINUOUS
OFF
POWER
2
AFTERFLOW
MODEL CODE SERIALNO.
THELINCOLN ELECTRIC CO. CLEVELAND,OHIO U.S.A.
INPUT
PORTABLEHI-FREQ
WARNING
OFF
O
ON
L9440
1
HIGH FREQUENCY
LOCAL
115V 1.3 A 50/60Hz
LINCOLN R
ELECTRIC
0
1
2
3
4
56
7
8
9
10
CURRENT
CONTROL
SWITCH
TM
CURRENT CONTROL
REMOTEAMPTROL
HF
STARTONLY
20%
350A
60% 100%
250A 180A
RATEDCAPACITY
20ATO350A
TO GAS
INPUT
FITTING
FLOWMETER
ARGON GAS
CYLINDER
K870 FOOT AMPTROL
-OR-
-OR-
K963 HAND AMPTROL
K814 ARC START SWITCH
M17533
11/96
REGULATOR
EF
WELDING CABLES MUST BE PROPERLY SIZED FOR THE CURRENT AND DUTY CYCLE OF APPLICATION. A T12246 BYPASS CAPACITOR ASBLY. MUST BE INSTALLED IN THE RANGER 10 TO PROTECT THE RANGER 10 FROM DAMAGE.
NOTE: This diagram is for reference only. It was accurate at the time of printing , however Lincoln Electric reserves the right to make improvements and modifications as necessary, if you supect this information to be inaccurate, write to the Service Department for a replacement. Give the equipment code number..
TIG MODULE

INSTALLATION
–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. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
THE ENGINE WELDER OPERATING MANUAL.
APPLICATIONS. SEE OPERATING MANUAL.
N.C. PLACE WELDER TERMINALS SWITCH TO " REMOTELY CONTROLLED" POSITION.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
N.D. PLACE OUTPUT CONTROL SWITCH IN "REMOTE CONTROL" POSITION.
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
N.E. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.
N.B. USE POLARITY SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE RANGE SWITCH TO A "STICK/WELD" POSITION.
FLOWMETER
K963-3 CONTROL CABLE
Keep guards in place. Keep away from moving parts.
WARNING
Only qualified personnel should install,use or service this equipment.
Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing.
INPUT
REGULATOR
TO GAS
FITTING
Do not touch electrically live parts.
CYLINDER
ARGON GAS
TO WORK
[ ]
NOTE: This diagram is for reference only. It was accurate at the time of printing , however Lincoln Electric reserves the right to make improvements and modifications as necessary, if you supect this information to be inaccurate, write to the Service Department for a replacement. Give the equipment code number..
TIG MODULE