IM800 RETURN TO MAIN MENU July, 2004 Vantage 500 CUMMINS For use with machines having Code Numbers: 10996 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. Most importantly, think before you act and be careful.
SAFETY i i WARNING CALIFORNIA PROPOSITION 65 WARNINGS For Diesel Engines: diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. For Gasoline Engines: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
SAFETY ii ARC RAYS can burn. 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.
SAFETY iii 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.
SAFETY iv iv PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse.
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! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi vi TABLE OF CONTENTS Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Location / Ventilation . . .
vii vii TABLE OF CONTENTS Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 _________________________________________________________________________________________________ Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION A-1 A-1 TECHNICAL SPECIFICATIONS - Vantage 500 CUMMINS (K2272-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting System Capacities Cummins B3.3 Diesel Engine 4 cylinder 56HP (42 kw) @ 1800 RPM High Idle 1900 Low Idle 1425 Full Load 1800 199 cu. in (3.3L) 12VDC battery & Starter Fuel (25 US gal) 94.6L Oil: (2 US gal) 7.5L Coolant: (2.6 US gal) 11.8L Bore x Stroke 3.74” x 4.
INSTALLATION A-2 Read this entire installation section before you start installation. A-2 LOCATION / VENTILATION The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area.
INSTALLATION A-3 A-3 LIFTING HIGH TEMPERATURE OPERATION The Vantage lift bale should be used to lift the machine. The Vantage is shipped with the lift bale retracted. Before attempting to lift the Vantage the lift bale must be secured in a raised position. Secure the lift bale as follows: At temperatures above 40°C (104°F), output voltage derating may be necessary. For maximum output current ratings, derate welder voltage rating 2 volts for every 10°C (21°F) above 40°C (104°F). a.
INSTALLATION A-4 PRE-OPERATION ENGINE SERVICE A-4 ENGINE COOLANT READ the engine operating and maintenance instructions supplied with this machine. WARNING WARNING HOT COOLANT can burn skin. • Stop engine while fueling. •Do not remove cap if radiator is hot. • Do not smoke when fueling. • Keep sparks and flame away from tank. ------------------------------------------------------------------------------------- • Do not leave unattended while fueling.
INSTALLATION A-5 The Vantage is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative (-) battery terminal. Remove the insulating cap from the negative battery terminal. Replace and tighten negative battery cable terminal. NOTE: This machine is furnished with a wet charged battery; if unused for several months, the battery may require a booster charge.
INSTALLATION A-6 A-6 STANDBY POWER CONNECTIONS REMOTE CONTROL OUTPUT The Vantage is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K936-2 hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CVWIRE modes and when a remote control is connected to the 6pin Connector, the auto-sensing circuit automatically switches the OUTPUT control from control at the welder to remote control.
INSTALLATION A-7 A-7 3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-50) to the double-pole circuit breaker using No. 6, 4 conductor cable of the desired length. (The 50 amp, 120/240 VAC plug is available in the optional K802R plug kit.) 2. Take necessary steps to assure load is limited to the capacity of the Vantage by installing a 50 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 50 amps.
INSTALLATION A-8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS A-8 CONNECTION OF AN LN-23P WIRE FEEDER TO THE VANTAGE • Shut the welder off. Shut off welder before making any electrical connections. • Connect the LN-23P per instructions on the appropriate connection diagram in the DIAGRAMS section. (NOTE): When connecting an LN-23P to the Vantage, a K350-1 adapter kit must be used.
INSTALLATION A-9 A-9 CONNECTION OF THE LN-25 TO THE VANTAGE The LN-25 with or without an internal contactor may be used with the Vantage. See the appropriate connection diagram in the DIAGRAMS section. NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the Vantage. • Shut the welder off. CONNECTION OF PRINCE XL SPOOL GUN TO THE VANTAGE Connection of the Prince XL Spool Gun requires the use of the K1849-1 Adapter Module. • Shut the Welder off.
OPERATION B-1 B-1 SAFETY INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section before operating The Vantage is a diesel engine-driven welding power source. The machine uses a brush type alternating current generator for DC multi-purpose welding and for 120/240 VAC auxiliary standby power. The welding control system uses state of the art Chopper Technology™. your Vantage.
OPERATION B-2 B-2 CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow. Figure B.1 Case Front Panel Controls 4 5 6 7 8 9 10 3 11 12 13 15 14 20 21 1 2 19 16 17 22 18 ENGINE CONTROLS (Items 1 through 9) 3. HOUR METER 1. RUN The hour meter displays the total time that the engine has been running. This meter is a useful indicator for scheduling preventive maintenance.
OPERATION B-3 6. OIL PRESSURE GAUGE The gauge displays the engine oil pressure when the engine is running. c. When welding ceases and the AC power load is turned off, a fixed time delay of approximately 12 seconds starts. d. If the welding or AC power load is not restarted before the end of the time delay, the idler reduces the engine speed to low idle speed. 7. ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal operating temperatures.
B-4 OPERATION WELDING CONTROLS (Items 10 through 19) 10. OUTPUT CONTROL: The OUTPUT dial is used to preset the output voltage or current as displayed on the digital meters for the four welding modes. When in the CC-STICK, DOWNHILL PIPE or CV-WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector, the auto-sensing circuit automatically switches the OUTPUT CONTROL from control at the welder to the remote control.
B-5 OPERATION 20. CIRCUIT BREAKERS B-5 ENGINE OPERATION These circuit breakers provide separate overload current protection for each 120V circuit at the 240V receptacle, each 120V receptacle, the 120VAC in the 14-Pin connector, the 42VAC in the 14-Pin connector and battery circuit overload protection. 21. 120VAC RECEPTACLES These two 120VAC (5-20R) receptacles with ground fault circuit interruption protection provide 120VAC for auxiliary power. Each receptacle has a 20 amp total rating.
OPERATION B-6 BREAK-IN PERIOD WELDER OPERATION The engine used to supply power for your welder is a heavy duty, industrial engine. It is designed and built for rugged use. It is very normal for any engine to use small quantities of oil until the breakin is accomplished. Check the oil level twice a day during the break-in period. In general this takes 50 to 100 hours of operation. DUTY CYCLE IMPORTANT B-6 Duty Cycle is the ratio of the uninterrupted on-load duration to 10 minutes.
OPERATION B-7 n general the ‘Touch Start’ feature avoids tungsten contamination without the use of a Hi-frequency unit. If the use of a high frequency generator is desired, the K930-2 TIG Module can be used with the Vantage. The settings are for reference. The Vantage is equipped with the required R.F. bypass circuitry for the connection of high frequency generating equipment. The Vantage and any high frequency generating equipment must be properly grounded.
OPERATION B-8 CV-WIRE MODE Connect a wire feeder to the Vantage and set welder controls according to the instructions listed earlier in this section. The Vantage in the ”CV-WIRE” position, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding). Welding can be finely tuned using the “ARC CONTROL”.
OPERATION B-9 B-9 TABLE B.4 Vantage Simultaneous Welding and Power Loads Welding Output at NEMA Voltage (V=.04I + 20) Permissible Power Watts (Unity Power Factor) 0-250A/30V 350A/34V 400A/36V 450A/38V 500A/40V Permissible Auxiliary Current in Amperes @ 120VAC * +/- 10% @ 240 VAC +/- 10% 12,000 8,100 5,600 2,900 0 100** 68** 46 24 0 50 34 23 12 0 * Each duplex receptacle is limited to 20 amps. ** Not to exceed 50A per 120 VAC branch circuit when splitting the 240 VAC output. TABLE B.
ACCESSORIES C-1 OPTIONAL FIELD INSTALLED ACCESSORIES K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240V, 50 amps. 120V plug may not be compatible with NEMA common household receptacles. K802-R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each and one dual voltage, full KVA plug rated at 120/240V, 50 amps, 120V plug is compatible with NEMA common household receptacles. K857 25 ft. (7.5 m) or K857-1 100 ft. (30.
MAINTENANCE D-1 SAFETY PRECAUTIONS D-1 ENGINE MAINTENANCE Refer to the “Periodic Checks” section of the Engine Operator’s Manual for the recommended maintenance schedule of the following: WARNING • Have a qualified technician do the maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • 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.
MAINTENANCE D-2 7. Inspect for holes and tears by looking through the element toward a bright light. Check for damaged gaskets or dented metal parts. Do not reuse damaged elements. Protect element from dust and damage during drying and storage. D-2 BATTERY HANDLING GASES FROM BATTERY can explode. • Keep sparks, flame and cigarettes away from battery. 8. Reinstall air filter element. After six cleanings replace air filter. A cleaned filter will have approximately 70% of the life of a new filter element.
MAINTENANCE D-3 CHARGING THE BATTERY When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The Vantage positive (+) battery terminal has a red terminal cover. If you need to charge the battery with an external charger, disconnect the negative cable first, then the positive cable before you attach the charger leads.
TROUBLESHOOTING E-1 E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING E-2 E-2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS Major Physical or Electrical Damage is 1. Contact your Local Lincoln Authorized Field Service Facility. Evident. Engine will not crank 1. Battery low. 2. Loose battery cable connections which may need Inspected, cleaned or tighten. 3. Faulty wiring in engine starting circuit. 4. Faulty engine starter.
TROUBLESHOOTING E-3 PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) E-3 RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Battery does not stay charged. 1. Faulty battery . 2. Faulty engine alternator. 3. Loose or broken lead in charging circuit. 4. Loose fan belt may need tightening. Engine will not idle down to low speed. 1. Idler switch in HIGH idle position, make sure switch is set to AUTO. 2. External load on welder or auxiliary power. 3. Mechanical problem in idler solenoid linkage. 4.
TROUBLESHOOTING E-4 PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) E-4 RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Engine goes to low idle but does not stay at 1. Faulty Peripheral PCB, Pull Coil/Battery low idle. PCB or Weld Control PCB. No welding output or auxiliary output. 1. Broken lead in rotor circuit. 2. Faulty field diode module. 3. Faulty Weld Control P.C. Board. 4. Faulty rotor. Welder has some/ no output and no control. 1. Faulty remote kit. Auxiliary output OK 2.
208 - J 77A 77B 76A 76B 75A 75B 2A 2B 4A 4B GND-B 8 16 1 9 6 J1 AMPHENOL,I.D. 6 8 1 M3 M5 M9 M2 M4 M6 M10 1 J7 CONTROL, MODE SEL.
F-2 DIAGRAMS CONNECTION DIAGRAM: Vantage 500 CUMMINS F-2
Vantage 500 CUMMINS TO WORK K867 UNIVERSAL ADAPTER PLUG 77 76 75 GND 21 4 2 32 31 41 42 81 82 SPARE } N.E. 21 4 2 32 31 77 76 75 GND N.D. N.E. SPLICE LEADS AND INSULATE. N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED,CONTROL IS AUTOMATICALLY SWITCHED TO REMOTE CONTROL. PLACE WIRE FEEDER SWITCH TO "WIRE FEEDER WITH CONTROL CABLE POSITION. N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY.
F-4 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS F-4
F-5 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS F-5
Vantage 500 CUMMINS TO WORK K867 UNIVERSAL ADAPTER PLUG 77 76 75 GND 21 4 2 32 31 41 42 81 82 SPARE } N.D. N.C. C B A GND 21 4 2 32 31 or service this equipment. Only qualified personnel should install,use Keep away from moving parts. Keep guards in place. N.D. SPLICE LEADS AND INSULATE. N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPICATIONS. SEE OPERATING MANUAL. N.B.
F-7 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS F-7
F-8 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS F-8
Vantage 500 CUMMINS + _ ELECTRODE CABLE TO WIRE FEED UNIT K595 CONTROL CABLE TO LN-8 INPUT CABLE PLUG TO WORK Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. Do not operate with panels open. Disconnect NEGATIVE (-) Battery lead before servicing. Do not touch electrically live parts. N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. SEE OPERATING MANUAL. N.B.
F-10 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS F-10
F-11 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS F-11
F-12 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS F-12
F-13 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS F-13
50.38 54.44 BOTTOM VIEW OF WELDER BASE. 19.63 23.69 42.35 50.15 63.10 45.38 * 37.30 14.63 * 6.55 CHANGE DETAIL: Revised overall height dimension. 6.53 * 24.97 6.56 * 42.00 46.35 50.81 31.50 5.86 * TRAILER MOUNTING HOLE LOCATIONS. Ref. DIMENSION PRINT M18962-3 A. 0 2 N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, EMPTY FUEL TANK AND COOLANT IN RADIATOR. 45.67 2.24 DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
l Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO l Keep flammable materials away. l Wear eye, ear and body protection. l Mantenga el material combustible l Protéjase los ojos, los oídos y el electrode with skin or wet clothing. l Insulate yourself from work and ground. l No toque las partes o los electrodos bajo carga con la piel o ropa mojada. l Aislese del trabajo y de la tierra.
l Keep your head out of fumes. l Use ventilation or exhaust to l Turn power off before servicing. l Do not operate with panel open or guards off. remove fumes from breathing zone. l Los humos fuera de la zona de respiración. l Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. l Gardez la tête à l’écart des fumées. l Utilisez un ventilateur ou un aspirateur pour ôter les fumées des zones de travail.
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