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IM894-B
®
March, 2010
VANTAGE 500 (CE)
For use with machines having Code Numbers: 11298, 11299, 11524, 11525, 11574, 11575
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, OPER-
ATE OR REPAIR THIS EQUIP-
MENT WITHOUT READING
THIS MANUAL AND THE SAFE-
TY PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, thi
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i i 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. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii 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” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 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 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product T Th ha an nk k Y Yo ou u ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchas
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vi vi SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln
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vii vii SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincol
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viii viii TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Machine Specification ...................................................................................................A-2 Safety Precautions ...................................................
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ix ix TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................................................D-1 Engine Service Items.............................................................................................D-1 E
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - VANTAGE® 500 (CE) (K2503-1, -2, -3, -4) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (ltrs.) System Perkins 4 cylinder 135.6(2.2) 12VDC Battery & Oil: Fuel: 15 gal. 404C-22T 37.2 HP High Idle 1575 starter 8.45Qts. (8L) (57 L) 11298, 11299 1500 RPM Bore x Stroke inch (mm) (Group 34; 65
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A-2 A-2 INSTALLATION MACHINE SPECIFICATIONS MODEL NUMBERS K2503-1, -3 (UK) K2503-2, -4 (EUROPE) 400V (3 Ph) x 1 Receptacles 400V (3 Ph) x 1 230V (1 Ph) x 2 230V (1 Ph) x 1 (5) 14 Pin Connector 115V x 1 6 Pin Connector 14 Pin Connector 6 Pin Connector 4-pole, 25Amp Residual Current Device (RCD) 4-pole, 25Amp (30mA trip current) (30mA trip current) 3 Phase,25 Amp x 1 Circuit Breakers (Thermal/Magnetic) 3 Phase,25 Amp x 1 1 phase, 15 Amp x 2 1 phase, 15 Amp x 1 for 230V 30 Amp x 2 for
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A-3 A-3 INSTALLATION SAFETY PRECAUTIONS FIGURE A.1 WARNING (VRD)-VOLTAGE REDUCTION DEVICE SWITCH IS LOCATED IN THIS AREA. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. ------------------------------------------------------------------------ ELECTRIC SHOCK can kill. • Do not touch electrica
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A-4 A-4 INSTALLATION 1. Design capacity of trailer vs. weight of Lincoln equipment and WARNING likely additional attachments. 2. Proper support of, and attachment to, the base of the welding • Lift only with equipment of ade- equipment so there will be no undue stress to the framework. quate lifting capacity. 3. Proper placement of the equipment on the trailer to insure • Be sure machine is stable when lift- stability side to side and front to back when being moved and ing. when standing by
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A-5 A-5 INSTALLATION OIL MUFFLER OUTLET PIPE The VANTAGE® 500 (CE) is shipped with the engine crankcase Using the clamp provided secure the outlet pipe to the outlet tube filled with high quality SAE 10W-30 Oil that meets classification CG- with the pipe positioned such that it will direct the exhaust in the 4 or CH-4 for diesel engines. Check the oil level before starting the desired direction. Tighten using a 9/16"(14mm) socket or wrench. engine. If it is n
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A-6 A-6 INSTALLATION WELDING OUTPUT CABLES ELECTRICAL CONNECTIONS With the engine off connect the electrode and work cables to the output studs. The welding process dic- MACHINE GROUNDING tates the polarity of the electrode cable. These con- Because this portable engine driven welder creates its nections should be checked periodically and tightened own power, it is not necessary to connect its frame to with a 3/4"(19mm) wrench. an earth ground, unless the machine is connected to premises wir
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A-7 A-7 INSTALLATION CONNECTION OF LINCOLN ELECTRIC AUXILIARY POWER WIRE FEEDERS The auxiliary power capacity is 16,500 watts Peak, Connection of LN-15 to the VANTAGE® 500 (CE) 14,500 Watts Continuous of 50 Hz, three phase power. The auxiliary power capacity rating in watts is 1. Shut the welder off. equivalent to volt-amperes at unity power factor. The max permissible current of the 400 VAC output is 22 2. For electrode Positive, connect the electrode amps. Output voltage is within ± 10% at
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A-8 A-8 INSTALLATION WARNING Connection of the LN-25 to the VANTAGE® 500 (CE). Shut off welder before making any electrical connections. ------------------------------------------------------------------------ The LN-25 with or without an internal contactor may be used with the VANTAGE® 500 (CE). See the appropriate connection diagram in Section F. NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the VANTAGE® 500 (CE). 1. Shut the welder
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B-1 B-1 OPERATION • Add oil (if necessary) to bring the level up to the full SAFETY PRECAUTIONS mark. Do not overfill. Close engine door. • Check radiator for proper coolant level. (Fill if nec- WARNING essary). • See Engine Owner’s Manual for specific oil and coolant recommendations. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine WARNING starting, operati
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B-2 B-2 OPERATION FIGURE B.1 1 11 2 9 3 10 4 14 13 15 12 7 17 8 22 16 21 20 18 5 19 6 When in the TOUCH START TIG mode and when an Amptrol is WELDING CONTROLS (Figure B.1) connected to the 6-Pin Connector, the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of 1. OUTPUT CONTROL- The OUTPUT dial is used to preset the the Amptrol. output voltage or current as displayed on the digital meters for the five welding modes. When in the CC-STICK, DOWNHILL PIPE, ARC GOUGING or
