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IM826-A
October, 2009
® ®
AIR VANTAGE 500 CUMMINS
For use with machines having Code Numbers: 11069, 11417
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 c
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i SAFETY i WARNING CALIFORNIA PROPOSITION 65 WARNINGS For Diesel Engines: diesel engine exhaust and For Gasoline Engines: The engine exhaust from this some of its constituents are known to the State of product contains chemicals known to the State of California to cause cancer, birth defects, and other California to cause cancer, birth defects, or other reproductive harm. reproductive harm. ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHIL
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ii SAFETY ii ARC RAYS can burn. ELECTRIC SHOCK 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and can kill. the rays of the arc when welding or observing open arc welding. Headshield 3.a. The electrode and work (or ground) circuits and filter lens should conform to ANSI are electrically “hot” when the welder is on. Z87.1 standards. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free 4.b.Use suitable clothing made from
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iii SAFETY iii CYLINDER may explode WELDING and CUTTING 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 SAFETY iv 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté specifiques qui parraissent dans ce la masse. Un court-circuit accidental peut provoquer un manuel aussi bien que les précautions de sûreté générales échauffement et un risque d’incendie.
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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 equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchaser
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vi vi TABLE OF CONTENTS Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Location / Ventilat
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vii vii TABLE OF CONTENTS Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 _________________________________________________________________________________________________ Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A-1 INSTALLATION A-1 TECHNICAL SPECIFICATIONS - AIR VANTAGE® 500 CUMMINS (K2325-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System Cummins 4 cylinder High Idle 1900 199 cu. in 12VDC battery Fuel B3.3 56HP (42 kw) Low Idle 1425 (3.3L) & Starter (25 US gal) Diesel Engine @ 1800 RPM Full Load 1800 94.6L Bore x Stroke Oil: (2 US gal) 3.74” x 4.53” 7.5L (95mm x 115mm) Coolant: (2.6 US gal) 9.8L RATED OUTPUT @ 104°F(40°C) - WELDER Duty Cyc
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A-2 INSTALLATION A-2 Read this entire installation section before you start LOCATION / VENTILATION installation. The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid restricting the SAFETY PRECAUTIONS cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area. WARNING CAUTION Do not attempt to use this equipment until you have thoroughly read all operating and maintenance m
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A-3 INSTALLATION A-3 LIFTING HIGH TEMPERATURE OPERATION The AIR VANTAGE® 500 lift bale should be used to lift the At temperatures above 40°C (104°F), output voltage derating machine. The AIR VANTAGE® 500 is shipped with the lift bale may be necessary. For maximum output current ratings, derate retracted. Before attempting to lift the AIR VANTAGE® 500 the lift welder voltage rating 2 volts for every 10°C (21°F) above 40°C bale must be secured in a raised position. Secure the lift bale as (104°F).
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A-4 INSTALLATION A-4 ENGINE COOLANT PRE-OPERATION ENGINE AND COMPRESSOR SERVICE WARNING WARNING HOT COOLANT can burn skin. READ the engine and compressor operating and maintenance instructions supplied with this machine. •Do not remove cap if radiator is hot. • Keep hands away from the engine muffler or HOT engine parts. ------------------------------------------------------------------------------------- • Stop engine and allow to cool before fuelling. The welder is shipped with the engine and
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A-5 INSTALLATION A-5 The AIR VANTAGE® 500 is shipped with the negative battery WELDING TERMINALS cable disconnected. Before you operate the machine, make sure The AIR VANTAGE® 500 is equipped with a toggle switch for the Engine Switch is in the OFF position and attach the selecting "hot" welding terminals when in the "WELD disconnected cable securely to the negative (-) battery terminal. TERMINALS ON" position or "cold" welding terminals when in the Remove the insulating cap from the negative ba
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A-6 INSTALLATION A-6 STANDBY POWER CONNECTIONS REMOTE CONTROL The AIR VANTAGE® 500 is suitable for temporary, standby or emergency power using the engine manufacturer’s OUTPUT recommended maintenance schedule. The AIR VANTAGE® 500 is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or The AIR VANTAGE® 500 can be permanently installed as a K857-1 Remote Control or for TIG welding, the K870 foot Amptrol standby power unit for 240 volt-3 wire, 50 amp serv
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A-7 INSTALLATION A-7 2. Take necessary steps to assure load is limited to the capacity 3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-50) to the of the AIR VANTAGE® 500 by installing a 50 amp, 240 VAC double-pole circuit breaker using No. 6, 4 conductor cable of double pole circuit breaker. Maximum rated load for each leg the desired length. (The 50 amp, 120/240 VAC plug is of the 240 VAC auxiliary is 50 amps. Loading above the rated available in the optional K802R plug kit.) output will red
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A-8 INSTALLATION A-8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical connections. ------------------------------------------------------------------------------------- CONNECTION OF LN-7, LN-8 OR LN-742 TO THE AIR VANTAGE® 500 • Shut the welder off. • Connect the LN-7, LN-8 OR LN-742 per instructions on the appropriate connection diagram in the DIAGRAMS section. • Set the “WIRE FEEDER VOLTMETER” switch to either “+” or “- ” as required by the
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A-9 INSTALLATION A-9 CONNECTION OF THE LN-25 TO THE AIR CONNECTION OF MAGNUM SC SPOOL GUN TO VANTAGE® 500 THE AIR VANTAGE® 500 (SEE SECTION F) The LN-25 with or without an internal contactor may be used with the AIR VANTAGE® 500. 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 AIR VANTAGE® 500. • Shut the welder off. • For electrode Positive, connect the electrode cable from
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B-1 OPERATION B-1 SAFETY INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section before operating The AIR VANTAGE® 500 is a diesel engine-driven welding power source. The machine uses a brush type alternating current your AIR VANTAGE® 500. generator for DC multi-purpose welding, for 120/240 VAC single phase and 240V three phase auxiliary standby power. The AIR VANTAGE® 500 also has a rotary screw 60 cfm air compressor WARNING built in.The welding control system uses state of th
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B-2 OPERATION 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 6 9 4 5 7 8 10 3 11 13 20 12 15 21 14 19 24 25 23 1 22 2 16 18 17 26 27 28 3. HOUR METER ENGINE CONTROLS (Items 1 through 9) The hour meter displays the total time that the engine has been 1. RUN STOP SWITCH running. This meter is a useful indicator for scheduling preventive Tog
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B-3 OPERATION B-3 6. OIL PRESSURE GAUGE c. When welding ceases and the AC power load is turned off, a fixed time delay of approximately 12 seconds The gauge displays the engine oil pressure when the engine is starts. running. d. If the welding or AC power load is not restarted before the end of the time delay, the idler reduces the engine 7. ENGINE PROTECTION speed to low idle speed. The yellow engine protection light remains off with proper oil e. The engine will automatically return to high i
