Lincoln Electric IM894-B manual

V ANT A GE 500 (CE) OPERA TOR’S MANUAL IM894-B March, 2010 Safety Depends on You L i n c o l n a r c w e l d i n g a nd c u t t i n g 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- M[...]

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. ________________________________________________[...]

ARC RA YS 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[...]

FOR ELECTRICALL Y 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[...]

iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v v T T h h a a n n k k Y Y o o u u 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 fo[...]

vi SAFETY vi 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 implement[...]

vii SAFETY vii 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 impleme[...]

viii viii T ABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Machine Specification ....................[...]

ix ix T ABLE OF CONTENTS Maintenance ......................................................................................................Section D Safety Precautions ......................................................................................... .......D-1 Routine Maintenance .............................................................[...]

VANTAGE ® 500 (CE) (1) Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced. (2) Reduced to less than ( 32V for Codes 11298, 11299 ) , ( 30V for Codes 11524, 11525, 11574, 11575 ) in the CC-stick Mode wh[...]

A-2 INST ALLA TION VANTAGE ® 500 (CE) A-2 MODEL NUMBERS K2503-1, -3 (UK) K2503-2, -4 (EUROPE) MACHINE SPECIFICA TIONS Receptacles Residual Current Device (RCD) Circuit Breakers (Thermal/Magnetic) Other Circuit Breakers 400V (3 Ph) x 1 230V (1 Ph) x 1 115V x 1 (5) 14 Pin Connector 6 Pin Connector 4-pole, 25Amp (30mA trip current) 3 Phase,25 Amp x 1[...]

A-3 INST ALLA TION VANTAGE ® 500 (CE) A-3 SAFETY PRECAUTIONS Only qualified personnel should install, use, or service this equipment. 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 mai[...]

A-4 INST ALLA TION VANTAGE ® 500 (CE) A-4 HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary. For maximum rating, derate the machine 1.0% for every 2000 ft. (610m) up to 6000 ft. (1828m) and 2.0% for every 2000 ft. (610m) over 6000 ft. (1828m). Due to new EPA and other local emissions regulations, modifications to the en[...]

OIL The VANTAGE® 500 (CE) is shipped with the engine crankcase filled with high quality SAE 10W-30 Oil that meets classification CG- 4 or CH-4 for diesel engines. Check the oil level before starting the engine. If it is not up to the full mark on the dip stick, add oil as required. Check the oil level every four hours of running time during the fi[...]

A-6 INST ALLA TION VANTAGE ® 500 (CE) A-6 ELECTRICAL CONNECTIONS MACHINE GROUNDING Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.) To prevent dangerous electric shock, other equipment to which this en[...]

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of LN-15 to the VANTAGE® 500 (CE) 1. Shut the welder off. 2. For electrode Positive, connect the electrode cable to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For elec- trode Negative, connect the electrode cable to the "-" te[...]

A-8 INST ALLA TION VANTAGE ® 500 (CE) A-8 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 diagr[...]

B-1 OPERA TION VANTAGE ® 500 (CE) B-1 SAFETY PRECAUTIONS 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. -------------------------------------[...]

B-2 OPERA TION B-2 WELDING CONTROLS (Figure B.1) 1. OUTPUT CONTROL- The OUTPUT dial is used to preset the 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 CV-WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector, the auto-sensing[...]

B-3 OPERA TION B-3 4. ARC CONTROL - The ARC CONTROL dial is active in the CV- WIR E, CC-S TIC K and DOWNH ILL P IPE m ode s, and has diff ere nt functions in these modes. This control is not active in the TIG and ARC GOUGING mode. CC-STICK mode: In this mode, the ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to ad[...]

B-4 OPERA TION B-4 ENGINE CONTROLS: 12. R UN / S T OP S W I T CH - RUN position ener- gizes the engine prior to starting. STOP position stops the engine. The oil pressure interlock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating. 13. GLOW PLUG PUSH BUTTON - • When pushed activates the glow p[...]

WELDER OPERA TION DUTY CYCLE Duty Cycle is the percentage of time the load is being applied in a 10 minute period. For example a 60% duty cycle, represents 6 minutes of load and 4 minutes of no load in a 10 minute period. ELECTRODE INFORMATION For any electrode the procedures should be kept within the rating of the machine. For information on elect[...]

When in the TOUCH START TIG mode and when a Amptrol is connected to the 6-Pin connector the OUT- PUT CONTROL dial is used to set the maximum cur- rent range of the current control of the Amptrol. The ARC CONTROL is not active in the TIG mode. To STOP a weld, simply pull the TIG torch away from the work. When the arc voltage reaches approximately 30[...]

Carbon Diameter Current Range (DC, electrode positive) 1/8"(3.2mm) 60-90 Amps 5/32"(4.0mm) 90-150 Amps 3/16"9(4.8mm) 200-250 Amps 1/4"(6.4mm) 300-400 Amps 3/8"(10.0mm) 400-Max.Amps AUXILIAR Y POWER: Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the wel[...]

C-1 ACCESSORIES C-1 FIELD INST ALLED OPTIONS / ACCESSORIES K903-1 SPARK ARRESTOR - Includes a heavy gage steel, approved spark arrestor, clamp and adapter for mounting to the muffler exhaust pipe. K704 ACCESSORY SET - Includes 35 ft. (10m) of elec- trode cable and 30 ft. (9.1m) of work cable, headshield, work clamp electrode holder. Cables are rate[...]

D-1 MAINTENANCE D-1 VANTAGE ® 500 (CE) SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Tu rn t he e ng in e off b ef or e wor ki ng ins id e the machine or servicing the engine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal[...]

D-2 MAINTENANCE D-2 ENGINE OIL CHANGE Drain the engine oil while the engine is warm to assure rapid and complete draining. It is recommended that each time the oil is changed the oil filter be changed as well. • Be sure the unit is off. Disconnect the negative bat- tery cable to ensure safety. • Locate oil drain hose and valve in bottom of base[...]

D-3 MAINTENANCE D-3 VANTAGE ® 500 (CE) Unfasten or unlatch the s ervice cover . Because the filter fits tightly over the outlet tube to create the critical seal, there will be some initial resistance, similar to breaking the seal on a jar . Gently move the end of the filter back and forth to break the seal then rotate while pulling straight out. A[...]

D-4 MAINTENANCE D-4 COOLING SYSTEM HOT COOLANT can burn skin. • Do not remove cap if radiator is hot. ------------------------------------------------------------------------ Check the coolant level by observing the level in the radiator and recovery bottle. Add 50/50 antifreeze / water solution if the level is close to or below the "LOW&quo[...]

D-5 MAINTENANCE D-5 FUEL FIL TER 1 . Check the fuel filter and fuel pre-filter for water accumulation or sediment. 2. Replace the fuel filter if it is found with excessive water accumulation or sediment. Empty fuel pre-fil- ter. ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Servic[...]

D-6 MAINTENANCE D-6 VANTAGE ® 500 (CE) WELDER / GENERA TOR MAINTENANCE STORAGE: Store in clean, dry protected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: It’s nor- mal for the brushes and slip rings to wear and [...]

E-1 TROUBLESHOOTING E-1 VANTAGE ® 500 (CE) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and rep[...]

E-2 TROUBLESHOOTING E-2 VANTAGE ® 500 (CE) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRO[...]

E-3 TROUBLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POS[...]

E-4 TROUBLESHOOTING E-4 VANTAGE ® 500 (CE) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRO[...]

E-5 TROUBLESHOOTING E-5 VANTAGE ® 500 (CE) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRO[...]

E-6 TROUBLESHOOTING E-6 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POS[...]

F-1 DIAGRAMS F-1 VANTAGE ® 500 (CE)[...]

F-2 DIAGRAMS F-2 VANTAGE ® 500 (CE)[...]

F-3 DIAGRAMS F-3 VANTAGE ® 500 (CE)[...]

F-4 DIAGRAMS F-4 VANTAGE ® 500 (CE)[...]

F-5 WIRING DIAGRAM F-5 VANTAGE ® 500 (CE) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number. ®[...]

F-6 WIRING DIAGRAM F-6 VANTAGE ® 500 (CE) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number. ®[...]

F-7 DIMENSION PRINT F-7 VANTAGE ® 500 (CE) L1 30 4 7 B 25.82 655.8 27.00 685.8 5.75 146.0 35.94 913.0 24.00 609.6 39.41 1001 20.60 523.3 28.95 735.3 36.06 915.9 30.81 782.6 60.00 1524.0 16.75 425.4 N.A. N.A. CENTER OF GRAVITY W ITH OIL IN ENGINE, COOLANT IN RA DIATOR, AND EMPTY FUEL TANK. 1.27 32.3 46.47 1180.36 6.03 153.25 62.59 1589.8 1.73 43.95[...]

NOTES VANTAGE ® 500 (CE)[...]

NOTES VANTAGE ® 500 (CE)[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL [...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your h ead out of fum es. ● Use ventila tio n or ex haus t t o remo ve [...]

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