Lincoln Electric Vantage 566 Operator's Manual
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Lincoln Electric Vantage 566 Operator's Manual

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Operator's Manual
Vantage
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10482
| Issue D ate Oct-18
© Lincoln Global, Inc. All Rights Reserved.
566
®
For use with machines having Code Numbers:
12828
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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  • Page 1 Operator’s Manual Vantage ® For use with machines having Code Numbers: 12828 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • Page 6 TABLE OF CONTENTS...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Page Synergic Welding Modes ............. . .B-11 Basic Welding Controls .
  • Page 8 ® VANTAGE INSTALLATION GENERAL DESCRIPTION OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR The Vantage ® 566 is a diesel engine-driven welding power Welding Range source. The machine uses a brush type alternating current gener- 30 - 600 Amps CC/CV ator for DC multi-purpose welding, for 120/240 VAC single phase and 240V three phase auxiliary standby power.
  • Page 9 ® VANTAGE INSTALLATION SAFETY PRECAUTIONS With the VRD switch in the “OFF” position, the VRD lights are non acti- vated. WARNING FIGURE A.1 Do not attempt to use this equipment until you have thor- oughly read all operating and maintenance manuals supplied ON / OFF VDR SWITCH with your machine.
  • Page 10 ® VANTAGE INSTALLATION ANGLE OF OPERATION HIGH TEMPERATURE OPERATION ® To achieve optimum engine performance the Vantage At temperatures above 104°F (40°C), output voltage derating may should be run in a level position. The maximum angle of operation be necessary. For maximum output current ratings, derate welder for the Deutz engine is 30 degrees in all directions.
  • Page 11 ® VANTAGE INSTALLATION TOWING Use a recommended trailer for use with this equipment for road, in-plant and The Vantage ® 566 is shipped with the engine crankcase filled with high yard towing by a vehicle . If the user adapts a non-Lincoln trailer, they must quality SAE 10W-30 Oil that meets (API class CJ-4 or better) for diesel assume responsibility that the method of attachment and usage does not engines.
  • Page 12 ® VANTAGE INSTALLATION BATTERY CONNECTION SPARK ARRESTOR Some federal, state or local laws may require that gasoline or CAUTION diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks Use caution as the electrolyte is a strong acid that can burn skin may present a fire hazard.
  • Page 13 ® VANTAGE INSTALLATION REMOTE CONTROL WELDING OUTPUT CABLES ® The Vantage 566 is equipped with a 12-pin and a 14-pin connec- With the engine off, route the electrode and work cables through the tor. To enable remote control capabilities, the LOCAL/REMOTE strain relief bracket provided on the front of the base and connect to the switch must be in the REMOTE position.
  • Page 14 ® VANTAGE INSTALLATION FIGURE A.3 CAUTION AUXILIARY POWER RECEPTACLES • Loose connections will cause the output terminals to over- 10A 42V/40V ARCLINK BREAKERS heat. The terminals may eventually melt. 20A 120V AUXILIARY BREAKERS BATTERY 20A BREAKER • Do not cross the welding cables at the output terminal connec- tion.
  • Page 15 ® VANTAGE INSTALLATION STANDBY POWER CONNECTIONS The Vantage ® 566 is suitable for temporary, standby or emer- 2. Take necessary steps to assure load is limited to the capacity of gency power using the engine manufacturer’s recommended the Vantage ® 566 by installing a 50 amp, 240 VAC double pole maintenance schedule.
  • Page 16 ® VANTAGE INSTALLATION CONNECTION OF WIRE FEEDERS WITH CONTROL FIGURE A.5 CABLE (14 PIN) Set Mode to Set Weld Terminals to WARNING Remotely Controlled CV Wire Set Polarity to Match Shut off welder before making any electrical connections. Electrode Polarity ------------------------------------------------------------------ CONNECTION OF LF-72, LF-74, FLEX FEED 74 HT, Set to...
  • Page 17 ® VANTAGE INSTALLATION CONNECTION OF ACROSS THE ARC WIRE FEEDERS FIGURE A.7 TO THE VANTAGE ® These connections instructions apply to both the LN-25 Pro and Weld Activ8 models. The feeders have an internal contactor and the electrode is not energized until the gun trigger is closed. When the Terminals On gun trigger is closed the wire will begin to feed and the welding Set Mode to...
  • Page 18 ® VANTAGE INSTALLATION CABLE INDUCTANCE AND ITS EFFECTS ON CONTROL CABLE CONNECTIONS WELDING General Guidelines Excessive cable inductance will cause the welding performance to Genuine Lincoln control cables should be used at all times (except degrade. There are several factors that contribute to the overall where noted otherwise).
  • Page 19 ® VANTAGE NOTES A-12...
  • Page 20 ® VANTAGE OPERATION SAFETY INSTRUCTIONS RECOMMENDED APPLICATIONS Read and understand this entire section before operating WELDER ® your Vantage 566. The Vantage ® 566 provides excellent constant current DC welding WARNING output for stick (SMAW) and TIG (GTAW) welding. The Vantage ®...
  • Page 21 ® VANTAGE OPERATION 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 ENGINE CONTROLS 1. STOP / (LOW IDLE/RUN) / (HIGH IDLE/RUN) SWITCH Toggling the switch to the RUN position energizes the fuel...
  • Page 22 ® VANTAGE OPERATION Idler Operational exceptions 4. OUTPUT CONTROL- The OUTPUT dial is used to preset the output voltage or current as displayed on the digital meters for When the WELDING TERMINALS switch is in the “Remotely the five welding modes. Controlled”...
  • Page 23 ® VANTAGE OPERATION 6. DIGITAL OUTPUT METERS- The digital meters allow the preset arc output voltage (CV-WIRE mode) or preset arc current FIGURE B.2 (CC-STICK, DOWNHILL PIPE, ARC GOUGING and TIG modes) to be set prior to welding using the OUTPUT control dial. During welding, the meter display the actual output voltage (VOLTS) and current (AMPS).
  • Page 24 ® VANTAGE OPERATION • Alternate CV mode selection. Default CV mode will be non-syner- gic FCAW-SS (mode 6). Alternate settings will be non-synergic GMAW (mode 5) and non-synergic FCAW-GS (mode 7). The left display will show “CV” and “type” alternately at 0.5 second intervals.
  • Page 25 ® VANTAGE OPERATION • Test Modes for grid load testing. The left display will show “tESt” and “LoAd” alternately at 0.5 second intervals. The right display will show “CC” (mode 200)(Figure B.9), “CV” (mode 201)(Figure B.10) or “OFF” (normal operation)(Figure B.11). This setting is not remembered between machine power cycles and will default to OFF at each power on.
  • Page 26 ® VANTAGE OPERATION 7. WELD TERMINALS ON SWITCH 13. 12-PIN CONNECTOR Output is enabled when in the ON position. Output is remotely controlled For attaching optional remote control equipment. The ® when in the REMOTE position. This control is not active in ArcLink K2909-1 (12-pin to 6-pin) adapter cable is included for modes.
  • Page 27 ® VANTAGE OPERATION 18. 20A 120V AUXILIARY BREAKERS 26. DIAGNOSTIC PLUG 19. 50A 240V 3 PHASE BREAKER This is used by Field Service shops to connect and trou- bleshoot engine error codes and is found on the firewall inside the machine on the service side. (Figure B.12) 20.
  • Page 28 ® VANTAGE OPERATION 31. STATUS LED (See Table B.1) Status The status LED indicates system status. Normal oper- ation is a steady green light. Note: During normal power-up, the LED may flash red and/or green as the equipment performs self tests.
  • Page 29 ® VANTAGE OPERATION WELDER OPERATION TOUCH START TIG MODE ® The Vantage 566 can be used in a wide variety of DC TIG welding DUTY CYCLE applications. Duty cycle is the percentage of time the load is being applied in a 10 The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten minute period.

  • Page 30: Synergic Welding Modes

    If a UltimArc™ Control allows the operator to vary the arc charac- special weld mode is desired, contact the local Lincoln Electric sales teristics. UltimArc™ Control is adjustable from –10.0 to +10.0 with representative.
  • Page 31 ® VANTAGE OPERATION Most pulse welding programs are synergic. As the wire feed speed is adjusted, the Vantage ® 566 will automatically recalculate the waveform parameters to maintain similar arc properties. The Vantage ® 566 utilizes “adaptive control” to compensate for changes in the electrical stick-out while welding.

  • Page 32: Typical Current Ranges For Tungsten Electrodes

    ® VANTAGE OPERATION SETTINGS WHEN USING THE K930-2 TIG MODULE • Set the WELD MODE switch to the “Touch Start TIG Setting”. • Set the Stop/Auto Idle/High Idle switch to the “AUTO/RUN” position. • Set the WELDING TERMINALS switch to the “Remotely Controlled”...

  • Page 33: Cv-Wire Mode

    ® VANTAGE OPERATION CV-WIRE MODE PARALLELING ® Connect a wire feeder to the Vantage 566 and set welder con- When paralleling machines in order to combine their outputs, all trols according to the instructions listed earlier in this section. units must be operated in the CC-STICK mode at the same output settings.
  • Page 34 ® VANTAGE OPERATION ® TABLE B.5 VANTAGE 566 DEUTZ SIMULTANEOUS WELDING AND POWER LOADS WELD 1 PHASE 3 PHASE BOTH 1 AND 3 PHASE AMPS WATTS AMPS WATTS AMPS WATTS AMPS 12,000 20,000 ------ 12,000 17,800 ------ PLUS 12,000 14,000 ------ 12,000 12,000...
  • Page 35 ® VANTAGE OPERATION The following additional modes can be accessed via an ArcLink feeder Synergic CV Modes Metal Dia. Steel Stainless Core Flux Core Aluminum Argon Argon Argon inches CO2 Tri-Mix Argon Mix CO2 4043 5356 .030 • • • •...
  • Page 36 ® VANTAGE NOTES B-17...

  • Page 37: Accessories

    6 and 14-pin remote connec- ® tions can be made to this unit. For all Lincoln Electric Chopper Technology Square Wave™ TIG 175 engine-driven welders. Mounts on roof with K2663-1 Docking Kit.

  • Page 38: Wire Feeder Options

    ® VANTAGE ACCESSORIES WIRE FEEDER OPTIONS ™ LN-25 IRONWORKER WIRE FEEDER ® Portable CV unit for flux-cored and mig welding with maxtrac wire drive system. includes digital meters for wire feed speed/amperage and voltage, gas solenoid, internal contactor and 5/64 in. (2.0 mm) drive roll kit for cored wire.
  • Page 39 ® VANTAGE NOTES...

  • Page 40: Maintenance

    ® VANTAGE MAINTENANCE SAFETY PRECAUTIONS WARNING CAUTION • Have a qualified technician do the maintenance and trou- AIR FILTER bleshooting work. • Turn the engine off before working inside the machine. WARNING • Remove guards only when necessary and replace them when the maintenance requiring their removal is complete.
  • Page 41 ® VANTAGE MAINTENANCE Service Instructions Service Instructions Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Inspect the New Filter for Damage Inspect the New Filter for Damage Remove the Filter Remove the Filter Inspect the new filter carefully, paying attention to Unfasten or unlatch the the inside of the open end, which is the service cover.

  • Page 42: Fuel Filtersd-3

    ® VANTAGE MAINTENANCE FUEL FILTERS BATTERY HANDLING GASES FROM BATTERY can explode. WARNING • Keep sparks, flame and cigarettes away from When working on the fuel system battery. • Keep naked lights away, do not smoke! • Do not spill fuel! To prevent EXPLOSION when: ------------------------------------------------------------------ •...

  • Page 43: Charging The Battery

    ® VANTAGE MAINTENANCE CHARGING THE BATTERY WELDER / GENERATOR MAINTENANCE When you charge, jump, replace, or otherwise connect battery STORAGE cables to the battery, be sure the polarity is correct. Improper Store the Vantage ® 566 in a clean, dry protected areas. polarity can damage the charging circuit.
  • Page 44 ® VANTAGE MAINTENANCE FIGURE D.2 Green Light GFCI TESTING AND RESETTING PROCEDURE The GFCI should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI: • If the GFCI has tripped, first carefully remove any load and check it for damage.

  • Page 45: Troubleshooting

    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.
  • Page 46 ® VANTAGE TROUBLE SHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION ENGINE PROBLEMS Major Physical or Electrical Damage . Contact your Local Lincoln is Evident. Authorized Field Service Facility. 1. Battery low. Engine will not crank 2.
  • Page 47 ® VANTAGE TROUBLE SHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE 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.
  • Page 48 ® VANTAGE TROUBLE SHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION FUNCTION PROBLEMS Engine goes to low idle but does 1. Faulty Weld Control PCB or Idler not stay at low idle. relay.
  • Page 49 ® VANTAGE NOTES...

  • Page 50: Wiring

    ® VANTAGE WIRING DIAGRAMS...
  • Page 51 ® VANTAGE CONNECTION DIAGRAMS...
  • Page 52 ® VANTAGE CONNECTION DIAGRAMS...
  • Page 53 ® VANTAGE CONNECTION DIAGRAMS...
  • Page 54 ® VANTAGE CONNECTION DIAGRAMS...
  • Page 55 ® VANTAGE CONNECTION DIAGRAMS...
  • Page 56 ® VANTAGE CONNECTION DIAGRAMS...
  • Page 57 ® VANTAGE CONNECTION DIAGRAMS...
  • Page 58 ® VANTAGE CONNECTION DIAGRAMS...
  • Page 59 ® VANTAGE CONNECTION DIAGRAMS F-10...
  • Page 60 ® VANTAGE CONNECTION DIAGRAMS F-11...
  • Page 61 ® VANTAGE CONNECTION DIAGRAMS F-12...
  • Page 62 ® VANTAGE CONNECTION DIAGRAMS F-13...
  • Page 63 ® VANTAGE DIMENSION PRINT F-14...
  • Page 64 ® VANTAGE NOTES F-15...
  • Page 65 ® VANTAGE NOTES F-16...
  • Page 66 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 67 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 68 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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