Lincoln Electric AIR VANTAGE IM10066 Operator's Manual
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Lincoln Electric AIR VANTAGE IM10066 Operator's Manual

Lincoln Electric AIR VANTAGE IM10066 Operator's Manual

Lincoln electric welder user manual
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RETURN TO MAIN MENU
IM10066
®
AIR VANTAGE 500 (AU)
November, 2010
11656
For use with machine having Code Number:
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OPERATOR'S MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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  • Page 1 RETURN TO MAIN MENU IM10066 ® AIR VANTAGE 500 (AU) November, 2010 11656 For use with machine having Code Number: 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 ...

  • Page 2: California Proposition 65 Warnings

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. bE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY bY QUALIFIED INDIVIDUALS.
  • Page 3 SAFETY...
  • Page 4 SAFETY...
  • Page 5 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.
  • Page 6 SAFETY AIR VANTAGE® 500 (AU)
  • Page 7 SAFETY AIR VANTAGE® 500 (AU)
  • Page 8 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.

  • Page 9: Table Of Contents

    Welding Terminals...A-5 Welding Output Cables ...A-5 Machine Grounding ...A-5 Remote Control ...A-6 Auxiliary Power Receptacles and Standby Power Connections ...A-6 Connection of Lincoln Electric Wire Feeders...A-7, A-8 ________________________________________________________________________________ Operation...Section b Safety Precautions ...B-1 General Description...B-1 Recommended Application - Welder, Air Compressor and Generator...B-1 Controls and Settings ...B-2...
  • Page 10 Fuel Filters ...D-3 Cooling System...D-3 Battery Handling ...D-3 Charging the Battery ...D-4 Nameplate / Warning Decal Maintenance ...D-4 Welder / Generator Maintenance ...D-4 Engine Maintenance Components ...D-4 ________________________________________________________________________ Troubleshooting ...Section E ________________________________________________________________________ Connection Diagrams, Wiring Diagrams and Dimension Print...Section F ________________________________________________________________________ Parts List ...P-661 Series...

  • Page 11: Installation

    Cummins 56 HP (42kw) B3.3 1800 RPM Diesel Engine RATED OUTPUT @ 104°F(40°C) - WELDER Duty Cycle 100% OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR Compressor Model Description VMAC™ Belt-Drive Rotary S700157 Screw Air Compressor 60 CFM @ 100PSI Height 42.0 in...

  • Page 12: Safety Precautions

    Also, locate the welder so that the engine exhaust fumes are prop- erly vented to an outside area. DO NOT MOUNT OVER COMbUSTIbLE SURFACES...

  • Page 13: Lifting

    For maximum rating, derate the welder output 4% for every 300 meters (984 ft.) above 1500 meters (4920 ft.). For output of 500A and below, derate the welder output 4% for every 300 meters (984 ft.) above 2100 meters (6888 ft.).

  • Page 14: Pre-Operation Engine And Compressor Service

    HOT COOLANT can burn skin. •Do not remove cap if radiator is hot. ------------------------------------------------------------------------ The welder is shipped with the engine and radiator filled with a 50% mixture of ethylene glycol and water. See the MAINTENANCE section and the engine Operator’s Manual for more information on coolant.

  • Page 15: Muffler Outlet Pipe

    To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must: • be grounded to the frame of the welder using a grounded type plug or be double insulated. • Do not ground the machine to a pipe that carries explosive or combustible material.

  • Page 16: Remote Control

    6-pin Connector, the auto-sensing circuit automatically switches the OUTPUT control from control at the welder to remote control. When in TOUCH START TIG mode and when a Amptrol is connected to the 6-Pin Connector, the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol.

  • Page 17: Connection Of Lincoln Electric Wire Feeders

    "+" terminal of the welder and work cable to the "-" terminal of the welder. For elec- trode Negative, connect the electrode cable to the "-" terminal of the welder and work cable to the "+" terminal of the welder. 3. Across The-Arc Model: •...
  • Page 18 1. Shut the welder off. 2. For electrode Positive, connect the electrode cable from the LN-25 to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable from the LN-25 to the "-"...

  • Page 19: Operation

    ------------------------------------------------------------------------ • Only qualified personnel should operate this equipment. • Always operate the welder with the sliding door closed and the side panels in place as these pro- vide maximum protection from moving parts and insure proper cooling air flow.

  • Page 20: Controls And Settings

    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. ENGINE CONTROLS (Items 1 through 9) 1. RUN STOP SWITCH Toggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds.

  • Page 21: Welding Controls

    Pin Connector, the auto-sensing circuit automati- cally switches the OUTPUT CONTROL from con- , the engine runs at trol at the welder to the remote control. In the CV-WIRE mode, when the wire feeder control cable is connected to the 14-Pin Connector, the...

  • Page 22: Auxiliary Power Controls

    Connector, the auto-sensing circuit automatically switches the OUTPUT control from control at the welder to remote control. 18. 14-PIN CONNECTOR: For attaching wire feeder control cable. Includes contactor closure circuit, auto-sensing remote control circuit, and 42VAC or 115VAC power.

  • Page 23: Air Compressor Controls

    23. GROUND STUD: Provides a connection point for connecting the machine case to earth ground. Refer to “MACHINE GROUNDING” in the Installation chapter for proper machine grounding informa- tion. 24. RCD: “Residual Current Device” provides protection from active to ground contact. RCD will not protect against electrical shock resulting from contact with active and neutral wires.

  • Page 24: What Are Vrd And Rocv Devices

    (30-50V). Also, the cur- rent is turned On and Off by a gun trigger, which also controls the wire feed. Therefore, the welder is not exposed to open circuit voltage unless the trigger is turned on and the wire is feeding. Also, electrodes are not changed as frequently as for stick welding (MMAW).

  • Page 25: Starting Technique

    PERIOD 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 break-in is accom- plished.

  • Page 26: Duty Cycle

    WELDER OPERATION 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.

  • Page 27: Wire Welding-Cv

    WIRE WELDING-CV Connect a wire feeder to the AIR VANTAGE® 500 (AU) (AU)according to the instructions in INSTALLA- TION INSTRUCTIONS Section. The AIR VANTAGE® 500 (AU) in the ”CV-WIRE” position, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) elec- trodes and solid wires for MIG welding (gas metal arc welding).

  • Page 28: Paralleling

    b-10 PARALLELING When paralleling machines in order to combine their outputs, all units must be operated in the CC-STICK mode only at the same output settings. To achieve this, turn the WELD MODE switch to the CC-STICK position. Operation in other modes may produce errat- ic outputs, and large output imbalances between the units.

  • Page 29: Optional Field Installed Accessories

    K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CON- TROL - Portable control provides same dial range as the output control on the welder from a location up to the specified length from the welder. Has convenient plug for easy connection to the welder.

  • Page 30: Compressor Maintenance

    • Check coolant level. WARNING • Only VMAC certified and approved synthetic oil MUST used. Shut Welder/Compressor for 3 minutes, open the pressure supply valve to ensure the system is depressurized prior to removing the compres- sor oil level dipstick. ------------------------------------------------------------------------ WEEKLY Blow out the machine with low pressure air periodical- ly.
  • Page 31 Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Remove the Filter Remove the Filter Unfasten or unlatch the service cover. Because the filter fits tightly over the outlet tube to create the critical seal, there will be some initial resistance, similar to breaking Rotate the the seal on a jar.

  • Page 32: Fuel Filters

    • CONNECTING A bATTERY CHARGER - Remove battery from welder by dis- connecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last.

  • Page 33: Welder / Generator Maintenance

    Fleetguard Water Separator Battery ----- Engine Oil Change See Manual MAINTENANCE WELDER / GENERATOR MAINTE- NANCE STORAGE Store the AIR VANTAGE® 500 (AU) in a clean, dry protected areas. CLEANING Blow out the generator and controls periodically with low pressure air. Do this at least once a week in par- ticularly dirty areas.

  • Page 34: How To Use Troubleshooting Guide

    HOW TO USE TROUbLESHOOTING GUIDE 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.
  • Page 35 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. Engine will not crank Engine will crank but not start. Engine shuts down shortly after starting. Engine shuts down while under a load. Engine runs rough.
  • Page 36 4. Loose fan belt may need tighten- ing. 1. Idler switch in HIGH idle position, make sure switch is set to AUTO. 2. External load on welder or auxil- iary power. 3. Mechanical problem in idler sole- noid linkage. 4. Faulty wiring in solenoid circuit.
  • Page 37 (SYMPTOMS) Engine goes to low idle but does not stay at low idle. No welding output or auxiliary output. Welder has some/ no output and no control. Auxiliary output OK No welding output. Auxiliary output No auxiliary power. 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.

  • Page 38: Wiring Diagram

    WIRING DIAGRAM AIR VANTAGE® 500 (AU)
  • Page 39 DIAGRAMS AIR VANTAGE® 500 (AU)
  • Page 40 DIAGRAMS AIR VANTAGE® 500 (AU)
  • Page 41 DIAGRAMS AIR VANTAGE® 500 (AU)
  • Page 42 DIAGRAMS AIR VANTAGE® 500 (AU)
  • Page 43 DIAGRAMS AIR VANTAGE® 500 (AU)
  • Page 44 DIAGRAMS AIR VANTAGE® 500 (AU)
  • Page 45 DIAGRAMS AIR VANTAGE® 500 (AU)
  • Page 46 DIAGRAMS AIR VANTAGE® 500 (AU)
  • Page 47 F-10 F-10 DIAGRAMS AIR VANTAGE® 500 (AU)
  • Page 48 F-11 F-11 DIAGRAMS AIR VANTAGE® 500 (AU)
  • Page 49 F-12 F-12 DIAGRAMS AIR VANTAGE® 500 (AU)

  • Page 50: Dimension Print

    F-13 F-13 DIMENSION PRINT AIR VANTAGE® 500 (AU)
  • Page 51 NOTES AIR VANTAGE® 500 (AU)
  • Page 54 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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Air vantage 500Air vantage 500 au

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