Lincoln Electric VANTAGE 500 Operator's Manual
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Lincoln Electric VANTAGE 500 Operator's Manual

Lincoln electric welder user manual
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See also: Service Manual , Operator's Manual
For use with machine having Code Number:
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 thought-
ful operation on your part.
And, most
importantly, think before you act
and be careful.
Equipped with VRD (VOLTAGE REDUCTION DEVICE)
See Installation and Operation sections for an explanation.
• 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
RETURN TO MAIN MENU
VANTAGE 500
11467
• World's Leader in Welding and Cutting Products •
®
Copyright © Lincoln Global Inc.
April, 2009

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Summary of Contents for Lincoln Electric VANTAGE 500

  • Page 1 VANTAGE 500 For use with machine having Code Number: 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 thought- ful operation on your part.

  • 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: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding materials from welding can easily go through small cracks and openings to adjacent areas.
  • 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 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 7: Table Of Contents

    Welding Terminals...A-6 Welding Output Cables ...A-6 Cable Installation...A-6 Auxiliary Power Receptacles and Plugs ...A-7 Standby Power Connections ...A-7 Premises Wiring ...A-8 Connection of Lincoln Electric Wire Feeders...A-9, A-10 ________________________________________________________________________________ Operation...Section B Safety Precautions ...B-1 General Description...B-1 For Auxiliary Power ...B-1 Engine Operation...B-1...
  • Page 8 Fuel ...D-4 Bleeding the Fuel System ...D-4 Fuel Filter ...D-5 Engine Adjustment ...D-5 Battery Maintenance ...D-5 Servicing Optional Spark Arrestor ...D-5 Welder / Generator Maintenance ...D-6 Storage ...D-6 Cleaning...D-6 Brush Removal and Replacement ...D-6 ________________________________________________________________________ Troubleshooting ...Section E How to Use Troubleshooting Guide...E-1 Troubleshooting Guide...E-2 thru E-6...

  • Page 9: Installation

    4 cylinder 43 HP PERKINS 1850 RPM 404D-22T Turbo Charged water cooled Diesel Engine RATED OUTPUT @ 104° F (40° C) - WELDER Welding Process Current/Voltage/Duty Cycle DC Constant Current DC Pipe Current Touch-Start™TIG DC Constant Voltage Arc Gouging RATED OUTPUT @ 40° C (104° F)

  • Page 10: Machine Specification

    INSTALLATION MACHINE SPECIFICATIONS RECEPTACLES AUXILIARY POWER CIRCUIT Breaker OTHER CIRCUIT BREAKERS (2)120VAC Duplex (5-20R) GFCI Protected Two 20AMP for Two Duplex Receptacle 10AMP for Battery Charging Circuit (1) 120/240 VAC Dual Voltage (1) 50AMP for Dual Voltage and for 10AMP for 42V Wire Feeder Power Full KVA (14-50R) 3-Phase (3-pole) (1) 240VAC 3-Phase (15-50R)

  • Page 11: Installation

    The welder should be located to provide an unrestrict- ed flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are prop- erly vented to an outside area. STACKING VANTAGE®...

  • Page 12: High Altitude Operation

    HIGH TEMPERATURE OPERATION At temperatures above 104°F(40°C), Welder output derating is necessary. For maximum output ratings, derate the welder output 2 volts for every 18°F(10°C) above 104°F(40°C). Cold weather starting: With a fully charged battery and the proper oil, the engine should start satisfactorily down to -15°F(-...

  • Page 13: Fuel

    EXAMPLE: When the OUTPUT CONTROL on the welder is set to 200 amps the current range on the remote control will be 40-200 amps, rather than the full 40-300 amps. Any current range that is less than the full range provides finer current resolution for more fine tuning of the output.

  • Page 14: Electrical Connections

    WARNING • 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 15: Auxiliary Power Receptacles

    AUXILIARY POWER RECEPTACLES Start the engine and set the “IDLER” control switch to the “High Idle” mode. Voltage is now correct at the recepta- cles for auxiliary power. This must be done before a tripped GFCI module can be reset properly. See the MAINTENANCE section for more detailed information on testing and resetting the GFCI module.

  • Page 16: Premises Wiring

    CONNECTION OF VANTAGE 500 TO PREMISES WIRING • Only a licensed, certified, trained electrician should install the machine to a premises or residential electrical system. Be certain that: • The installation complies with the National Electrical Code and all other applicable electrical codes.

  • 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 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 elec- trode cable from the LN-25 to the "-" terminal of the welder and work cable to the "+"...

  • Page 19: Operation

    • Insulate yourself from work and ground • Always wear dry insulating gloves. • Always operate the welder with the hinged door closed and the side panels in place. • Read carefully the Safety Precautions page before operating this machine. Always follow...

  • Page 20: Welding Controls

    EXAMPLE: When the OUTPUT CONTROL on the welder is set to 200 amps the current range on the remote control will be 40-200 amps, rather than the full 40-300 amps. Any current range that is less than the full range provides finer current resolution for more fine tuning of the output.
  • Page 21 4. ARC CONTROL - The ARC CONTROL dial is active in the CV-WIRE, CC-STICK and DOWNHILL PIPE modes, and has different 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 adjust for a soft or crisp arc.

  • Page 22: Engine Controls

    ENGINE CONTROLS: 12. RUN/STOP SWITCH -RUN position energizes the engine prior to starting. STOP position stops the engine. The oil pressure inter- lock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating. 13.

  • Page 23: Stopping The Engine

    STOP the engine by placing the RUN-STOP switch in the STOP position. NOTE: A fuel shut off valve is located on the fuel pre-filter. 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 24: Tig Welding

    The OUTPUT CONTROL dial adjusts the full output range for pipe welding. The ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or more forceful digging arc (crisp). Increasing the number from -10(soft) to +10(crisp) increases the short circuit current which results in a more forceful digging arc.

  • Page 25: Wire Welding-Cv

    This will keep the "Solid State" contactor open and provide a "cold" electrode until the Amptrol or Arc Start Switch is pressed. When using the TIG Module, the OUTPUT CONTROL on the VANTAGE® 500 is used to set the maximum range of the CUR- RENT CONTROL on the TIG Module or an Amptrol if connect- ed to the TIG Module.

  • Page 26: Accessories

    E6.214 click on Search Icon. 3. On the results screen click on Engine Driven Welders: Vantage 500 4. On this results screen which shows Vantage 500 sales literature document, scroll down to the begin- nig of the RECOMMENDED OPTIONS page.

  • Page 27: Maintenance

    SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete.

  • Page 28: Engine Service Items

    • Locate oil drain hose and valve in bottom of base and pull through the hole in the battery access panel on the welder. • Open oil drain valve by lifting up spring loaded lever and rotate 90 counterclockwise.
  • Page 29 Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Remove the Filter Remove the Filter Rotate the filter while pulling straight out. Clean Both Surfaces of the Outlet Tube Clean Both Surfaces of the Outlet Tube and Check the Vacuator™ Valve and Check the Vacuator™...

  • Page 30: Cooling System

    COOLING SYSTEM WARNING HOT COOLANT • 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"...

  • Page 31: Fuel Filter

    ● CONNECTING A BATTERY CHARGER — remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.

  • Page 32: Storage

    WARNING • Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equip- ment may result in danger to the technician and machine operator and will invalidate your factory warranty.

  • Page 33: Troubleshooting

    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 34: Troubleshooting

    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. 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 35 3. Faulty engine alternator or charg- er module. Consult authorized Engine Service Shop. 1. Idler switch in High idle position. Set switch to Auto. 2. External load on welder or auxil- iary power. Remove all external loads. 3. Faulty PC board or idler sole- noid.
  • Page 36 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine will not go to high idle when using auxiliary power. Engine will not go to high idle under weld or auxiliary loading. Engine does not develop full power. Engine runs rough. Engine will not go to high idle when attempting to weld or using auxil- iary power.
  • Page 37 2. "Weld Terminals" switch in wrong position. Place switch in "Weld Terminals On" position when welding without control cable. 3. Faulty PC board or welder alterna- tor. 1. Poor remote/control cable connec- tion to 6-pin or 14-pin connector. Check connections.
  • Page 38 3. "Weld Terminals" switch in wrong position. Place switch in "Weld Terminals On" position when welding without control cable. 4. Faulty PC board or welder alterna- tor. 1. Ensure VRD ON/OFF switch is in the “ON” position. 2. If light is burned out, replace both VRD lights.
  • Page 39 DIAGRAMS ® VANTAGE...
  • Page 40 DIAGRAMS ® VANTAGE...
  • Page 41 DIAGRAMS ® VANTAGE...
  • Page 42 DIAGRAMS ® VANTAGE...
  • Page 43 DIAGRAMS VANTAGE® 500...
  • Page 44 DIAGRAMS VANTAGE® 500...
  • Page 45 DIAGRAMS VANTAGE® 500...
  • Page 46 DIAGRAMS VANTAGE® 500...
  • Page 47 DIAGRAMS VANTAGE® 500...

  • Page 48: Wiring Diagram

    F-10 F-10 WIRING DIAGRAM ® VANTAGE...

  • Page 49: Dimension Print

    F-11 F-11 DIMENSION PRINT ® VANTAGE...
  • Page 50 NOTES ® VANTAGE...
  • Page 51 NOTES VANTAGE® 500...
  • Page 52 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 53 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE WARNUNG ATENÇÃO...
  • 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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