Lincoln 435 User Manual

Operator’s Manual

Vantage®435

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

IM10494 | Issue D ate Jun-18

For use with machines having Code Numbers:

12851

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

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

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. And, most importantly,

think before you act and be careful.

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Safety Data Sheet (SDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust

exposes you to chemicals known to the State of California to cause cancer and birth defects,

or other reproductive harm.

• Always start and operate the engine in a well-ventilated area.

•

If in an exposed area, vent the exhaust to the outside.

•

Do not modify or tamper with the exhaust system.

•

Do not idle the engine except as necessary.

For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive harm. www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting ANSI Standard Z49.1” from the American Welding Society, P.O. Box 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.

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.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

Safety 02 of 04 - 5/16/2018

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.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see It ems 6.c. and 8.

ARC RAYS 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 your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding

hardfacing (see instructions on container or SDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation unless exposure assessments indicate otherwise. In confined spaces or in some circumstances, outdoors, a respirator may also be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the Safety Data Sheet (SDS) and follow your employer’s safety practices. SDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 5/16/2018

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 sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association, 14501 George Carter Way Chantilly, VA 20151.

FOR ELECTRICALLY 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 Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

TABLE OF CONTENTS

VANTAGE®435

Page

Installation ..................................................................................................................................................Section A

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

VRD (Voltage Reduction Device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Location and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Pre-Operation Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Exhaust Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Air Cleaner Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Welding Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Standby Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

Connection of

Vantage

435

to Premises Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

Connection of Lincoln Electric Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9 - A-10

Connection of LF-72, LF-74, Flex Feed 74 HT, Flex Feed 84 to

Vantage

435 . . . . . . . . . .A-9

Connection of Across the Arc Wire Feeders to

Vantage

435

. . . . . . . . . . . . . . . . . . . . . .A-10

Cable Inductance and its Effects on Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-11

Control Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-11

Operation ....................................................................................................................................................Section B

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2, B-3

Stop/(Low Idle/Run)/(High Idle/Run) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Dash Board Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

VRD Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4 - B-9

Digital Output Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Hidden Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Hidden Setup Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Exiting Hidden Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Weld Terminals On Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Arc Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Weld Mode Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

42V / 115V Wire Feeder Voltage Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

42V and 115V Wire Feeder Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

5-Pin Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

12-Pin Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

14-Pin Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Weld Output Terminals “+” Positive and “–” Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Local / Remote Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Polarity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

20A 120V Auxiliary Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

50A 240V 3 Phase Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Battery 20A Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

240VAC Three Phase Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

120/240 VAC Single Phase Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

10A 42V/40V ArcLink Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

TABLE OF CONTENTS

VANTAGE®435

Page

Ground Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Diagnostic Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9

Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10

Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10

Stick Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10

CC-Stick Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10

Downhill Pipe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10

Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10

Touch Start TIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10

Common Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Definition of Welding Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Non-Synergic Welding Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Synergic Welding Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Basic Welding Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Weld Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Wire Feed Speed (WFS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

UltimArc

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

VANTAGE

Settings when using K930-2 TIG Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-13

Typical Current Ranges for Tungsten Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-13

CV-Wire Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-14

Constant Voltage Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-14

Synergic CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-14

Non Synergic CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-14

Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-14

Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-14

Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-14

Simultaneous Welding and Auxiliary Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-14

Extension Cord Length Recommendations Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-15

Weld Set Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-16

Accessories................................................................................................................................................Section C

Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Wire Feeder Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Maintenance ..............................................................................................................................Section D

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Service Instructions- Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Preventing Electrical Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Preventing Battery Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Preventing Battery Buckling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Nameplates / Warning Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Welder / Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Replacement Service Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Troubleshooting ........................................................................................................................Section E

How to use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2 - E-4

Wiring, Connection Diagrams and Dimension Print .....................................................................Section F

Parts List .....................................................................................................................................parts.lincolnelectric.com

Content/details may be changed or updated without notice. For most current Instruction Manuals, go to parts.lincolnelectric.com.

NOTES

VANTAGE®435

A-1

INSTALLATION

VANTAGE®435

GENERAL DESCRIPTION

The Vantage®435 is a diesel engine-driven welding power source. The machine uses a brush type alternating current generator for DC multi-purpose welding, for 120/240 VAC single phase and 240V three phase auxiliary standby power. The welding control system uses state of the art Chopper Technology™.

TECHNICAL SPECIFICATIONS

INPUT - DIESEL ENGINE

RATED OUTPUT @ 104°F(40°C) - WELDER

Duty Cycle Welding Output Volts at Rated Amps

100% 400 Amps 36 Volts

(DC multi-purpose)

100% 450 Amps 32 Volts

(DC multi-purpose)

60% 520 Amps 30 volts

(DC multi-purpose)

PHYSICAL DIMENSIONS

(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) Top of Enclosure. Add 10.12” (257.0mm) for exhaust and air cleaner. (3) Includes Door. Base is 27.0”(685.8mm) wide.

OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR

Make /Model

(K4107-16)

Deutz D2.9L4 Naturally

Aspirated Diesel Engine

EPA TIER 4 Final Compliant

Description

4 cylinder 34.8HP (25.9 kw)

Naturally Aspirated

Water Cooled

Diesel Engine

Speed (RPM)

High Idle 1800 Low Idle 1500

Full Load

Displacement

177 cu. in. (2.9L)

Bore x Stroke

3.6” x 4.3”

92mm x 110mm

Starting System

12VDC battery and Starter

with Automatic Glow Plugs

Capacities

Fuel 20 US gal (75.7L) Oil: 2.35 US gal. (8.9L)

Welding Range

30 - 520 Amps CC/CV

20 - 250 Amps TIG

Open Circuit Voltage

60 Max OCV @ 1800 RPM

Auxiliary Power

(1)

120/240 VAC

11,000 WATTS, 60 Hz., Single Phase

17,000 WATTS, 60 Hz., Three Phase

Height

(2)

Width

(3)

Depth

Weight

39.1 in (993.7 mm)

28.4 in. (721.0mm)

65.1 in. (1653.7mm)

1526 lbs. (692 kg) (Approx.)

A-2

INSTALLATION

VANTAGE®435

SAFETY PRECAUTIONS

Do not attempt to use VANTAGE® 435 until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance

instructions and parts lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside

------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts

------------------------------------------------------------------

Only qualified personnel should install, use or service VANTAGE® 435.

VRD (VOLTAGE REDUCTION DEVICE)

The VRD reduces the OCV (Open Circuit Voltage) at the welding output terminals while not welding to less than 30VDC when the resistance of the output circuit is above 200Ω (ohms).

The VRD requires that the welding cable connections be kept in good electrical condition because poor connections will contribute to poor starting. Having good electrical connections also limits the possibility of other safety issues such as heat-generated damage, burns and fires.

The machine is shipped with the VRD switch in the “OFF” position. To turn it “On” or “Off”:

• Turn the engine “Off”.

• Disconnect the negative battery cable.

• Lower the Front panel by removing 4 side panel screws.

(See Figure

A.1)

• Place the VRD switch in the “On” or “Off” position. (See Figure A.1)

With the VRD switch in the “OFF” position, the VRD lights are deactivated.

FIGURE A.1

LOCATION AND VENTILATION

The welder should be located to provide an unrestricted 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 properly vented to an outside area.

DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface should be covered with a steel plate at least .06”(1.6mm) thick, which should extend not less than 5.90”(150mm) beyond the equipment on all sides.

---------------------------------------------------------------------

STORING

1. Store the machine in a cool, dry place when it is not in use. Protect it from dust and dirt. Keep it where it can’t be accidentally damaged from construction activities, moving vehicles, and other hazards.

2. Drain the engine oil and refill with fresh oil. Run the engine for about five minutes to circulate oil to all the parts. See the ENGINE OPERATION section manual for details on changing oil.

3. Remove the battery, recharge it, and adjust the electrolyte level. Store the battery in a dry, dark place.

STACKING

Vantage

435 machines cannot be stacked.

WARNING

REMOVE 4 FRONT PANEL SCREWS TO ACCESS (VRD) SWITCH

ON / OFF VRD SWITCH

FRONT PANEL ROTATES AWAY FROM THE FRONT PART OF WELDER

A-3

INSTALLATION

VANTAGE®435

ANGLE OF OPERATION

To achieve optimum engine performance the Vantage®435 should be run in a level position. The maximum angle of operation for the Deutz engine is 15 degrees in all directions. When operating the welder at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity. Also the effective fuel capacity will be slightly less than the specified 20 gal.(75.7 ltrs.) will be slightly less than the amount specified.

LIFTING

The Vantage

435 weighs approximately 1641 lbs. (744kg.) with a full tank of fuel and 1526 lbs. (692kg) less fuel. A lift bail is mounted to the machine and should always be used when lifting the machine.

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

• Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder.

FALLING • Do not lift machine if lift bale is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bale.

------------------------------------------------------------------

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary. For maximum rating, derate the welder output in accordance with the guidelines in Table A.1 for this engine model from the manufacturer:

TABLE A.1 DEUTZ D 2.9 L4

ALTITUDE MAXIMUM POWER

METERS FEET AVAILABLE (%)

0-750 0-2461 99 1000 3281 95 2000 6562 95 3000 9842 93 4000 13123 88 5000 16404 74 6000 19685 60

HIGH TEMPERATURE OPERATION

At temperatures above 104°F (40°C), output voltage derating may be necessary. For maximum output current ratings, derate welder voltage rating 2 volts for every 21°F (10°C) above 104°F (40°C).

Cold weather starting:

With a fully charged battery and OW40 oil, the engine should start satisfactorily down to -20°F (-29°C). If the engine must be frequently started at or below 0°F (-18°C) cold starting aids are recommended. At temperatures below 23°F (-5°C) fuels in accordance with ASTM S975 Grade 1D diesel fuel is recommended. Allow the engine to idle for 3 to 5 minutes or until the water temperature begins to rise before applying load to switching to high idle.

Under no conditions should ether or other starting fluids be used with this engine!

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WARNING

A-4

INSTALLATION

VANTAGE®435

TOWING

Use a recommended trailer for use with Vantage® 435 for road, inplant and yard towing by a vehicle(1). If the user adapts a non-Lincoln trailer, they must assume responsibility that the method of attachment and usage does not result in a safety hazard or damage the welding equipment. Some of the factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of the welding equipment so there will be no undue stress to the framework.

3. Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced.

4. Typical conditions of use, i.e., travel speed; roughness of surface on which the trailer will be operated; environmental conditions; like maintenance.

5. Conformance with federal, state and local laws.

(1)

Consult applicable federal, state and local laws regarding specific requirements for use on public highways.

VEHICLE MOUNTING

Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail.

• Only transport VANTAGE® 435 on serviceable vehicles which are rated and designed for such loads.

• Distribute, balance and secure loads so vehicle is stable under conditions of use.

• Do not exceed maximum rated loads for components such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of vehicle.

• Follow vehicle manufacturer’s instructions.

------------------------------------------------------------------

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instructions supplied with this machine.

• Stop engine and allow to cool before fueling.

• Do not smoke when fueling.

• Fill fuel tank at a moderate rate and do not overfill.

• Wipe up spilled fuel and allow fumes to clear before starting engine.

• Keep sparks and flame away from tank.

------------------------------------------------------------------

OIL

The

Vantage®435

is shipped with the engine crankcase filled with high quality SAE 10W-30 Oil that meets classification CJ-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 first 50 running hours. Refer to the engine Operator’s Manual for specific oil recommendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the Engine Operator’s Manual for more details on the proper

service and maintenance intervals.

FUEL

USE DIESEL FUEL ONLY-

Ultra low sulphur fuel only.

• Fill the fuel tank with clean, fresh fuel. The capacity of the tank is

20 gallon (75.7 L). When the fuel gauge reads empty the tank contains approximately 2 gallon (7.6 L) of reserve fuel.

NOTE: A fuel shut off valve is located just before the pre-filter/sedi-

ment filter. Which should be in the closed position when the welder is not used for extended periods of time.

------------------------------------------------------------------------

ENGINE COOLING SYSTEM

Air to cool the engine is drawn in the side and exhausted through radiator and case back. It is important that the intake and exhaust air is not restricted. Allow a minimum clearance of 1ft. (0.6m) from the case back and 16 in. (406mm) from either side of the base to a vertical surface.

------------------------------------------------------------------------

BATTERY CONNECTION

Use caution as the electrolyte is a strong acid that can burn skin and damage eyes.

------------------------------------------------------------------------

The

Vantage®435

is shipped with the negative battery cable disconnected. Make certain that the RUN-STOP switch is in the STOP position. Remove the two screws from the battery tray using a screwdriver or a 3/8"(10mm) socket. Attach the negative battery cable to the negative battery terminal and tighten using a 1/2"(13mm) socket or wrench.

NOTE: This machine is furnished with a wet charged battery; if unused for several months, the battery may require a booster charge. Be careful to charge the battery with the correct polarity. (See Battery in “Maintenance Section”)

WARNING

CAUTION

WARNING

A-5

INSTALLATION

VANTAGE®435

EXHAUST OUTLET PIPE

Remove cap from DPF outlet pipe protruding from roof. Using the clamp provided secure the exhaust outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction away from the air intake. Tighten using a 1/2"(13mm) socket or wrench.

SPARK ARRESTOR

Some federal, state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard.

The Diesel Oxidation Catalyst (DOC) on this engine qualifies as a spark arrestor that meets local regulations.

AIR CLEANER INSTALL

All parts below are shipped with the machine in a separate box attached to the crate.(See Figure A.2)

• Remove cap from air intake hose.

• Tighten air hose clamp just below service indicator to hold clamp while pushing air cleaner onto hose

(1)

, once hose is in

place loosen air hose clamp slide down and tighten clamp.

• Install 2 hex head screws, washers using a 1/2” (13mm) wrench or socket to mounting bracket securing air cleaner.

• Unclip air cleaner end cap and rotate “TOP” text to be at approximately 9 o’clock position.

• SERVICE INDICATOR

Air cleaner service indicator provides a Go/No-Go visual indication of useful filter service life.

(1)

Permissable to use a soap water solution as a lubricant to aid in hose installation.

MOUNTING BRACKET

VACUATOR VALVE

INLET HOOD

EXHAUST OUTLET

CLAMP

(5/16-18x 1.25 HHCS) (2)

(LOCK WASHER) (2)

(MAIN WASHER) (2)

SERVICE INDICATOR

AIR HOSE CLAMP

FIGURE A.2

A-6

INSTALLATION

VANTAGE®435

REMOTE CONTROL

This Vantage®435 is equipped with a 12-pin and a 14-pin connector, along with a wireless remote control. To enable remote control capabilities, the LOCAL/REMOTE switch must be in the REMOTE position.

Only STICK mode output adjustment is controlled by the wireless remote.

For the DOWNHILL PIPE or CC-STICK weld mode selector switch positions, remote setting of the preset arc current is set through the 12 pin connector or the 14 pin connector depending on the setup menu setting (12 pin connector is the factory default setting). The OUTPUT CONTROL knob is used to set the maximum arc current preset range for the remote input. The left display will show the arc current preset.

For the TOUCH START TIG weld mode selector switch position, remote setting of the preset arc current is set through the 12 pin connector (typically using a foot Amptrol). The OUTPUT CONTROL knob is used to set the maximum arc current preset range for the remote input. The left display will show the maximum setting for the arc

current preset range as set by the OUTPUT CONTROL knob.

EXAMPLE: When the OUTPUT CONTROL on the welder is set to

200 amps, the arc current preset range on the remote control will preset over the range from minimum to 200 amps, rather than the full minimum to maximum preset arc current range. Any preset arc current range that is less than the full range provides finer arc current preset resolution for more fine tuning of the output.

For the ARC GOUGING weld mode selector switch position, remote setting of the preset arc current is set through the 12 pin connector. The remote input sets the arc current preset over the full range from minimum to maximum. The left display will show the arc current preset.

WIRELESS REMOTE CONTROL

Cold Starting Procedure

(See Figure B.3)

1. Toggle the ON/OFF toggle to the ON position to activate the remote. The STOP/IDLE switch on the control panel needs to be switched to the HIGH IDLE position to START the

Vantage®435

with the wireless remote.

The toggle switch on the receiver box is shipped from the factory

in the OFF position. If it is desired to operate the

Vantage®435 using the controls on the front panel and not the wireless controls, leave the receiver toggle switch in the OFF position

2. Push the START/CI button once on the Transmitter. The greeting screen will illuminate.

3. Push the START/CI button a second time. START will appear in the upper left hand corner of the screen. The glow plugs are pre heating . Wait 15 seconds for glow plugs to pre heat.

4. Push the START/CI button a third time to start the

Vantage®435

. RUN will appear in the upper right hand side of the screen. The Vantage®435

will start in the AUTO IDLE position and CI will display on the screen. To go to HIGH IDLE, push the CO button on the Transmitter. The STOP/IDLE switch on the control panel will remain in the HIGH idle position when using the wireless remote.

5. Push the increase button to test the increase function. Push the decrease button to test the decrease function.

Warm Starting Procedure

(See Figure B.3)

1. Same as steps 1 and 2 from cold start procedure.

2. Push the START button on the transmitter a second time to energize the Receiver and Transmitter. The word START will appear in the upper right hand corner of the screen. Push G.P./SEL button to terminate the glow plugs.

3. Same as step 4 and 5 from cold start procedure.

Shut Down Procedure

(See Figure B.3)

1. Push the STOP button on the Transmitter to shut the engine down.

2. Push the STOP/IDLE switch on the control panel to the OFF position.

Idle Control Operation

(See Figure B.3)

The unit will start and function in AUTO idle. To change the unit to HIGH idle, press the CO button on the transmitter one time. To return the unit to AUTO idle, press the CI button on the transmitter one time.

Output Adjustment

(See Figure B.3)

The output of the welder can be adjusted using the up and down arrow buttons on the transmitter.

Only STICK mode output adjustment is controlled by the wireless remote.

FIGURE B.3

This equipment is capable of remote starting and may start without warning if activated.

Always disconnect battery and turn the Receiver Box Toggle Switch to the “Off” position before servicing this equipment.

OUTPUT 2

STOP

START

G P SEL

IDLE

C O

—

AMPS

WARNING

A-7

INSTALLATION

VANTAGE®435

For operation with a control cable wire feeder: With the CV-WIRE weld mode selector switch position and the WELD TERMINALS ON switch in the REMOTE position, remote

setting of the preset arc voltage is set through the 14 pin connector. The remote input sets the arc voltage preset range from

10.0V to 45.0V. The right display will show the arc voltage preset.

For operation with an across the arc wire feeder (for example, an LN-25 PRO): With the CV-WIRE weld mode selector switch position and the WELD TERMINALS ON switch in the ON position, remote setting

of the preset arc voltage is set through the 12 pin connector. The remote input sets the arc voltage preset range from 10.0V to

45.0V. The right display will show the arc voltage preset.

For the ARCLINK weld mode selector switch position, remote capability is possible only with an ArcLink compatible digital remote control through the 12 pin connector.

NOTE: To connect accessories with a 6 pin connector, use the

included 12-pin to 6-pin adaptor (K2909-1).

-----------------------------------------------------------------

WELDING TERMINALS

The

Vantage®435

is equipped with a toggle switch for selecting "hot" welding terminals when in the "WELD TERMINALS ON" position or "cold" welding terminals when in the "REMOTELY CONTROLLED" position. When in ArcLink, the output of the weld terminals is controlled by the mode selected.

WELDING OUTPUT CABLES

With the engine off, route the electrode and work cables through the strain relief bracket provided on the front of the base and connect to the terminals provided. These connections should be checked periodically and tightened if necessary.

Listed in Table A.2 are copper cable sizes recommended for the rated current and duty cycle. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop.

TABLE A.2

PULSE WELDING

hen pulse welding, always use 4/0 cable. The cables must be sized based upon the peak current of the pulse waveform, not the average current. Do not coil the electrode or work cable. Limit the combined length of the electrode and work cable to 60 feet. Undersized cables, coiled cables and long lengths all increase cable inductance and lower pulse welding performance.

CABLE INSTALLATION

Install the welding cables to your

VANTAGE®520 SD

as follows.

1. The engine must be OFF to install welding cables.

2. Remove the flanged nuts from the output terminals.

3. Connect the electrode holder and work cables to the weld output terminals.

The terminals are identified on the case front.

4. Tighten the flanged nuts securely.

5. Be certain that the metal piece you are welding (the “work”) is properly

connected to the work clamp and cable.

6. Check and tighten the connections periodically.

• Loose connections will cause the output terminals to over-

heat. The terminals may eventually melt.

• Do not cross the welding cables at the output terminal con-

nection. Keep the cables isolated and separate from one

another.

------------------------------------------------------------------

CAUTION

OUTPUT CABLE GUIDELINES

Percent Duty

Amperes

200

250

300

350

400

500

600

** Tabled values are for operation at ambient temperatures of 104°F (40°C) and below. Applications above

104°F (40°C) may require cables larger than recommended, or cables rated higher than 167°F (75°C).

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES [RUBBER COVERED COPPER - RATED 167°F (75°C)]**

Cycle

0 to 50 Ft. 50 to 100 Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft.

100

2/0

1/0

2/0

3/0

2/0

3/0

2-1/0

2/0

1/0

2/0

3/0

2/0

3/0

2-1/0

2/0

3/0

2-1/0

2-2/0

1/0

2/0

3/0

4/0

1/0

2/0

3/0

4/0

2-3/0

A-8

INSTALLATION

VANTAGE®435

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 powered by this engine driven welder must:

a) be grounded to the frame of the welder using a grounded type

plug, or b) be double insulated. When this welder is mounted on a truck or trailer, its frame must be securely

connected to the metal frame of the vehicle. When this engine driven welder is connected to premises wiring such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the section entitled “Standby Power Connections” as well as the article on grounding in the latest National Electrical Code and the local codes.

In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal ground stake going into the ground for at least 10Ft.(3.1m) or to the metal framework of a building which has been effectively grounded. The National Electric Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.

AUXILIARY POWER RECEPTACLES

Start the engine and set the “IDLE/RUN/STOP” switch to the “High Idle” mode. Voltage is now correct at the receptacles for auxiliary power. This must be done before a tripped GFCI can be reset properly. See the MAINTENANCE section for more detailed information on testing and resetting the GFCI. (For location of receptacles see Figure A.3)

The auxiliary power of the

Vantage®435 consists of two 20 Amp-

120 VAC (5-20R) duplex receptacles with GFCI protection, one 50 Amp 120/240 VAC (14-50R) receptacle and one 50 Amp 240VAC Three-Phase (15-50R) receptacle.

The auxiliary power capacity is 11,000 Watts Continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The max permissible current of the 240 VAC output is 50amps.

The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissible current of 50 Amps per output to two separate 120 VAC branch circuits (these circuits cannot be paralleled). Output voltage is within ± 10% at all loads up to rated capacity.

The Three-Phases auxiliary power capacity is 17,000 watts continuous. The maximum current is 40 amps.

FIGURE A.3

120 V DUPLEX RECEPTACLES AND GFCI

A GFCI protects the two 120V auxiliary power receptacles.

A GFCI (Ground Fault Circuit Interrupter) is a device to protect against electric shock should a piece of defective equipment connected to it develop a ground fault. If this situation should occur, the GFCI will trip, removing voltage from the output of the receptacle. If a GFCI is tripped see the MAINTENANCE section for detailed information on testing and resetting it. A GFCI should be properly tested at least once every month.

The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle.

NOTE: The 240 V receptacle has two 120 V circuits, but are of opposite polarities and cannot be paralleled.

All auxiliary power is protected by circuit breakers. The 120V has 20 Amp circuit breakers for each duplex receptacle. The 120/240V Single Phase and the 240V Three-Phases have a 50 Amp 3-pole Circuit Breaker that disconnects both hot leads and all Three Phases simultaneously.

AUXILIARY POWER RECEPTACLES

240 VAC THREE PHASE RECEPTACLE

120/240 VAC SINGLE PHASE RECEPTACLE

120 V RECEPTACLE

20A 120V AUXILIARY BREAKERS

50A 240V THREE POLE BREAKER

FIGURE A.4 Connection of the VANTAGE®435 to Premises Wiring

A-9

INSTALLATION

VANTAGE®435

STANDBY POWER CONNECTIONS

The Vantage®435 is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule.

The Vantage

435 can be permanently installed as a standby power unit for 240 volt-3 wire, 50 amp service. Connections must be made by a licensed electrician who can determine how the 120/240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes. Refer to the connection diagram shown in Figure A.4.

1. Install the double-pole, double-throw switch between the power

company meter and the premises disconnect. Switch rating must be the same or greater than the customer’s premises disconnect and service over current protection.

2. Take necessary steps to assure load is limited to the capacity of the Vantage

435 by installing a 50 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 50 amps. Loading above the rated output will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motor-driven equipment and may result in overheating of the Vantage

435

engine and / or alternate windings.

3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-50P) to the double-pole circuit breaker using No. 6, 4 conductor cable of the desired length.

4. Plug this cable into the 50 Amp 120/240 Volt receptacle on the Vantage

435 case front.

240 VOLT

240 Volt

60 Hz.

3-Wire

Service

POWER

COMPANY

METER

120 VOLT

GROUNDED CONDUCTOR

DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

240 VOLT

50AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

GND

GROUND

NEUTRAL BUS

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

LOAD

50 AMP, 120/240 VOLT

RECEPTACLE

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

A-10

INSTALLATION

VANTAGE®435

CONNECTION OF WIRE FEEDERS WITH CONTROL CABLE (14 PIN)

Shut off welder before making any electrical connections.

------------------------------------------------------------------

CONNECTION OF LF-72, LF-74, FLEX FEED 74 HT, FLEX FEED 84, LN-25 PRO DUAL POWER TO THE VANTAGE

435

• Shut the welder off.

• Set the “WIRE FEEDER VOLTMETER” switch to either “+” or “-” as required by the electrode being used (See Figure A.5).

• For electrode Positive, connect the electrode cable to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable "-" terminal of the welder and work cable to the "+" terminal of the welder.

• Set the “MODE” switch to the “CV-WIRE” position.

• Adjust the “ARC CONTROL” knob to desired Crispness. SOFT for MIG and CRISP for Innershield.

• Set the “WELDING TERMINALS” switch to the “REMOTELY CONTROLLED” position.

• Set the wire feeder voltage switch to 42V.

• Connect the 14 pin control cable from the wire feeder to the

engine drive (See Figure A.6).

• Set the “REMOTE/LOCAL” switch to “REMOTE” if the feeder is equipped with a remote output control knob.

WARNING

Set Polarity to

match electrode

polarity

Set to

Remote

Set weld terminals to

remotely controlled

Set mode to

CV Wire

Set to

42V

FIGURE A.6

FIGURE A.5

ENGINE WELDER

WIRE FEEDER

K1797-xx CABLE

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