Lincoln 500 CE, 400 CE User Manual

VANTAGE® 400 & 500 CE

OPERATOR’S MANUAL

IM2005

07/2015

REV03

ENGLISH

Lincoln Electric Bester Sp. z o.o.

ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland

www.lincolnelectric.eu

THE LINCOLN ELECTRIC COMPANY

EC DECLARATION OF CONFORMITY

Manufacturer and technical documentation holder:

EC Company:

Hereby declare that welding equipment:

Fulfills all relevant provisions of listed Council Directives, amendments and standards:

EN12601: 2010, Reciprocating internal combustion engine

Notified body (for 2000/14/EC Conformity):

Guaranteed sound power level: LWA 96 dB (net power Pel = 11.9 kW)

Measured sound power level: LWA 95 dB (net power Pel = 11.9 kW)

CE marking affixed in 15

Frank Stupczy, Manufacturer Dario Gatti, European Community Representative Compliance Engineering Manager European Engineering Director Machines 28 January 2015 30 January 2015

Place: 22801 St. Clair Ave. Cleveland Ohio 44117-1199 USA

MCD74c

The Lincoln Electric Company 22801 St. Clair Ave. Cleveland Ohio 44117-1199 USA

Lincoln Electric Europe S.L. c/o Balmes, 89 - 80 2a 08008 Barcelona SPAIN

Vantage 400 with CE marking, K2502 (may contain prefixes and suffixes)

Machinery Directive 2006/42/EC; Low Voltage Directive (LVD) 2006/95/EC; Electromagnetic Compatibility (EMC) Directive 2004/108/EC; Noise emission in the environment by equipment for use outdoors 2000/14/EC; Annex VI, procedure 1;

driven generating sets – Safety; EN 60974-1:2005, Safety requirements for arc welding equipment, power sources; EN 60974-10: 2007, Arc Welding Equipment-Part 10: Electromagnetic compatibility (EMC) requirements; EN ISO 3744, Acoustic – Determination of sound power levels of noise sources using sound pressure … 1995

LNE – Number: 0071 ZA de Trappes-Élancourt 29, avenue Roger Hennequin 78197 TRAPPES Cedex

Place: Via Fratelli Canepa, 8 16010 Serra Riccò – Genova - Italy

English English

THE LINCOLN ELECTRIC COMPANY

EC DECLARATION OF CONFORMITY

Manufacturer and technical documentation holder:

EC Company:

Hereby declare that welding equipment:

Fulfills all relevant provisions of listed Council Directives, amendments and standards:

EN12601: 2010, Reciprocating internal combustion engine driven

Notified body (for 2000/14/EC Conformity):

Guaranteed sound power level:

Measured sound power level: LWA 94 dB (net power Pel = 17.1 kW)

CE marking affixed in 15

Frank Stupczy, Manufacturer Compliance Engineering Manager

30 January 2015

Place: 22801 St. Clair Ave. Cleveland Ohio 44117-1199 USA

MCD80c

The Lincoln Electric Company 22801 St. Clair Ave. Cleveland Ohio 44117-1199 USA

Lincoln Electric Europe S.L. c/o Balmes, 89 - 80 2a 08008 Barcelona SPAIN

Vantage 500 with CE marking, K2503 (may contain prefixes and suffixes)

generating sets – Safety; EN 60974-1:2005, Safety requirements for arc welding equipment, power sources; EN 60974-10: 2007, Arc Welding Equipment-Part 10: Electromagnetic compatibility (EMC) requirements; EN ISO 3744, Acoustic – Determination of sound power levels of noise sources using sound pressure … 1995

LNE – Number: 0071 ZA de Trappes-Élancourt 29, avenue Roger Hennequin 78197 TRAPPES Cedex

LWA 95 dB (net power Pel = 17.1 kW)

Dario Gatti, European Community Representative European Engineering Director Machines

30 January 2015

Place: Via Fratelli Canepa, 8 16010 Serra Riccò – Genova - Italy

English English

III

English English

THANKS! For having chosen the QUALITY of the Lincoln Electric products.  Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified

immediately to the dealer.

 For future reference record in the table below your equipment identification information. Model Name, Code &

Serial Number can be found on the machine rating plate.

Model Name:

………………...…………………………….…………………………………………………………………………………………..

Code & Serial number:

………………….……………………………………………….. …………………………………………………….……………..

Date & Where Purchased:

…………………………………………………………………... ……………………….…………………………………………..

ENGLISH INDEX

Technical Specifications ...................................................................................................................................................... 1

Electromagnetic Compatibility (EMC) ................................................................................................................................. 3

Safety .................................................................................................................................................................................. 5

Installation and Operator Instructions ................................................................................................................................. 6

Diagrams ........................................................................................................................................................................... 21

WEEE ................................................................................................................................................................................ 25

Spare Parts ....................................................................................................................................................................... 25

Electrical Schematic .......................................................................................................................................................... 25

Suggested Accessories ..................................................................................................................................................... 25

12/05

English English

(3)

Technical Specifications

VANTAGE ®400 (CE) (K2502-1, -2, -3, -4) VANTAGE

VANTAGE 400 CE

Perkins 404C-22

K2502-1,-2

11296, 11297

Perkins 404D-22

K2502-3,-4 11463, 11464 12195, 12308

VANTAGE 500 CE

Perkins 404C-22T

Codes 11299 and below

Perkins 404D-22T

Codes11299

500 (CE) (K2503-1, -2, -3, -4)

Model Description Speed rpm

4 cylinder 1500 rpm

Water cooled

Diesel Engine

VANTAGE 400 CE

27.6HP

Naturally aspirated

VANTAGE 500 CE

37.2HP

Turbo Charged

Welding Process

INPUT – DIESEL ENGINE

Displaceme

VANTAGE 400 CE

High Idle 1565

Full Load 1500

Low Idle 1200

VANTAGE 500 CE

High Idle 1575

Full Load 1575

2200 cm

Bore and

87,1 x 92,5

Stroke

Low Idle 1200

RATED OUTPUT @ 40°C - WELDER

Welding Output

Current/Volatge/Duty

Cycle

Starting system Capacities

Oil:

8.0l

12Vdc Battery

and Starter

(Group 34;650)

65A Alternator

with build in

regulator

Radiator Coolant:

VANTAGE 400:

7.6l

VANTAGE 500:

9.0l

Max. Weld

Output Range

OCV@Rated Load

RPM

Fuel:

57l

Fuel

75.7l

30 TO 400 AMPS 40 TO 300 AMPS 20 TO 250 AMPS

14 TO 34V

90 TO 400 AMPS

30 TO 400 AMPS

14 TO 34V

60V

(2)

VANTAGE 400 CE

VANTAGE 500 CE

DC Constant Current

DC Pipe Current

Touch-StartTM TIG

DC Constant Voltage

Arc Gouging

DC Constant Current

350/34V/100% 300/32V/100% 250/30V/100% 350/34V/100% 350/34V/100%

400/36V/100%

450/38V/60%

DC Pipe Current 300/38V/60% 40 TO 300 AMPS

Touch-StartTM TIG 250/30V/100% 20 TO 250 AMPS

DC Constant Voltage

400/36V/100%

450/38V/60%

Arc Gouging 450/38V/60% 90 TO 500 AMPS

RATED OUTPUT @ 40°C - GENERATOR

(1)

VANTAGE 400 & 500

6,900 Watts Peak

3,400 Watts Peak 3,400 Watts Peak

Auxiliary Power

/ 6,900 Watts Continuous, 50 Hz 230 Volts 1-Phase (Euro)

(3)

/ 3,400 Watts Continuous, 50 Hz 230 Volts 1-Phase (UK)

(3)

/ 3,400 Watts Continuous, 50 Hz 115 Volts 1-Phase (UK)

Sound Levels (Sound power: 96 dB Lwa)

VANTAGE 400 CE 14,000 Watts Peak / 13,200 Watts Continuous, 50 Hz 400 Volts 3-Phase (Euro/UK)

VANTAGE 500 CE 16.5000 Watts Peak / 14,500 Watts Continuous, 50 Hz 400 Volts 3-Phase (Euro/UK)

ENGINE

LUBRIFICATION EMISSIONS FUEL SYSTEM GOVERNOR

(VANTAGE 400: Codes 11296, 11297

Full Pressure

with Full Flow Filter

VANTAGE 500: Codes 11299 and below):

EPA Tier Il

(VANTAGE 400: Codes 11463, 11464,

12195, 12308

VANTAGE 500: Codes above 11299) EPA

Mechanical Fuel Pump, Auto air

bleed

system, Electric shutoff solenoid,

Indirect fuel injector.

VANTAGE 400:

Mechanical

VANTAGE 500:

Electronic

Tier IV Interim Compliant

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Single Element Automatic Idler

Low noise Muffler:

Top outlet can be rotated.

Made from long life, aluminized

steel.

Shutdown on low oil

pressure & high engine

coolant temperature

English English

ENGINE WARRANTY: 2 years / 2000 hours, all non-electric components, 3 years major non-electric components . See Perkins

(4)

warranty for details.

PHYSICAL DIMENSIONS

Height Width Length Weight

VANTAGE 400 CE 913mm VANTAGE 500 CE 913mm

(1)

Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up

to rated capacity. When welding, available auxiliary power will be reduced.

(2)

Reduced to less than (32V for Codes VANTAGE 400: 11296, 11297,VANTAGE 500: 11298,11299)(30V for Codes

686 mm 1524 mm 559 kg

(4)

687 mm 1590 mm 586 kg

VANTAGE 400: 11463, 11464 and VANATAGE 500: 11524,11525, 11574, 11575) in the CC-stick Mode when VRD (VOLTAGE REDUCTION DEVICE) is on.

(3)

Maximum per circuit breaker rating.

(4)

To Top of enclosure. Add 7.35 (186.7mm) to top of exhaust. Add 3.87”(98.3mm) to top of Lift Bail.

MACHINE SPECIFICATIONS

MODEL NUMBERS

Receptacles

Residual Current Device (RCD)

Circuit Breakers (Thermal/Magnetic)

Other Circuit Breakers

(5)

Center-Tapped to ground

VANTAGE 400 K2502-1, -3 (UK) VANTAGE 500 K2503-1, -3 (UK)

400V (3 phase) x 1 230V (1 phase) x 1

115V x 1

(5)

14 Pin connector

6 Pin connector

(30mA trip current)

3 phase, 25 A x 1

1 phase, 15 A x 1 for 203V

30A x 2 fpr m115V

10A for Battery Charging Circuit

10A for Wire Feeder Power

VANTAGE 400 K2502-2,-4 (EUROPE)

VANTAGE 500 K2503-2, -4 (EUROPE)

400V (3 phase) x 1 230V (1 phase) x 1

14 Pin connector

6 Pin connector

4-pole, 25A

3 phase, 25 A x 1 1 phase, 15 A x 2

Equipped with VRD (VOLTAGE REDUCTION DEVICE)

See Installation and Operation sections for an explanation

English English

Electromagnetic Compatibility (EMC)

Conformance

Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc.

This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electro-magnetic compatibility in those locations, due to conducted as well as radiated disturbances.

Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons. Follow your local and national standards for installation and use. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding

equipment; b) radio and television transmitters and receivers; c) computer and other control equipment; d) safety critical equipment, e.g., guarding of industrial equipment; e) the health of the people around, e.g., the use of pacemakers and hearing aids; f) equipment used for calibration or measurement g) the immunity of other equipment in the environment. The user shall ensure that other equipment being used in

the environment is compatible. This may require additional protection measures; h) the time of day that welding or other activities are to be carried out.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Public Supply System

Welding equipment should be connected to the public supply system according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the system. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

WARNING

English English

Welding Cables The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.

Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard

for arc welding equipment.”

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