Lincoln Electric VANTAGE 400, 11467, Vantage 500, 11962, 12359 Operator's Manual

...

Operator’s Manual

VANTAGE 400

For use with machines having Code Numbers:

11530, 11785, 11920, 12305, 12319

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM989-D | Issue D ate Jul-16

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

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.

WARNING

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

CAUTION

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.

se corrective lenses if necessary

U 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.

Safety 01 of 04 - 06/15/2016

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Gasoline Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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.

SAFETY

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

heir removal is complete. Always use the greatest care when

t 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

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.

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 02 of 04 - 06/15/2016

SAFETY

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

f 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

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.

between the

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.

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

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 03 of 04 - 06/15/2016

SAFETY

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

rom starting a fire. Remember that welding sparks and hot

f 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.

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,

tc. should be suitable for the application and

e 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.

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.

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 04 of 04 - 06/15/2016

VANTAGE 400

TABLE OF CONTENTS

Page

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

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

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

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

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

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

Angle of Operation ................................................................................................................................A-2

Lifting......................................................................................................................................................A-2

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

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

Cold Weather Operation...........................................................................................................................A-3

Towing .................................................................................................................................................A-3

Vehicle Mounting ..................................................................................................................................A-3

Pre-Operation Engine Service........................................................................................................................A-3

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

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

Engine Coolant .....................................................................................................................................A-4

Battery Connections..............................................................................................................................A-4

Muffler Outlet Pipe................................................................................................................................A-4

Spark Arrester ......................................................................................................................................A-4

Remote Control........................................................................................................................................A-4

Electrical Connections...................................................................................................................................A-5

Machine Grounding...............................................................................................................................A-5

Welding Terminals................................................................................................................................A-5

Welding Output Cables ............................................................................................................................A-5

Cable Installation .....................................................................................................................................A-5

Auxiliary Power Receptacles and Plugs .........................................................................................................A-6

Standby Power Connections..........................................................................................................................A-6

Premises Wiring .............................................................................................................................................A-7

Connection of Lincoln Electric Wire Feeders .............................................................................................A-8,A-9

________________________________________________________________________________

Operation Section B

Safety Precautions .......................................................................................................................................B-1

General Description.......................................................................................................................................B-1

For Auxiliary Power .......................................................................................................................................B-1

Engine Operation............................................................................................................................................B-1

Add Fuel .......................................................................................................................................................B-1

Break in Period .............................................................................................................................................B-1

Welder Controls......................................................................................................................................B-2,B-3

Engine Controls.............................................................................................................................................B-4

Starting and Stopping the Engine..........................................................................................................B-4

Fuel Consumption.................................................................................................................................B-4

Welding Operation ........................................................................................................................................B-5

Duty Cycle and Electrode Information ...................................................................................................B-5

Constant Current (Stick) Welding ..........................................................................................................B-5

Typical Current Ranges for Tungsten Electrodes ...................................................................................B-5

Downhill Pipe (Stick) Welding ...............................................................................................................B-6

Tig Welding ..........................................................................................................................................B-6

Wire Welding-CV...................................................................................................................................B-7

Arc Gouging..........................................................................................................................................B-7

Auxiliary Power .............................................................................................................................................B-7

Simultaneous Welding and Power Loads...............................................................................................B-7

Extension Cord Recommendations........................................................................................................B-7

________________________________________________________________________________

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

Field Installed

________________________________________________________________________________

Options / Accessories .........................................................................................................C-1

ANTAGE 400

TABLE OF CONTENTS

aintenance ..............................................................................................................................Section D

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

Routine Maintenance ....................................................................................................................D-1

Engine Service Items ...................................................................................................................D-1

Engine Oil Change................................................................................................................D-2

Engine Oil Filter Change .......................................................................................................D-2

Air Cleaner ...........................................................................................................................D-2

Service Instructions And Installation Tips for Engine Air Filter ...............................................D-3

Cooling System............................................................................................................................D-4

Fan Belt ...............................................................................................................................D-4

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

GFCI Testing and Resetting Procedure..................................................................................D-6

________________________________________________________________________

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

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

Troubleshooting Guide....................................................................................................E-2 thru E-6

________________________________________________________________________

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

________________________________________________________________________

Parts List .......................................................................................................................................P-590

________________________________________________________________________

GENERAL DESCRIPTION

The VANTAGE 400 is a diesel engine powered DC multi-process

elding power source and 120 / 240 volt AC power generator.

w The engine drives a generator that supplies three phase power for the DC welding circuit, single phase and Three Phase power for the AC auxiliary outlets. The DC welding control system uses state of the art Chopper Technology (CT™) for superior welding performance.

The Vantage 400 is fitted with a selectable VRD (Voltage Reduction Device). The VRD operates in the CC-Stick mode reducing the OCV to <13 volts, increasing operator safety when welding is performed in environments with increased hazard of electric shock.

FOR AUXILIARY POWER:

Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings providing no welding current is being drawn.

ENGINE OPERATION

Before Starting the Engine:

PRODUCT DESCRIPTION

• Be sure the machine is on a level surface.

• Open side engine door and remove the engine oil dipstick and wipe it with a clean cloth. Reinsert the dipstick and check the level on the dipstick.

• Add oil (if necessary) to bring the level up to the full mark. Do not overfill. Close engine door.

• Check radiator for proper coolant level. (Fill if necessary).

• See Engine Owner’s Manual for specific oil and coolant recommendations.

TECHNICAL SPECIFICATIONS - VANTAGE 400 (K2410-3, K2410-4, K2410-7)

INPUT - DIESEL ENGINE

ake/Model Description Speed (RPM) Displacement Starting Capacities

PERKINS cu. in. (ltrs.) System

4 cylinder 135.6(2.2)

32.7 HP High Idle 1880 starter (75.7 L) 1800 RPM Bore x Stroke inch (mm) (Group 34; 650 Oil: 8.45Qts. (8L)

404D-22 naturally aspirated Full Load 1800 cold crank amps)

water cooled

Diesel Engine Low Idle 1400 (87.1 x 92.5mm) W/Built in Regulator 8.0 Qts. (7.6L)

3.43 X 3.64

65 Amp Alternator Radiator Coolant:

RATED OUTPUT @ 104° F (40° C) - WELDER

Welding Process

DC Constant Current

DC Pipe Current

Touch-Start™TIG

DC Constant Voltage

Arc Gouging

Welding Output Current/Voltage/Duty Cycle

400A / 36V / 100% 450A / 32V / 100%

300A / 32V / 100% 250A / 30V / 100% 400A / 36V / 100% 450A / 32V / 100% 400A / 36V / 100%

Output Range

30 TO 500 AMPS

40 TO 300 AMPS 20 TO 250 AMPS

14 TO 36 VOLTS

90 to 450 Amps

RATED OUTPUT @ 104° F (40° C).- GENERATOR

Auxiliary Power

12,000 Watts Peak, / 11,000 Watts Continuous, 60 Hz 120/240 Volts Single Phase

19,000 Watts Peak, / 17,000 Watts Continuous, 60 Hz, 240 Volts 3-Phase

12VDC Battery &

Max. Weld OCV

@Rated Load RPM

60 Volts

Fuel: 20 gal.

INSTALLATIONVANTAGE 400

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

35.94* in. 25.30 in 60.00 in.

913 mm 643 mm 1524 mm

1230 lbs. (559kg.)

ENGINE

LUBRICATION EMISSIONS FUEL SYSTEM GOVERNOR

Full Pressure K2410-3 EPA Tier 4 Interim Compliant Mechanical Fuel Pump, Auto air bleed Mechanical

with Full Flow Filter K2410-4 EPA Tier 4 Interim Compliant system, Electric shutoff solenoid,

K2410-7 EPA Tier 4 Final Compliant Indirect fuel injector.

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Low noise Muffler: Shutdown on low oil

Single Element Automatic Idler Top outlet can be rotated. pressure & high engine

Made from long life, aluminized steel. coolant temperature

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

MACHINE SPECIFICATIONS

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS

(2) 120VAC Duplex (5-20R) GFCI protected (1) 120/240VAC Dual Voltage (1) 50AMP for Dual Voltage and for 10AMP for 42V Wire Feeder Power (Full KVA (14-50R)14-50R) 3-Phase (3-pole) (1) 240VAC 3-Phase (15-50R)

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.

* To Top of enclosure, add 10.68”(271.3mm) to top of exhaust pipe. Add 6.67”(169.4mm) to top of Lift Bail.

2. Reduced to less than 30V in the CC-stick Mode when VRD (VOLTAGE REDUCTION DEVICE) is on.

Two 20AMP for Two Duplex Receptacle 10AMP for Battery Charging Circuit

A-1

SAFETY PRECAUTIONS

(

VRD)-VOLTAGE REDUCTION DEVICE

WITCH IS LOCATED IN THIS AREA.

REMOVE 4 FRONT PANEL S

CREWS TO ACC ESS

(VRD) SWITCH

WARNING

o not attempt to use this equipment until you have thor-

D oughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

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

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from 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.

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

See additional warning information at front of this

operator’s manual.

Only qualified personnel should install, use, or service this equipment.

VRD (VOLTAGE REDUCTION DEVICE)

The VRD feature provides additional safety in the CC-Stick mode especially in an environment with a higher risk of electric shock such as wet areas and hot humid sweaty conditions.

The VRD reduces the OCV (Open Circuit Voltage) at the welding output terminals while not welding to less than 30V DC when the resistance of the output circuit is above 200 (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 control panel by removing 4 front 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 “On” position, the VRD lights

are enabled.

INSTALLATIONVANTAGE 400

IGURE 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.

STACKING

VANTAGE 400 machines cannot be stacked.

ANGLE OF OPERATION

Engines are designed to run in the level condition which is where the optimum performance is achieved. The maximum angle of continuous operation is 25 degrees in all directions, 35 degrees Intermittent (less than 10 minutes continuous) in all directions. If the engine is to be operated at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity in the crankcase.

When operating the welder at an angle, the effective fuel capacity will be slightly less than the amount specified.

LIFTING

The VANTAGE 400 weighs approximately 1345lbs. (611kg.) with a full tank of fuel 1230lbs.(559kg) less fuel. A lift bail is mounted to the machine and should always be used when lifting the machine.

A-2

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

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

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

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

INSTALLATIONVANTAGE 400

. 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 mainte-

ance.

5. Conformance with federal, state and local laws.

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

(

(1)

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”)

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary. For maximum rating, derate the machine 2.5% to 3.5% for every 1000 ft. (305m). Due to new EPA and other local emissions regulations, modifications to the engine for high altitude are restricted within the United States. For use above 6000 ft.(1828 m) an authorized Perkins engine field service shop should be contacted to determine if any adjustments can be made for operation in higher elevations.

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(-26C°). If the engine must be frequently started at or below 0°F (-18°C), it may be desirable to install cold-starting aides. The use of No. 1D diesel fuel is recommended in place of No. 2D at temperatures below 23°F (-5°C). Allow the engine to warm up before applying a load or switching to high idle.

Note: Extreme cold weather starting may require longer glow plug operation.

VEHICLE MOUNTING

WARNING

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

• Only transport this Equipment 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.

WARNING

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

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

TOWING

Use a recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle(1). If the user adapts a non-Lincoln trailer, he 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.

• 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.

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

A-3

INSTALLATIONVANTAGE 400

OIL

The VANTAGE 400 is shipped with the engine crankcase filled with high quality SAE 10W-30 Oil that meets classification CG-4 or CH-4 for diesel engines. Check the oil level before starting

he engine. If it is not up to the full mark on the dip stick, add oil

t as required. Check the oil level every four hours of running time

uring the first 50 running hours. Refer to the engine Operator’s

d 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

WARNING

• Fill the fuel tank with clean, fresh fuel. The capacity of the tank is 20 gals. (75.7 ltrs). When the fuel gauge reads empty the tank contains approximately 2 gals. (7.6ltrs.) of reserve fuel.

WARNING

NOTE: A fuel shut off valve is located on 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

MUFFLER OUTLET PIPE

Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction. Tighten using a 9/16" socket or wrench.

SPARK ARRESTER

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 standard muffler included with this welder does not qualify as a spark arrester. When required by local regulations, a suitable spark arrester, such as the K903-1 must be installed and properly maintained.

WARNING

An incorrect spark arrestor may lead to damage to the engine or adversely affect performance.

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

REMOTE CONTROL

The VANTAGE® 400 is equipped with a 6-pin and a 14-pin connector. When in the ARC GOUGING or CV-WIRE modes and when a remote control is connected to the 6-pin Connector, the auto-sensing circuit automatically switches the OUTPUT control from control at the welder to remote control.

When in TOUCH START TIG mode and when a Amptrol is connected to the 6Pin Connector, the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol.

When in the CC-STICK or DOWNHILL PIPE mode and when a remote control is connected to the 6-Pin or 14-Pin connector, the output control is used to set the maximum current range of the remote.

WARNING

Air to cool the engine is drawn in the side and exhausted through radiator & 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 16in.(406mm) from either side of the base to a vertical surface.

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

BATTERY CONNECTION

CAUTION

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

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

The VANTAGE 400 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" socket. Attach the negative battery cable to the negative battery terminal and tighten using a 1/2" socket or wrench.

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

The 14-pin connector is used to directly connect a wire feeder control cable. In the CV-WIRE mode, when the control cable is connected to the 14-pin connector, the auto-sensing circuit automatically makes the Output Control inactive and the wire feeder voltage control active.

NOTE: When a wire feeder with a built in welding voltage control is connected to the 14-pin connector, do not connect anything to the 6pin connector.

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

ELECTRICAL CONNECTIONS

A-4

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.)

INSTALLATIONVANTAGE 400

current and duty cycle. Length refers to the distance from the

elder to the work and back to the welder. Cable diameters are

w increased for long cable lengths to reduce voltage drops.

TABLE A.1

CABLE INSTALLATION

To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must:

• Be grounded to the frame of the welder using a grounded type plug or be double insulated.

WARNING

• Do not ground the machine to a pipe that carries explosive or combustible material.

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

When this welder is mounted on a truck or trailer, its frame

WARNING

must be electrically bonded to the metal frame of the vehicle. Use a #8 or larger copper wire connected between the machine grounding stud and the 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 code.

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 water pipe going into the ground for at least ten feet and having no insulated joints, or to the metal framework of a building which has been effectively grounded.

The National Electrical 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.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

Cable Length

0-100 Ft. (0-30 meters)

100-150 Ft. (30-46 meters)

150-200 Ft. (46-61 meters)

Install the welding cables to your VANTAGE 400 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.

Cable Size for

400 Amps

60% Duty Cycle

2 / 0 AWG

3 / 0 AWG

CAUTION

• Do not cross the welding cables at the output terminal

connection. Keep the cables isolated and separate from one another.

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

AUXILIARY POWER RECEPTACLES

WELDING TERMINALS

The VANTAGE 400 is equipped with a toggle switch for selecting "hot" welding terminal when in the "WELD TERMINALS ON" position or "cold" welding terminal when in the "REMOTELY CONTROLLED" position.

WELDING OUTPUT CABLES

With the engine off connect the electrode and work cables to the output studs. The welding process dictates the polarity of the electrode cable. These connections should be checked periodically and tightened with a 3/4" wrench.

Table A.1 lists recommended cable sizes and lengths for rated

Start the engine and set the “IDLER” control 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.

The auxiliary power of the VANTAGE 400 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 12,000 watts Peak, 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

A-5

INSTALLATIONVANTAGE 400

is 50amps.

The 240 VAC output can be split to provide two separate 120 VAC

utputs with a max permissible current of 50 Amps per output to

o 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 peak, 19,000 watts continuous. The maximum current is 45 amps.

120 V DUPLEX RECEPTACLES AND GFCI

A GFCI protects, the two 120V Auxiliary Power receptacles. A GFCI (Ground Fault Circuit Interrupter) electrical receptacle 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.

circuit breaker. Maximum rated load for each leg of the 240

AC auxiliary is 50 amperes. Loading above the rated output

V will reduce output voltage below the allowable - 10% of rated

oltage which may damage appliances or other motor-driven

v equipment and may result in overheating of the engine and/or alternator windings.

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. (The 50 amp, 120/240 VAC plug is available in the optional K802R plug kit or as part number T12153-9.)

• Plug this cable into the 50 Amp, 120/240 Volt receptacle on the case front.

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.

STANDBY POWER CONNECTIONS

The VANTAGE 400 is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule.

The VANTAGE 400 can be permanently installed as a standby power unit for 240 VAC, 3 wire, single phase, 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.

• 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.

• Take necessary steps to assure load is limited to the capacity of the generator by installing a 50 amp, 240 VAC double pole

A-6

CONNECTION OF VANTAGE 400 TO PREMISES WIRING

240 Volt

0 Hz.

-Wire

Service

POWER

COMPANY

METER

240 VOLT

120 VOLT

OAD

NEUTRAL BUS

ROUND

PREMISES

ISCONNECT AND

SERVICE

OVERCURRENT

ROTECTION

GND

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

240 VOLT

ROUNDED CONDUCTOR

0AMP

240 VOLT

OUBLE POLE

CIRCUIT

BREAKER

OUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES S

ERVICE OVERCURRENT

ROTECTION.

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT

RECEPTACLE

INSTALLATIONVANTAGE 400

WARNING

• 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.

• The premises is isolated and no feedback into the utility system can occur. Certain state and local laws require the premis-

es to be isolated before the generator is linked to the premises. Check your state and local requirements.

• A double pole, double throw transfer switch in conjunction with the properly rated double throw circuit breaker is connect-

ed between the generator power and the utility meter.

A-7

INSTALLATIONVANTAGE 400

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

Connection of LN-7 or LN-8 to the VANTAGE 400

1. Shut the welder off.

2. Connect the LN-7 or LN-8 per instructions on the appropriate

connection diagram in Section F.

3. Set the "WIRE FEEDER VOLTMETER" switch to either "+" or

"-" as required by the electrode being used.

4. Set the "MODE" switch to the "CV WIRE " position.

5. Set the "ARC CONTROL" knob to "0" initially and adjust to

suit.

6. Set the "WELD TERMINALS" switch to the "REMOTELY CON-

TROLLED" position.

7. Set the "IDLE" switch to the "HIGH" position.

Connection of LN-15 to the VANTAGE 400

4. Control Cable Model:

• Connect Control Cable between Engine Welder and Feeder.

• Set the "WELD TERMINALS" switch to "REMOTELY CONTROLLED"

Set the MODE switch to the "CV-WIRE " position.

•

• Set the "WIRE FEEDER VOLTMETER" switch to either "+" or "-" as required by the electrode polarity being used.

• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

• Set the "IDLE" switch to the "AUTO" position.

• When the gun trigger is closed, the current sensing circuit will cause the VANTAGE 400 engine to go to the high idle speed, the wire will begin to feed and the welding process started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

1. Shut the welder off.

2. 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 to the "-" terminal of the welder and work cable to the "+" terminal of the welder.

3. Across The-Arc Model:

• Attach the single lead from the front of the LN-15 to work using the spring clip at the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current.

• Set the "WELD TERMINALS" switch to "WELD TERMINALS ON".

A-8

INSTALLATIONVANTAGE 400

WARNING

Connection of the LN-25 to the VANTAGE 400 Shut off welder before makin g any elec tri cal connections.

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

The LN-25 with or without an internal contactor may be used with the VANTAGE 400. See the appropriate connection diagram in Section F.

NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the VANTAGE

400.

1. Shut the welder off.

2. For electrode Positive, connect the electrode cable from the LN-25 to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable from the LN-25 to the "-" terminal of the welder and work cable to the "+" terminal of the welder.

Spool Gun (K487-25) and Cobramatic to VANTAGE 400

• Shut the welder off.

• Connect per instructions on the appropriate connection diagram in Section F.

Connection of PRINCE XL SPOOL GUN to the VANTAGE 400

Connection of the Prince XL Spool Gun requires the use of the K1849-1 Adapter Module.

• Shut the Welder off.

• 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.

• Connect the Control Cable of the Spool Gun to the Adapter Module and connect the Control Cable of the Adapter Module to the Welder.

3. Attach the single lead from the front of the LN-25 to work using the spring clip at the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current.

4. Set the MODE switch to the "CV-WIRE " position.

5. Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"

6. Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

7. Set the "IDLE" switch to the "AUTO" position. When not welding, the VANTAGE 400 engine will be at the low idle speed. If you are using an LN-25 with an internal contactor, the electrode is not energized until the gun trigger is closed.

8. When the gun trigger is closed, the current sensing circuit will cause the VANTAGE 400 engine to go to the high idle speed, the wire will begin to feed and the welding process started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

• Connect the Gas Hose.

• Set the MODE switch to the "CV-WIRE " position.

• Set the "WELD TERMINALS" switch to "WELD TERMINALS ON".

• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

• Set the “IDLE” switch to the “HIGH” position.

CAUTION

If you are using an LN-25 without an internal contactor, the electrode will be energized when the VANTAGE 400 is started.

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

A-9

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions,

et ailed engine starting, operating an d maintenanc e

d instructions, and parts lists.

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

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• 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 operat-

ing this machine. Always follow these and any other safety procedures included in this manual and in the Engine Instruction Manual.

GENERAL DESCRIPTION

The VANTAGE 400 is a diesel engine powered DC multi-process welding power source and 120 / 240 volt AC power generator. The engine drives a generator that supplies three phase power for the DC welding circuit, single phase and Three Phase power for the AC auxiliary outlets. The DC welding control system uses state of the art Chopper Technology (CT™) for superior welding performance.

Th e Van ta ge 400 is fitt ed with a sele ct ab le VRD(Voltage Reduction Device). The VRD operates in the CC-Stick mode reducing the OCV to <13 volts, increasing operator safety when welding is performed in environments with increased hazard of electric shock.

OPERATIONVANTAGE 400

ADD FUEL

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from tank.

• Do not leave unattended while fueling.

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

DIESEL FUEL

can cause fire.

• Do not overfill tank, fuel expansion may cause overflow.

DIESEL FUEL ONLY

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

• Remove the fuel tank cap.

• Fill the tank. DO NOT FILL THE TANK TO THE POINT OF OVERFLOW.

• Replace the fuel cap and tighten securely.

• See Engine Owner’s Manual for specific fuel recommendations.

BREAK-IN PERIOD

The engine will use a small amount of oil during its “break-in” period. The break-in period is about 50 running hours.

FOR AUXILIARY POWER:

Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings providing no welding current is being drawn.

ENGINE OPERATION

Before Starting the Engine:

• Be sure the machine is on a level surface.

• Open side engine door and remove the engine oil dipstick and wipe it with a clean cloth. Reinsert the dipstick and check the level on the dipstick.

• Add oil (if necessary) to bring the level up to the full mark. Do not overfill. Close engine door.

• Check radiator for proper coolant level. (Fill if necessary).

• See Engine Owner’s Manual for specific oil and coolant recommendations.

Check the oil every four hours during break-in. Change the oil after the first 50 hours of operation and every 200 hours thereafter. Change the oil filter at each oil change.

CAUTION

During break-in, subject the Welder to moderate loads. Avoid long periods running at idle. Before stopping the engine, remove all loads and allow the engine to cool several minutes.

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

B-1

ANTAGE 400

OPERATION

FIGURE B.1

WELDING CONTROLS (Figure B.1)

1. OUTPUT CONTROL-

voltage or current as displayed on the digital meters for the five welding modes. When in the ARC GOUGING or CV-WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector, the auto-sensing circuit automatically switches the OUTPUT CONTROL from control at the welder to the remote control.

The OUTPUT dial is used to preset the output

2. DIGITAL OUTPUT METERS-The digital meters allow the output

voltage (CV-WIRE mode) or current (CC-STICK,DOWN HILL PIPE and TIG modes) to be set prior to welding using the OUTPUT control dial. During welding, the meter display the actual output voltage (VOLTS) and current (AMPS). A memory feature holds the display of both meters on for seven seconds after welding is stopped. This allows the operator to read the actual current and voltage just prior to when welding was ceased.

When in the CC-STICK or DOWNHILL PIPE mode and when a remote control is connected to the 6-Pin or 14-Pin connector, the output control is used to set the maximum current range of the remote.

In the CV-WIRE mode, if the feeder being used has a voltage control when the wire feeder control cable is connected to the 14-Pin Connector, the auto-sensing circuit automatically makes OUTPUT CONTROL inactive and the wire feeder voltag e control active. Otherwise, the OUTPUT CONTROL is used to preset the voltage. When in the TOUCH START TIG mode and when an Amptrol is connected to the 6-Pin Connector, the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol.

While the display is being held the left-most decimal point in each display will be flashing. The accuracy of the meters is +/- 3%.

3. WELD MODE SELECTOR SWITCH-

(Provides Five selectable welding modes)

CV-WIRE ARC GOUGING DOWNHILL PIPE CC-STICK TOUCH START TIG

B-2

ANTAGE 400

OPERATION

4. ARC CONTROL- The ARC CONTROL dial is active in the CV-WIRE,

CC-STICK and DOWNHILL PIPE modes, and has different functions in

hese modes. This control is not active in the TIG mode and ARC

t GOUGING mode.

CC-STICK mode: In this mode, the ARC CONTROL dial sets the short

ircuit current (arc-force) during stick welding to adjust for a soft or

c crisp arc. Increasing the dial from –10 (soft) to +10 (crisp) increases the short circuit current and prevents sticking of the electrode to the plate while welding. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with a setting at 0.

DOWNHILL PIPE mode: In this mode, the ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or a 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. Typically a forceful digging arc is preferred for root and hot passes. A softer arc is preferred for fill and cap passes where weld puddle control and deposition ("stacking" of iron) are key to fast travel speeds. It is recommended that the ARC CONTROL be set initially at 0.

CV-WIRE mode: In this mode, turning the ARC CONTROL clock wise from –10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp and narrow. It acts as an inductance/pinch control. The proper setting depends on the procedure and operator preference. Start with a setting of 0.

5. WELD OUTPUT TERMINALS WITH FLANGE NUT- Provides a

connection point for the electrode and work cables.

6. GROUND STUD- Provides a connection point for connecting

the machine case to earth ground.

7. 14-PIN CONNECTOR- For attaching wire feeder control cables.

Includes contactor closure circuit, auto-sensing remote control circuit, and 120V and 42V power. The remote control circuit operates the same as the 6 Pin Amphenol.

8. 6-PIN CONNECTOR- For attaching optional remote control equip-

ment. Includes auto-sensing remote control circuit.

9. WELD TERMINALS CONTROL SWITCH- In the WELD TERMI-

NALS ON position, the output is electrically hot all the time. In the REMOTELY CONTROLLED position, the output is controlled by a wire feeder or amptrol device, and is electrically off until a remote switch is

depressed.

cator lights. A red light when lit indicates

reater than 30V and a green light when

Voltage) is equal to or

lit indicates

OCV(Open Circuit Voltage)

OCV (Open Circuit

is less than 30V.

The VRD “On/Off” switch inside the control panel must be “On” for the VRD function to be active and the lights to be enabled. When the machine is first started with VRD enabled, both lights

ill illuminate for 5 seconds.

These lights monitor the

OCV (Open Circuit Voltage)

and weld voltage at all times. In the CC-Stick mode when not welding the green light will illuminate indicating that the VRD has reduced the OCV to less than 30V. During welding the red light will illuminate whenever the arc voltage is equal to or greater than 30V. This means that the red and green light may alternate depending on the weld voltage. This is normal operation.

If the red light remains illuminated when not welding in the CCstick mode, the VRD is not functioning properly. Please refer to your local field service shop for service.

If the VRD is turned “On” and the lights don’t come “On”, refer to the trouble shooting section.

TABLE B.1

MODE VRD "ON" VRD "OFF"

CC-STICK OCV Green (OCV Reduced)

While Red or Green

Welding (Depends on Weld Voltage) * CV-WIRE OCV Red (OCV Not Reduced) Weld Terminals On Red (OCV Not Reduced) Weld Terminals Remotely Controlled Gun Trigger Closed Green (No OCV) Weld Terminals Remotely Controlled Gun Trigger Open No Lights

While Red or Green

Welding (Depends on Weld Voltage) * PIPE OCV Green (No Output)

While Not Applicable (No Output)

Welding ARC GOUGING

While Not Applicable (No Output)

Welding TIG OCV Green (Process is Low Voltage)

While Green (Process is Low Voltage)

Welding

OCV Green (No Output)

VRD INDICATOR LIGHTS

* It is normal for the lights to alternate between colors while welding.

10. WIRE FEEDER VOLTMETER SWITCH:

Matches the polarity of the wire feeder voltmeter to the polarity of the electrode.

11. VRD (Voltage Reduction Device) INDICATOR LIGHTS- On the front panel of the VANTAGE 400 are two indi-

B-3

ANTAGE 400

OPERATION

ENGINE CONTROLS:

12. RUN/STOP SWITCH - RUN position energizes the engine prior

to starting. STOP position stops the engine. The oil pressure interlock switch prevents battery drain if the switch is left in the RUN

osition and the engine is not operating.

13. GLOW PLUG PUSH BUTTON -

• When pushed activates the glow plugs. Glow plug should not be activated for more than 20 seconds continuously.

14. START PUSH BUTTON - Energizes the starter motor to crank

the engine.

15. IDLER SWITCH- Has two positions as follows:

1) In the HIGH position, the engine runs at the high idle speed

controlled by the engine governor.

2) In the AUTO position, the idler operates as follows:

• When switched from HIGH to AUTO or after starting the engine, the engine will operate at full speed for approximately 12 seconds and then go to low idle speed.

• When the electrode touches the work or power is drawn for lights or tools (approximately 100 Watts minimum), the engine accelerates and operates at full speed.

• When welding ceases or the AC power load is turned off, a fixed time delay of approximately 12 seconds starts. If the welding or AC power load is not restarted before the end of the time delay, the idler reduces the engine speed to low idle speed.

• The engine will automatically return to high idle speed when there is welding load or AC power load reapplied.

16. ELECTRIC FUEL GAUGE- The electric fuel gauge gives accu-

rate and reliable indication as to how much fuel is in the fuel tank.

17. ENGINE HOUR METER- Displays the total time that the engine has

been running. This meter is useful for scheduling prescribed maintenance.

18. ENGINE PROTECTION LIGHT- A warning indicator light for Low

Oil Pressure and/or Coolant Over Temperature.The light is off when the systems are functioning properly. The light will come on and the engine

TABLE B.2

TYPICAL VANTAGE 400 FUEL CONSUMPTION

Low Idle - No Load 1400 R.P.M. High Idle - No Load 1880 R.P.M. DC Weld Output 400 Amps @ 36 Volts 17,000 Watts 3 Phase 11,000 Watts 1 Phase

PERKINS 404C-22 Gal./Hr (Liters/Hr)

.26 (.97)

.42 (1.57)

1.18 (4.46)

1.24 (4.68) .90 (3.42)

Running Time for

20 gallons / hours

76.92

47.62

16.95

16.13

22.22

will shutdown when there is Low Oil Pressure and/or the Coolant is Over Temperature.

Note: The light remains off when the RUN-STOP switch is in the "ON" position prior to starting the engine.However if the engine is not started within 60 seconds the light will come on. When this happens the RUNSTOP switch must be returned to the "OFF" position to reset the engine protection system and light.

19. BATTERY CHARGING LIGHT- A warning indicator light

for Low/No battery charge. The light is off when the systems are functioning properly. The light will come on if there is a Low/No battery con-

dition but the machine will continue to run. Note: The light may or may not come on when the RUN-STOP switch is in the "ON" position. It will come on during cranking and stay on until the engine starts. After starting the engine the light will go off unless a Low/No battery charge condition exists.

20. COOLANT TEMPERATURE GAUGE-A indicator of engine coolant

temperature.

21. OIL PRESSURE GAUGE- A indicator of engine Oil Pressure.

22. CIRCUIT BREAKER- For protection of Battery Charging Circuit.

23. CIRCUIT BREAKER- For protection of 42V Wire Feeder circuit.

STARTING THE ENGINE

1. Remove all plugs connected to the AC power receptacles.

2. Set IDLER switch to AUTO.

3. Press Glow Plug Button and hold 15 to 20 seconds.

4. Set the RUN/STOP switch to RUN.

5. Press START button until the engine starts or for up to 10 seconds.

Continue to hold the glow plug button for up to an additional 10 seconds.

6. Release the engine START button immediately when the engine

starts.

7. The engine will run at high idle speed for approximately 12 seconds

and then drop to low idle speed. Allow the engine to warm up at low idle for several minutes before applying a load and/or switching to high idle. Allow a longer warm up time in cold weather.

NOTE: This data is for reference only. Fuel consumption is approximate and can be influenced by many factors, including engine maintenance, environmental conditions and fuel quality.

B-4

ANTAGE 400

OPERATION

NOTE: If the unit fails to start turn Run/Stop switch to off and

repeat step 3 through step 7 after waiting 30 seconds.

CAUTION

• Do not allow the starter motor to run continuously than 20 seconds.

• Do not push the START button while the engine is run-

ning because this can damage the ring gear and/or the starter motor.

• IF the Engine Protection or Battery Charging Lights do

“not” turn off shortly after starting the engine shut off the engine immediately and determine the cause.

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

NOTE: When starting for the first time, or after and extended period of time of not operating, it will take longer than normal to start because the fuel pump has to fill the fuel system. For best results, bleed the fuel system as indicated in Maintenance Section of this manual.

STOPPING THE ENGINE

Remove all welding and auxiliary power loads and allow the engine to run at low idle speed for a few minutes to cool 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.

ELECTRODE INFORMATION

For any electrode the procedures should be kept within the rating of the machine. For information on electrodes and their proper application see (www.lincolnelectric.com) or the appropriate Lincoln publication.

for more

set to the minimum number without electrode sticking. Start with the dial set at 0.

NOTE: Due to the low OCV with the VRD on, a very slight delay during striking of the electrodes may occur. Due to the

equirement of the resistance in the circuit to be low for a

r VRD to operate, a good metal-to-metal contact must be made between the metal core of the electrode and the job. A poor connection anywhere in the welding output circuit may limit the operation of the VRD. This includes a good connection of the work clamp to the job. The work clamp should be connected as close as practical to where the welding will be performed.

A. For New Electrodes

E6010 - Touch, Lift to Start the Arc E7018, E7024 - Touch, Rock Back and Forth in Joint, Lift .

Once the arc is started, normal welding technique for the application is then used.

B. For Re-Striking Electrodes

Some electrodes form a cone at the end of the electrode after the welding arc has been broken, particularly iron powder and low hydrogen electrodes. This cone will need to be broken off in order to have the metal core of the electrode make contact.

E6010 - Push, Twist in Joint, Lift E7018, E7024 - Push, Rock Back and Forth in Joint, Lift.

Once the arc is started, normal welding technique for the application is then used.

For other electrodes the above techniques should be tried first and varied as needed to suit operator preference. The goal for successful starting is good metal to metal contact.

For indicator light operation, see table B.1.

DOWNHILL PIPE Welding

The VANTAGE 400 can be used with a broad range of DC stick electrodes. The MODE switch provides two stick welding settings as follows:

CONSTANT CURRENT (CC-STICK) WELDING

The CC-STICK position of the MODE switch is designed for horizontal and vertical-up welding with all types of electrodes, especially low hydrogen. The OUTPUT CONTROL dial adjusts the full output range for stick welding. The ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or crisp arc. Increasing the number from -10(soft) to +10(crisp) increases the short circuit current and prevents sticking of the electrode to the plate while welding. This can also increase spatter. It is recommended that the ARC CONTROL be

This slope controlled setting is intended for "out-of-position" and "down hill" pipe welding where the operator would like to control the current level by changing the arc length.

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.

Typically a forceful digging arc is preferred for root and hot passes. A softer arc is preferred for fill and cap passes where weld puddle control and deposition (“stacking” of iron) are key to fast

B-5

ANTAGE 400

travel speeds. This can also increase spatter.

It is recommended that the ARC CONTROL be set to the minimum

umber without electrode sticking. Start with the dial set at 0.

NOTE: With the VRD switch in the “ON” position there is no output in the DOWNHILL PIPE mode.

For indicator light operation, see table

B.1.

TIG WELDING

The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the OUTPUT CONTROL dial is first set to the desired current and the tungsten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and, in general, no tungsten contamination. Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.

OPERATION

he VANTAGE 400 can be used in a wide variety of DC TIG weld-

T ing applications. In general the ‘Touch Start’ feature allows contamination free starting without the use of a Hi-frequency unit. If desired, the K930-2 TIG Module can be used with the VANTAGE

400. The settings are for reference.

ANTAGE 400 settings when using the K930-2 TIG Module with

V an Amptrol or Arc Start Switch:

• Set the MODE Switch to the TOUCH START TIG setting.

• Set the "IDLER" Switch to the "AUTO" position.

• Set the "WELDING TERMINALS" switch to the "REMOTELY CONTROLLED" position. This will keep the "Solid State" contactor open and provide a "cold" electrode until the Amptrol or Arc Start Switch is pressed.

When in the TOUCH START TIG mode and when a Amptrol is connected to the 6-Pin connector the OUTPUT CONTROL dial is used to set the maximum current range of the current control of the Amptrol.

When using the TIG Module, the OUTPUT CONTROL on the VANTAGE 400 is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module. NOTE: The TIG process is to receive a low voltage welding process.

There is no difference in operation with the VRD “On” or “Off” for

The ARC CONTROL is not active in the TIG mode. To STOP a

this mode. For indicator light operation, see table B.1.

weld, simply pull the TIG torch away from the work. When the arc voltage reaches approximately 30 Volts the arc will go out and the machine will reset the current to the Touch Start level.

To reinitiate the arc, retouch the tungsten to the work and lift. Alternatively, the weld can be stopped by releasing the Amptrol or arc start switch.

WIRE WELDING-CV

Connect a wire feeder to the VANTAGE 400 according to the instructions in INSTALLATION INSTRUCTIONS Section.

The VANTAGE 400 in the CV-WIRE mode, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding). Welding can be

TABLE B.3

TYPICAL CURRENT RANGES

Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH

Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)

1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel Tungsten Tungsten

.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6

0.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)

0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)

1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6

3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8 1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)

5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10 3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10) 1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)

(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases. (2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure EWP

1% Thoriated EWTh-1

2% Thoriated EWTh-2

Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications. (3) DCEP is not commonly used in these sizes. (4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:

(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures and high duty cycles.

# 4 = 1/4 in. (6 mm) # 5 = 5/16 in. (8 mm) # 6 = 3/8 in. (10 mm) # 7 = 7/16 in. (11 mm) # 8 = _ in. (12.5 mm) #10 = 5/8 in. (16 mm)

(1)

FOR TUNGSTEN ELECTRODES

(2)

B-6

ANTAGE 400

OPERATION

finely tuned using the ARC CONTROL. Turning the ARC CONTROL clockwise from –10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp and narrow. It acts as an inductance/pinch control. The proper setting depends on the procedure and operator preference. Start with the dial set at 0.

NOTE: In the CV-Mode with VRD “On”, the OCV(Open Circuit Voltage) is

not reduced. For indicator light operation, see table B.1.

ARC GOUGING

The VANTAGE 400 can be used for arc gouging. For optimal performance, set the MODE switch to

et the OUTPUT CONTROL knob to adjust output current to the desired

S level for the gouging electrode being used according to the ratings in the following Table B.4.

Carbon Diameter

1/8"(3.2mm) 60-90 Amps 5/32"(4.0mm) 90-150 Amps 3/16"9(4.8mm) 200-250 Amps 1/4"(6.4mm) 300-400 Amps 5/16"(8.0mm) 400-Max.Amps

The ARC CONTROL is not active in the ARC GOUGING Mode. The ARC CONTROL is automatically set to maximum when the ARC GOUGING mode is selected which provides the best ARC GOUGING performance.

NOTE: With the VRD switch in the “ON” position there is no output in the Arc Gouging Mode. For indicator light operation, see Table B.1.

ARC GOUGING.

TABLE B.4

Current Range (DC, electrode

positive)

Weld

Amps

0 100 200 300 400 500

PLUS

AUXILIARY POWER:

Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings providing no welding current is being drawn.

Simultaneous Welding and Auxiliary Power Loads

The a uxi liary power r ati ngs are wi th no weld ing l oad . Simultaneous welding and power loads are specified in the following Table B.5.

TABLE B.5

VANTAGE 400 Simultaneous Welding and Power Loads

1 PHASE

WATTS AMPS

11,000 46 11,000 46

8,000 33 4700 20 1700 7

WATTS AMPS

17,000 41 15,400 37 13,000 31

9400 23 3400 8

TABLE B.6

VANTAGE 400 (CE) Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

3 PHASE

WATTS AMPS

11,000 11,000 -

8,000 4,700 1,700 -

BOTH 1 & 3 PHASE

Current

(Amps)

15 20 15 20 44

Voltage

Volts

120 120 240 240 240

Load

(Watts)

1800 2400 3600 4800 9500

Maximum Allowable Cord Length in ft. (m) for Conductor Size

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

(9)

(18)

40 30 75 60

Conductor size is based on maximum 2.0% voltage drop.

(12)

(9) (23) (18)

50 150 100

B-7

(23) (15) (46) (30) (15)

125

88 225 175

(38) (27) (69) (53) (27)

175 138 350 275 150

(53) (42)

(107)

(84) (46)

300 225 600 450 225

(91)

(69) (183) (137)

(69)

+ 56 hidden pages

Lincoln Electric VANTAGE 400, 11467, Vantage 500, 11962, 12359 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual