Lincoln Electric IM10102 User Manual

Operator’s Manual
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AIR VANTAGE ®650 CUMMINS
For use with machines having Code Numbers:
11654
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SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause can­cer, birth defects, and other reproductive harm.
The Above For Diesel Engines
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.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
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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.
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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.
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1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
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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.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
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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.
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.
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SAFETY
ii
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
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
skin or wet clothing. Wear dry, hole-free
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
fumes and gases away from the breathing zone. When
welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) 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. In confined spaces or in some circum­stances, outdoors, a respirator may 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 coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating prod­ucts.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
ventilation and/or exhaust at the arc to keep
vapors
to
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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SAFETY
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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
Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f. 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.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode if damaged.
7.a.Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
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.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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SAFETY
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PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv­antes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions pour le porte-électrode sʼapplicuent aussi au pistolet de soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer des risques dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de nʼimporte quelle partie du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de soudage. Se protéger avec des vêtements de protection libres de lʼhuile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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SAFETY
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. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.
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 construction of 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.
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Note: The welding circuit may or may not be earthed for safety reasons according to national codes.
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 prob­lems 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.
AIR VANTAGE® 650 CUMMINS
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SAFETY
Electromagnetic Compatibility (EMC)
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
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda­tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. 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 manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
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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
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1.
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod­uct standard for arc welding equipment.”
AIR VANTAGE® 650 CUMMINS
Thank You
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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
CUSTOMER ASSISTANCE POLICY
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.
Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
Your Product”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register
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.
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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
Storing...........................................................................................................................A-2
Stacking ........................................................................................................................A-3
Angle of Operation ........................................................................................................A-3
Lifting.............................................................................................................................A-3
High Altitude Operation .................................................................................................A-3
High Temperature Operation ........................................................................................A-3
Towing...........................................................................................................................A-3
Vehicle Mounting...........................................................................................................A-3
Pre-Operation Engine and Compressor Service ..................................................................A-4
Oil..................................................................................................................................A-4
Fuel and Fuel Cap.........................................................................................................A-4
Engine Coolant System.................................................................................................A-4
Battery Connections......................................................................................................A-4
Muffler Outlet Pipe ........................................................................................................A-5
Spark Arrestor ...............................................................................................................A-5
Air Cleaner Inlet Hood ..........................................................................................................A-5
Welding Terminals................................................................................................................A-5
Welding Output Cables .................................................................................................A-5
Machine Grounding.......................................................................................................A-5
Remote Control ....................................................................................................................A-6
Auxiliary Power Receptacles and Standby Power Connections...................................A-6, A-7
Premises Wiring ...................................................................................................................A-8
Connection of Lincoln Electric Wire Feeders..............................................................A-9, A-10
Electrical Device used with this Product.............................................................................A-11
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Operation.........................................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
General Description..............................................................................................................B-1
Auxiliary Power ............................................................................................................B-1
Engine Operation ..........................................................................................................B-1
Add Fuel ...............................................................................................................................B-2
Hand Primer Button..............................................................................................................B-2
Recommended Applications.................................................................................................B-2
Air Compressor ....................................................................................................................B-2
Generator .............................................................................................................................B-2
Welder Controls......................................................................................................B-3 thru B-4
Engine Controls....................................................................................................................B-5
Engine Operations................................................................................................................B-7
Welder Operations................................................................................................B-8 thru B-10
Auxiliary Power Operation..................................................................................................B-11
Simultaneous Welding and Auxiliary Power Loads.....................................................B-11
Accessories.........................................................................................................Section c
Optional Field Installed Accessories......................................................................C-1
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TABLE OF CONTENTS
Maintenance.......................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Maintenance .......................................................................D-1
Compressor Maintenance .....................................................................................D-1
Engine Maintenance..............................................................................................D-1
Air Filter...........................................................................................................D-1
Service Instructions for Engine Air Cleaner...........................................................D-2
Fuel Filters ......................................................................................................D-3
Cooling System...............................................................................................D-3
Battery Handling .............................................................................................D-4
Charging the Battery .............................................................................................D-4
Servicing Muffler with Internal Spark Arrester .......................................................D-4
Nameplate / Warning Decal Maintenance.............................................................D-5
Welder / Generator Maintenance ..........................................................................D-5
Engine Maintenance Components ........................................................................D-5
GFCI Receptacle Testing and Reseting Procedure ..............................................D-6
________________________________________________________________________
Troubleshooting..............................................................................................Section E
________________________________________________________________________
Connection Diagrams, Wiring Diagrams and Dimension Print...................Section F
________________________________________________________________________
Parts List.....................................................................................................P-684 Series
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A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - AIR VANTAGE® 650 CUMMINS (K2961-1)
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Dry Capacities
cu. in. (ltrs.) System
A-1
4 cylinder High Idle 1860 199(3.3)
69 HP (51.4kw) starter (94.6 L)
Cummins
®
B3.3T 1800 RPM Full Load 1860
Bore x Stroke inch (mm)
12VDC Battery &
Oil: 2 gal. (7.6L) Turbo Charged Diesel Engine Low Idle 1500
3.74 X 4.53
(95 x 115mm) 4.0gal. (15.1L)
Radiator Coolant:
RATED OUTPUT @ 104°F(40°C) - WELDER
Duty Cycle Welding Output Volts at Rated Amps
100% 600 Amps (DC multi-purpose) 44 Volts
60% 650 Amps (DC multi-purpose) 40 volts 40% 700 Amps (DC multi-purpose) 38 volts
OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR
Welding Range
30 - 700 Amps CC/CV
20 - 250 Amps TIG
Open Circuit Voltage
60 Max OCV @ 1860 RPM
Auxiliary Power
120/240 VAC
12,000 WATTS, 60 Hz., Single Phase
20,000 WATTS, 60 Hz., Three Phase
(1)
Fuel: 25 gal.
COMPRESSOR SPECIFICATIONS
Compressor Model
®
VMAC
S700159
Description Delivery Maximum System Compressor Capacities
Pressure Protection
Belt-Drive Rotary
Screw Air Compressor
High Idle Mode: 150 PSI 60 SCFM @ 100PSI
(10.5 kg/cm2) 200 PSI
(28.3 Ltr/sec. @
Safety Relief Valve
(14.1 kg/cm2)
7.0 kg/cm)
High Temperature
Automatic Shutdown
290° F (143°C)
PHYSICAL DIMENSIONS
Height
(2)
Width
36.9 in 28.5 in. 77.0 in. 2018 lbs.
(937mm) (724 mm) (1956 mm) (915 kg)
Lift Bail weight rating 2500 lbs. (1134 kg.) Maximum.
(1) Output rating in watts is equivalent to volt-amperes at unity power factor.
Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced. (2) Top of Enclosure, add 8.3” (211mm) for exhaust pipe, also add 3.65”(93mm) for metal skid. (3) Without metal skid.
(3)
Depth Weight
(Approx.)
1.3 gal.(5.0 ltrs)
AIR VANTAGE® 650 CUMMINS
A-2
SAFETY PRECAUTIONS
WARNING
INSTALLATION
A-2
FIGURE A.1
Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs 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 operatorʼs 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 200Ω (ohms).
The VRD requires that the welding cable connections be kept in good electrical condition because poor connections will contribute to poor starting. Having good electrical con­nections also limits the possibility of other safety issues such as heat-generated damage, burns and fires.
The machine is shipped with the VRD switch in the “Off” position. To turn it “On” or “Off”:
• Turn the engine “Off”.
• Disconnect the negative battery cable.
• Lower the 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.
(VRD)-VOLTAGE REDUCTION DEVICE SWITCH IS LOCATED IN THIS AREA.
REMOVE 4 FRONT PANEL SCREWS TO ACCESS (VRD) SWITCH
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.
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface should be covered with a steel plate at least .06”(1.6mm) thick, which should extend not less than 5.90”(150mm) beyond the equipment on all sides.
------------------------------------------------------------------------
STORING
1. Store the machine in a cool, dry place when it is
not in use. Protect it from dust and dirt. Keep it where it canʼt be accidentally damaged from con­struction activities, moving vehicles, and other hazards.
2. Drain the engine oil and refill with fresh 10W30
oil. Run the engine for about five minutes to cir­culate oil to all the parts. See the MAINTE­NANCE section of this manual for details on changing oil.
3. Remove the battery, recharge it, and adjust the
electrolyte level. Store the battery in a dry, dark place.
AIR VANTAGE® 650 CUMMINS
A-3
INSTALLATION
A-3
STACKING
AIR VANTAGE® 650 CUMMINS machines cannot be stacked.
ANGLE OF OPERATION
To achieve optimum engine performance the AIR VANTAGE position.
The maximum angle of operation for the machine with the compressor running is 25 degrees continuous in all directions.
The maximum angle of operation for the machine with the compressor not running is 35 degrees continuous in all directions.
When operating the welder at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity. Also the effec­tive fuel capacity will be slightly less than the specified 25 gal.(94.6 ltrs.).
®
650 CUMMINS should be run in a level
LIFTING
The
AIR VANTAGE® 650 CUMMINS
weighs approximate­ly 2188 lbs.(992 kg) with a full tank of fuel, 2018 lbs.(915kg) less fuel. A lift bail is mounted to the machine and should always be used when lifting the machine.
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.
• DO NOT EXCEED MAXIMUM LIFT BAIL WEIGHT RATING.
( SEE TECHNICAL SPECIFICATIONS PAGE)
------------------------------------------------------------------------
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary. For maxi­mum rating, derate the welder output 4% for every 300 meters (984 ft.) above 1500 meters (4920 ft.). For output of 500A and below, derate the welder output 4% for every 300 meters (984 ft.) above 2100 meters (6888 ft.).
Contact a Cummins Service Representative for any engine adjust­ments that may be required.
HIGH TEMPERATURE OPERATION
At temperatures above 40°C (104°F), output voltage derating may be necessary. For maximum output current ratings, derate welder
voltage rating 2 volts for every 10°C (21°F) above 40°C (104°F).
TOWING
The recommended trailer for use with this equipment for road, in­plant and yard towing by a vehicle user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor 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 that there will be no undue stress to the trailerʼs framework.
3. Proper placement of the equipment on the trailer to insure sta­bility side to side and front to back when being moved and when standing by itself.
4. Typical conditions of use, such as travel speed, roughness of surface on which the trailer will be operated, and environmental conditions.
5. Proper preventative maintenance of trailer.
6. Conformance with federal, state and local laws
(1)
Consult applicable federal, state and local laws regarding specific require­ments for use on public highways.
(1)
is Lincolnʼs K2637-2. If the
(1)
.
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 manufactureʼs instructions.
-----------------------------------------------------------------------------------------
AIR VANTAGE® 650 CUMMINS
A-4
INSTALLATION
PRE-OPERATION ENGINE AND COM­PRESSOR SERVICE
READ the engine and compressor operating and maintenance instructions supplied with this machine.
WARNING
A-4
ENGINE COOLANT
WARNING
HOT COOLANT can burn skin.
•Do not remove cap if radiator is hot.
• Keep hands away from the engine muffler or HOT engine parts.
• Stop engine and allow to cool before fuelling.
• Do not smoke when fuelling.
• Fill fuel tank at a moderate rate and do not over­fill.
• Wipe up spilled fuel and allow fumes to clear before starting engine.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
OIL
The AIR VANTAGE® 650 CUMMINS is shipped with the engine crankcase filled with high quality SAE 10W-30 oil (API class CD or better). Check the engine and compressor oil levels before starting the engine. If it is not up to the full mark on the dip stick, add oil as required. Check the oil level every four hours of run­ning time during the first 35 running hours. Refer to the engine and compressor Operatorʼs Manuals 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 and compressor Operatorʼs Manuals for the proper service and maintenance intervals.
------------------------------------------------------------------------
The welder is shipped with the engine and radiator filled with a 50% mixture of ethylene glycol and water. See the MAINTENANCE section and the engine Operatorʼs Manual for more information on coolant.
BATTERY CONNECTION
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes away from battery.
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY — disconnect negative cable from old battery first and connect to new battery last.
• CONNECTING A BATTERY CHARGER — remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.
• USING A BOOSTER — connect positive lead to battery first then connect negative lead to nega­tive battery lead at engine foot.
FUEL USE DIESEL FUEL ONLY
Fill the fuel tank with clean, fresh diesel fuel. The
capacity of the fuel tank is approximately 25 gallons (95 liters). See engine Operatorʼs Manual for specif­ic fuel recommendations. Running out of fuel may
require bleeding the fuel injection pump.
NOTE: Before starting the engine, open the fuel shut-
off valve (pointer to be in line with hose).
FUEL CAP
Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap.
AIR VANTAGE® 650 CUMMINS
BATTERY ACID can burn eyes and skin.
• Wear gloves and eye protection and be careful when working near battery.
• Follow instructions printed on battery.
------------------------------------------------------------------------
IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN:
a) Installing new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.
A-5
The AIR VANTAGE® 650 CUMMINS is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative (-) battery terminal.
Remove the insulating cap from the negative battery terminal. Replace and tighten negative battery cable terminal. NOTE: This machine is furnished with a wet charged battery; if unused for several months, the bat­tery may require a booster charge. Be sure to use the correct polarity when charging the battery.
INSTALLATION
MUFFLER OUTLET PIPE
Remove the plastic plug covering the muffler outlet tube. 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 position.
Listed in Table A.1 are copper cable sizes recom­mended for the rated current and duty cycle. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop.
Table A.1 Combined Length of Electrode and
Work Cables.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Parallel Length Cables
Lengths up to 150 ft. (46m) 150 ft. (46m) to 200 ft. (61m) 2 200 ft. (61m) to 250 ft. (76m)
Cable Size for
600 Amps
100% Duty Cycle
1/0 AWG (53mm 2/0 AWG (67mm
3/0 AWG(85mm
A-5
2)
2)
2)
SPARK ARRESTOR
Some federal, state or local laws may require that petrol or diesel engines be equipped with exhaust spark arrestors when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder has an internal spark arrestor. When required by local regulations, a suitable spark arrestor, must be installed and properly maintained.
CAUTION
An incorrect arrestor may lead to damage to the engine or adversely affect performance.
------------------------------------------------------------------------
AIR CLEANER INLET HOOD
Remove the plastic plug covering the air cleaner inlet. Install the air cleaner inlet hood to the air cleaner.
WELDING TERMINALS
The AIR VANTAGE® 650 CUMMINS is equipped with a toggle switch for selecting "hot" welding terminals when in the "WELD TERMINALS ON" position or "cold" welding terminals when in the "REMOTELY CONTROLLED" position.
MACHINE GROUNDING
Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.).
To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must:
WARNING
• Be grounded to the frame of the welder using a grounded type plug or be double insulated.
• Do not ground the machine to a pipe that carries explosive or combustible material.
------------------------------------------------------------------------
When this welder is mounted on a truck or trailer, its frame must be securely connected to the metal frame of the vehicle. When this engine driven welder is con­nected to premises wiring such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the sec­tion entitled “Standby Power Connections” as well as the article on grounding in the latest National Electrical Code and the local codes.
WELDING OUTPUT CABLES
With the engine off, route the electrode and work cables thru the strain relief bracket provided on the front of the base and connect to the terminals provid­ed. These connections should be checked periodically and tightened if necessary.
AIR VANTAGE® 650 CUMMINS
In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal ground stake going into the ground for at least 10 Feet or to the metal frame­work of a building which has been effectively ground­ed.
The National Electric Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.
A-6
INSTALLATION
A-6
REMOTE CONTROL
The AIR VANTAGE® 650 CUMMINS is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K963-3 hand Amptrol. When in the CC-STICK, 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 6-Pin Connector, the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol.
When in the 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.
EXAMPLE: When the OUTPUT CONTROL on the welder is set to 200 amps the current range on the remote control will be 40-200 amps, rather than the full 40-300 amps. Any current range that is less than the full range provides finer current resolution for more fine tuning of the output.
AUXILIARY POWER RECEPTACLES
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 AIR VANTAGE® 650 CUM­MINS consists of two 20 Amp-120 VAC (5-20R) duplex 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 Continuous of 60 Hz, single phase power. The auxil­iary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The max permissi­ble current of the 240 VAC output is 50 amps.
The 240 VAC output can be split to provide two sepa­rate 120 VAC outputs with a max permissible current of 50 Amps per output to two separate 120 VAC branch circuits (these circuits cannot be paralleled). Output voltage is within ± 10% at all loads up to rated capacity.
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 voltage control active. Otherwise, the OUTPUT CONTROL is used to preset the voltage.
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.
WARNING
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 6-pin connec­tor.
------------------------------------------------------------------------
The Three-Phases auxiliary power capacity is 20,000 watts continuous. The maximum current is 48 amps.
120 V DUPLEX RECEPTACLE AND GFCI
A GFCI protects the two 120V auxiliary power.
A GFCI (Ground Fault Circuit Interrupter) is a device to protect against electric shock should a piece of defective equipment connected to it develop a ground fault. If this situation should occur, the GFCI will trip, removing volt­age from the output of the receptacle. If a GFCI is tripped see the MAINTENANCE section for detailed information on testing and resetting it. A GFCI should be properly tested at least once every month.
The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle.
AIR VANTAGE® 650 CUMMINS
A-7
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 Three­Phases have a 50 Amp 3-pole Circuit Breaker that dis­connects both hot leads and all Three Phases simultane­ously.
INSTALLATION
STANDBY POWER CONNECTIONS
The AIR VANTAGE® 650 CUMMINS is suitable for temporary, standby or emergency power using the engine manufacturerʼs recommended maintenance schedule.
A-7
The AIR VANTAGE
®
650 CUMMINS can be perma­nently installed as a standby power unit for 240 volt-3 wire, 50 amp service. Connections must be made by a licensed electrician who can determine how the 120/240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes. The following information can be used as a guide by the electrician for most applications. Refer to the connection diagram shown in Figure A.2.
1. Install the double-pole, double-throw switch
between the power company meter and the premis­es disconnect.
Switch rating must be the same or greater than the customerʼs premises disconnect and service over cur­rent protection.
2. Take necessary steps to assure load is limited to
the capacity of the AIR VANTAGE
®
650 CUMMINS by installing a 50 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 50 amps. Loading above the rated output will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motor-driven equipment and may result in overheating of the AIR VANTAGE 650 CUMMINS engine.
®
3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-50) 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.)
4. Plug this cable into the 50 Amp 120/240 Volt recep-
®
tacle on the AIR VANTAGE
650 CUMMINS case
front.
AIR VANTAGE® 650 CUMMINS
A-8
INSTALLATION
A-8
240 Volt
60 Hz.
3-Wire
Service
Figure A.2 Connection of the AIR VANTAGE
240 VOLT
POWER
COMPANY
METER
DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT
PROTECTION.
120 VOLT
120 VOLT
50AMP
240 VOLT
®
650 CUMMINS to Premises Wiring
GROUNDED CONDUCTOR
NEUTRAL BUS
GROUND
N
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
LOAD
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
GND
N
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
AIR VANTAGE® 650 CUMMINS
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