Lincoln Electric VANTAGE 600 SD Operator's Manual

Operator’s Manual

VANTAGE® 600 SD

For use with machines having Code Numbers:

11981

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Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10177 | Issue D ate Jun-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.

o

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

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INSTALLATION

The VANTAGE®600 SD is a diesel engine-driven welding power source. The machine uses a brush type alternating current generator for DC multi-purpose welding, for 120/240 VAC single phase and 240V three phase auxiliary standby power. The welding control system uses state of the art Chopper Technology™.

TECHNICAL

SPECIFICATIONS

INPUT - DIESEL ENGINE

Make /Model

(K3239-1)

DEUTZ Turbo Charged

TD2.9L4 Diesel Engine

EPA TIER 4 Final Compliant

Speed (RPM)

High Idle 1800

Low Idle 1525

Full Load

Starting System

12VDC battery and Starter

with Automatic Glow Plugs

Turbo Charged Water Cooled

Description

4 cylinder 64HP (48 kw)

Diesel Engine

Displacement

178 cu. in. (2.9L)

Bore x Stroke

3.62” x 4.33”

92mm x 110mm

Capacities

Fuel 25 US gal (94.6L) Oil: 2.25 US gal. (8.5L)

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

Welding Range

30 - 600 Amps CC/CV

20 - 350 Amps TIG

Open Circuit Voltage

60 Max OCV @ 1800 RPM

Auxiliary Power

120/240 VAC

12,000 WATTS, 60 Hz., Single Phase

20,000 WATTS, 60 Hz., Three Phase

(1)

PHYSICAL DIMENSIONS

(2)

Height

(3)

Width

Depth

Weight

(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 16.8” (427mm) for exhaust and air cleaner. (3) Includes Door. Base is 31.6”(803mm) wide.

42.0 in (1066.8 mm)

32.9 in. (835.7mm)

69.0 in. (1753mm)

1662lbs. (753kg) (Approx.)

RATED OUTPUT @ 104°F(40°C) - WELDER

Duty Cycle Welding Output Volts at Rated Amps

100% 575 Amps 43 Volts

(DC multi-purpose)

60% 600 Amps 40 volts

(DC multi-purpose)

A-1

VANTAGE® 600 SD

ON / OFF VDR SWITCH

REMOVE 4 SIDE PANEL SCREWS TO ACCESS (VRD) SWITCH

FRONT PANEL ROTATES AWAY FROM THE FRONT PART OF WELDER

INSTALLATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.

ELECTRIC SHOCK can kill.

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

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

• Us e in o pen, w e ll ven t ilated are as 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

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

VRD (VOLTAGE REDUCTION DEVICE)

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

FIGURE A.1

LOCATION AND VENTILATION

The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area.

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

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

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

• Turn the engine “Off”.

• Disconnect the negative battery cable.

• Lower the Front panel by removing 4 side panel screws. (See Figure A.1)

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

A.1)

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.

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STORING

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

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

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

STACKING

VANTAGE

®

600 SD machines cannot be stacked.

A-2

VANTAGE® 600 SD

INSTALLATION

ANGLE OF OPERATION

To achieve optimum engine performance the VANTAGE®600 SD

hould be run in a level position. The maximum angle of operation

s for the Deutz engine is 30 degrees in all directions. When operating the welder at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity. Also

he effective fuel capacity will be slightly less than the specified

t 25 gal.(94.6 ltrs.)will be slightly less than the amount specified.

LIFTING

The VANTAGE with a full tank of fuel and 1662lbs. (753kg) less fuel. A lift bail is mounted to the machine and should always be used when lifting the machine.

®

600 SD weighs approximately 1836lbs. (832kg)

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

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

FALLING • Do not lift machine if lift bale is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bale.

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HIGH TEMPERATURE OPERATION

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

Cold weather starting:

With a fully charged battery and OW40 oil, the engine should start satisfactorily down to -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. For engines with common rail injection, the mixing of petroleum or kerosene and adding of extra low additives is not permissible. Fuels in accordance with ASTM S975 Grade 1D or DIN EN590-Arctic-Diesel may have no petroleum added. Allow the engine to warm up before applying a load or switching to high idle.

WARNING

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

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HIGH ALTITUDE OPERATION

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

TABLE A.1 DEUTZ D 2.9 L4

METERS FEET AVAILABLE (%)

ALTITUDE MAXIMUM POWER

0-750 0-2461 99

1000 3281 95

2000 6562 95

3000 9842 93

4000 13123 88

5000 16404 74

6000 19685 60

A-3

VANTAGE® 600 SD

INSTALLATION

TOWING

se a recommended trailer for use with this equipment for road, in-plant and

U yard towing by a vehicle assume responsibility that the method of attachment and usage does not result in a safety hazard or damage the welding equipment. Some of the factors to be considered are as follows:

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

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

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

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

5. Conformance with federal, state and local laws.

(1)

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

1)

(

. If the user adapts a non-Lincoln trailer, they must

(1)

VEHICLE MOUNTING

WARNING

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

OIL

The VANTAGE®600 SD is shipped with the engine crankcase filled with high quality SAE 10W-30 Oil that meets engines. Check the oil level before starting the engine. If it is not up to the full

ark on the dip stick, add oil as required. Check the oil level every four hours

m of running time during the first 50 running hours. Refer to the engine Operator’s Manual for specific oil recommendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the Engine Operator’s Manual for more details on the

proper service and maintenance intervals.

(API class CJ-4 or better)

for diesel

FUEL

USE DIESEL FUEL ONLY-

Ultra low sulphur fuel only.

WARNING

• Fill the fuel tank with clean, fresh fuel. The capacity of the tank is 25 gals. (94.6 ltrs). When the fuel gauge reads empty the tank contains approximately 2 gals. (7.6 ltrs.) of reserve fuel.

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

ment filter. Place the valve in the closed position when the welder is not used for extended periods of time.

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

• 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.

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PRE-OPERATION ENGINE SERVICE

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

WARNING

• 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.

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FUEL CAP

Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap.

WARNING

ENGINE COOLING SYSTEM

Air to cool the engine is drawn in the side and exhausted through radiator and case back. It is important that the intake and exhaust air is not restricted. Allow a minimum clearance of 1ft. (0.6m) from the case back and 16 in. (406mm) from either side of the base to a vertical surface. (Failure to resolve these guidelines may result in an overtemp condition resulting in engine shut down).

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A-4

VANTAGE® 600 SD

SERVICE INDICATOR

AIR HOSE CLAMP

MOUNTING BRACKET

EXHAUST OUTLET

CLAMP

SEAL

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

(LOCK WASHER) (2)

(MAIN WASHER) (2)

VACUATOR VALVE

INLET HOOD

INSTALLATION

BATTERY CONNECTION

CAUTION

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

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

The

VANTAGE®600 SD

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

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

WARNING

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.

SPARK ARRESTOR

ome federal, state or local laws may require that gasoline or

S diesel engines be equipped with exhaust spark arresters when

hey are operated in certain locations where unarrested sparks

t may present a fire hazard.

The DOC (Diesel Oxidation Catalyst) unit included with this

elder qualifies as a spark arrester.

w

WARNING

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

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AIR CLEANER INSTALL

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

• Remove cap from air intake hose and DOC exhaust attached on machine. Insert air cleaner into bracket between the two ridges of a larger diameter. Position the end cap so that “Top” is at 9 o’clock.

• Remove plug and install service indicator, use thread sealant or tape on pipe threads.

• Tighten air hose clamp just below service indicator to hold clamp while pushing air cleaner onto hose, once hose is in place loosen air hose clamp slide down and tighten clamp.

• Install 2 hex head screws, washers to mounting bracket securing air cleaner.

• SERVICE INDICATOR

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

FIGURE A.2

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.

EXHAUST OUTLET PIPE

Remove cap from DOC pipe protruding from roof. 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 away from the air intake. Tighten using a 1/4"(6mm) internal socket or allen wrench. Torque to 106in.lbs.(9ft.-lbs.)(12N-M)

A-5

VANTAGE® 600 SD

** Tabled values are for opera tion at ambient temperatures of 104°F (40°C) and below. Applications above 104°F (40°C) may require cables larger than recommended, or cables rated higher than 167°F (75°C).

200

250

300

350

400

500

600

Amperes

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

Percent Duty

C

ycle

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

60

100

30

40

60

100

60

100

40

60

100

60

80

100

2

3

2

1

2/0

1/0

2/0

3/0

2/0

3/0

2-1/0

2

3

2

1

2/0

1/0

2/0

3/0

2/0

3/0

2-1/0

2

1

2/0

3/0

2-1/0

1

1/0

2/0

3/0

4/0

2-2/0

1/0

2/0

3/0

4/0

2-3/0

O

UTPUT CABLE GUIDELINES

INSTALLATION

REMOTE CONTROL

he VANTAGE

T nector. To enable remote control capabilities, the LOCAL/REMOTE switch must be in the REMOTE position.

or the DOWNHILL PIPE or CC-STICK weld mode selector switch

F positions, remote setting of the preset arc current is set through the 12 pin connector or the 14 pin connector depending on the setup menu setting (12 pin connector is the factory default setting). The OUTPUT CONTROL knob is used to set the maximum arc current preset range for the remote input. The left display will show the arc current preset.

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

current preset range as set by the OUTPUT CONTROL knob.

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

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

®

00 SD is equipped with a 12-pin and a 14-pin con-

6

WELDING OUTPUT CABLES

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

nd tightened if necessary.

a

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

TABLE A.2

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

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

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

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

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

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

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

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

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

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WELDING TERMINALS

The welding terminals when in the "WELD TERMINALS ON" position or "cold" welding terminals when in the "REMOTELY CONTROLLED" position. When in ArcLink, the output of the weld terminals is controlled by the mode selected.

VANTAGE®600 SD

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

is equipped with a toggle switch for selecting "hot"

PULSE WELDING

W

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

CABLE INSTALLATION

Install the welding cables to your

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.

A-6

VANTAGE®600 SD

as follows.

VANTAGE® 600 SD

240 VAC THREE PHASE RECEPTACLE

120/240 VAC SINGLE PHASE RECEPTACLE

CIRCUIT BREAKERS

IDLER SWITCH

BATTERY 20A BREAKER

10A 42V/40V ARCLINK BREAKERS

20A 120V AUXILIARY BREAKERS

AUXILIARY POWER RECEPTACLES

CAUTION

• Loose connections will cause the output terminals to overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another.

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

MACHINE GROUNDING

Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.).

To prevent dangerous electric shock, other equipment powered by this engine driven welder must:

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

plug, or

b) be double insulated.

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

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

INSTALLATION

FIGURE A.3

120 V DUPLEX RECEPTACLES AND GFCI

A GFCI protects the two 120V auxiliary power receptacles.

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

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

AUXILIARY POWER RECEPTACLES

Start the engine and set the “IDLE/RUN/STOP” 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 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 Continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The max permissible current of the 240 VAC output is 50amps.

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

The Three-Phases auxiliary power capacity is 20,000 watts continuous. The maximum current is 50 amps.

VANTAGE®600 SD consists of two 20

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. (See Figure A.3)

A-7

VANTAGE® 600 SD

60 Hz.

3-Wire

POWER

COMPANY

METER

240 VOLT

120 VOLT

LOAD

N

NEUTRAL BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

N

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

240 VOLT

GROUNDED CONDUCTOR

50AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

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

SERVICE OVERCURRENT

PROTECTION.

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT

RECEPTACLE

STANDBY POWER CONNECTIONS

INSTALLATION

The VANTAGE®600 SD is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule.

The VANTAGE®600 SD can be permanently installed as a standby power unit for 240 volt-3 wire, 50 amp service. Connections must

e made by a licensed electrician who can determine how the

b 120/240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes. Refer to the connection diagram shown in Figure A.4.

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

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

FIGURE A.4 Connection of the VANTAGE® 600 SD to Premises Wiring

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

®

the VANTAGE

600 SD 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

hich may damage appliances or other motor-driven equipment

w and may result in overheating of the VANTAGE

®

600 SD engine

and / or alternate windings.

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

4. Plug this cable into the 50 Amp 120/240 Volt receptacle on the VANTAGE®600 SD case front.

A-8

VANTAGE® 600 SD

WIRE FEEDER

ENGINE WELDER

K1797-xx CABLE

Set Mode to

CV Wire

Set to

Remote

Set to

42V

Set Weld Terminals to

Remotely Controlled

Set Polarity to Match

Electrode Polarity

CONNECTION OF WIRE FEEDERS WITH CONTROL CABLE (14 PIN)

WARNING

Shut off welder before making any electrical connections.

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

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

®

VANTAGE

• Shut the welder off.

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

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

600 SD

IGURE A.5

F

INSTALLATION

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

• Adjust the “ARC CONTROL” knob to desired Crispness. SOFT for

• Set the “WELDING TERMINALS” switch to the “REMOTELY

• Set the wire feeder voltage switch to 42V.

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

• Set the “REMOTE/LOCAL” switch to “REMOTE” if the feeder is

MIG and CRISP for Innershield.

CONTROLLED” position.

engine drive (See Figure A.6).

equipped with a remote output control knob.

FIGURE A.6

A-9

VANTAGE® 600 SD

Set Mode to

CV Wire

Set to

Local

Weld

Terminals On

INSTALLATION

CONNECTION OF ACROSS THE ARC WIRE FEEDERS TO THE VANTAGE

hese connections instructions apply to both the LN-25 Pro and

T Activ8 models. The feeders have an internal contactor and the

lectrode is not energized until the gun trigger is closed. When the

e gun trigger is closed the wire will begin to feed and the welding process is started.

• 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.

• Attach the single lead from the front of the feeder 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 (See Figure A.8).

• Set the MODE switch to the "CV-WIRE" position (See Figure A.7).

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

®

600 SD

FIGURE A.7

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

• Set the “REMOTE/LOCAL” switch to “LOCAL” control.

FIGURE A.8

A-10

VANTAGE® 600 SD

B

A

C

WORK

VANTAGE

600 SD

®

INSTALLATION

CABLE INDUCTANCE AND ITS EFFECTS ON WELDING

xcessive cable inductance will cause the welding performance to

E degrade. There are several factors that contribute to the overall

nductance of the cabling system including cable size, and loop

i area. The loop area is defined by the separation distance between the electrode and work cables, and the overall welding loop length. The welding loop length is defined as the total of length of the electrode cable (A) + work cable (B) + work path (C) (See Figure A.9).

To minimize inductance always use the appropriate size cables, and whenever possible, run the electrode and work cables in close proximity to one another to minimize the loop area. Since the most significant factor in cable inductance is the welding loop length, avoid excessive lengths and do not coil excess cable. For long work piece lengths, a sliding ground should be considered to keep the total welding loop length as short as possible.

Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built into the 5-pin ArcLink control cable and is always connected to the wire drive feed plate when an ArcLink wire feeder is present. Enabling or disabling electrode voltage sensing is application specific, and automatically configured by the active weld mode.

Voltage sense leads requirements are based on the weld process (See Table A.3)

TABLE A.3

Process

Electrode Voltage Sensing

67 lead

GMAW

FCAW

GTAW

SMAW

(1)

The electrode voltage sense lead (67) is automatically enabled by the weld process, and integral to the 5 pin ArcLink control cable (K1543-xx) or K2683-xx.

Voltage sense at studs Voltage sense at studs

67 lead 67 lead

(1)

CONTROL CABLE CONNECTIONS

General Guidelines

Genuine Lincoln control cables should be used at all times (except

here noted otherwise). Lincoln cables are specifically designed

w for the communication and power needs of the Power Feed™systems. Most are designed to be connected end to end for ease of extension. Generally, it is recommended that the total length not exceed 200ft. (60.960m). The use of non-standard cables, especially in lengths greater than 25 feet, can lead to communication problems (system shutdowns), poor motor acceleration (poor arc starting), and low wire driving force (wire feeding problems). Always use the shortest length of control cable possible, and DO NOT coil excess cable.

Regarding cable placement, best results will be obtained when control cables are routed separate from the weld cables. This minimizes the possibility of interference between the high currents flowing through the weld cables, and the low level signals in the control cables.

Product specific Installation Instructions

®

Connection Between VANTAGE

600 SD and ArcLink®Compatible

Wire feeders (K1543, K2683 – ArcLink®Control Cable)

The 5-pin ArcLink®control cable connects the VANTAGE®600 SD to the wire feeder. The control cable consists of two power leads, one twisted pair for digital communication, and one lead for voltage sensing. The 5-pin ArcLink®connection on the VANTAGE®600 SD is located on control panel. The control cable is keyed and polarized to prevent improper connection. Best results will be obtained when control cables are routed separate from the weld cables, especially in long distance applications. The recommended combined length of the ArcLink®control cable network should not exceed 200ft. (60.960m).

Engine Welder and

FIGURE A.9

A-11

ANTAGE

V

®

00 SD

6

NOTES

A-12

ANTAGE

V

®

00 SD

6

OPERATION

SAFETY INSTRUCTIONS

ead and understand this entire section before operating

R your VANTAGE

®

600 SD.

WARNING

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

D oughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.

ELECTRIC SHOCK can kill.

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

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent

exhaust outside

• Do not stack anything near the engine.

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

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts

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

Only qualified personnel should operate this equipment.

RECOMMENDED APPLICATIONS

WELDER

he VANTAGE

T welding output for stick (SMAW) and TIG (GTAW) welding. The VANTAGE welding output for MIG (GMAW), Innershield (FCAW), Outershield

FCAW-G) and Metal Core (GMAW-C) welding. In addition the

( VANTAGE to 1/2”(13mm) in diameter.

The VANTAGE

®

00 SD provides excellent constant current DC

6

®

600 SD also provides excellent constant voltage DC

®

600 SD can be used for Arc Gouging with carbons up

®

600 SD is not recommended for pipe thawing.

GENERATOR

The

VANTAGE®600 SD and 240V three phase output for auxiliary power and emergency standby power.

provides smooth 120/240 VAC single phase

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the sliding door closed and the side panels in place as these provide maximum protection from moving parts and insure proper cooling air flow.

B-1

ANTAGE

V

®

00 SD

6

CONTROLS AND SETTINGS

All welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow.

igure B.1 CASE FRONT PANEL CONTROLS

F

OPERATION

12

1

14

7

8

9

1

11

2

13

15

31

0

3

3a

3b

3c

3d

3e

4

5

6a

6

16

17

23

11a

19

20

21

22

18

24

ENGINE CONTROLS

1. STOP / (LOW IDLE/RUN) / (HIGH IDLE/RUN) SWITCH

Toggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds. The engine must be started within that time or the fuel solenoid will degenerize, and the switch must be toggled to reset the timer.

Has two positions as follows:

1) In the “High” position , the engine runs at the high idle speed controlled by the governor.

2) In the “Auto” / position, the idler operates as follows:

25

a. 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.

b. 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.

c. When welding ceases and the AC power load is turned off, a

fixed time delay of approximately 12 seconds starts.

d. 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.

e. The engine will automatically return to high idle speed when the

welding load or A.C. power load is reapplied.

B-2

ANTAGE

V

dler Operational exceptions

I

®

00 SD

6

When the WELDING TERMINALS switch is in the “Remotely Controlled” position or the MODE SELECTION switch is in the

®

ArcLink

position the idler will operate as follows:

• When the triggering device (Amptrol, Arc Start Switch, etc.) is

pressed the engine will accelerate and operate at full speed provided a welding load is applied within approximately 12 seconds.

If the triggering device remains pressed but no welding load is

•

applied within approximately 12 seconds the engine may return to low idle speed.

• If the triggering device is released or welding ceases the

engine will return to low idle speed after approximately 12 seconds.

2. START SWITCH

Energizes the starter motor to crank the engine. With the engine "Run / Stop" switch in the "Run" position, push and release the Start button to start the engine:

• this switch has an amber light (Top of switch) to indicate Glow light, this engine will automatically apply power to the glow circuit and indicator light will turn off when glow is completed. (Engine will crank but will not start until glow cycle is completed)

• this switch also has a red light (Bottom of switch) it will light up when there are faults with the engine. (Check engine light comes on) Field Service Shop will need to connect to diagnostic plug to read error codes.

OPERATION

4. OUTPUT CONTROL- The OUTPUT dial is used to preset the

output voltage or current as displayed on the digital meters for

he five welding modes.

t

5. VRD (Voltage Reduction Device) INDICATOR LIGHTS- O

®

front panel of the VANTAGE when lit indicates OCV(Open Circuit Voltage) is equal to or greater than 30V and a green light when lit indicates OCV(Open Circuit Voltage) 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 will illuminate for 5 seconds.

These lights monitor the OCV(Open Circuit Voltage) and weld voltage at all times. 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 or both VRD lights flash when not welding, 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.

600 SD are two indicator lights. A red light

n the

3. DASH BOARD GAUGE

The dash board gauge displays 5 gauges:

3a. OIL PRESSURE

The gauge displays the engine oil pressure when the

engine is running.

3b. ENGINE TEMPERATURE

The gauge displays the engine coolant temperature.

3c. HOUR METER

The hour meter displays the total time that the engine

has been running. This meter is a useful indicator for scheduling preventive maintenance.

3d. FUEL LEVEL

Displays the level of diesel fuel in the fuel tank.

The operator must watch the fuel level closely to

prevent running out of fuel and possibly having to bleed the system.

3e. BATTERY VOLTAGE INDICATOR

Displays the battery voltage and indicates that the

charging system is functioning properly.

B-3

ANTAGE

HIDDEN SETUP MENU ACCESS PORT: INS ERT TOO L OR PAPER CLIP TO AC CESS

V

6.

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6

DIGITAL OUTPUT METERS-

The digital meters allow the preset arc output voltage (CV-WIRE mode) or preset arc current (CC-STICK, DOWNHILL PIPE, ARC GOUGING and TIG modes) to

e set prior to welding using the OUTPUT control dial. During

b 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.

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

OPERATION

FIGURE B.2

The meters will display all dashes for preset when ArcLink

®

mode is selected.

6a.

HIDDEN MENU BUTTON:

The hidden setup menu can be accessed any time the machine is on with the engine running and not in a welding arc (arc off or OCV). To access, press the hidden setup menu push button (Figure B.2.) with the appropriate tool or paper clip, if no tool is readily available.

NOTE: The menu system will exit automatically if any of the following

conditions are met:

• If no settings are changed for 10 seconds.

• If the mode selection switch position is changed.

• If the arc status changes to arc or short.

• If the entire setup menu sequence is cycled through.

HIDDEN SETUP MENU FUNCTIONS

• Hot start setting individually settable by mode. Hot start will not display if not applicable.

The left display will show “Hot” and “Strt” alternately at 0.5 second intervals. The right display will show a number from 0.0 to

10.0. The default value will be 5, (Figure B.3). This setting will be stored in system memory and will be remembered between machine power cycles.

FIGURE B.3

B-4

ANTAGE

FIGURE B.4 FIGURE B.5

FIGURE B.6

FIGURE B.7 FIGURE B.8

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Alternate CV mode selection. Default CV mode will be non-syner-

gic FCAW-SS (mode 6). Alternate settings will be non-synergic GMAW (mode 5) and non-synergic FCAW-GS (mode 7). The left display will show “CV” and “type” alternately at 0.5 second intervals. The right display will show “FC.SS”(Figure B.4),

FC.gS”(Figure B.5) or “MIG”(Figure B.6). This setting will be

“

stored in system memory and will be remembered between machine power cycles. This setting will only be visible if the process selection switch is in the CV Wire position.

OPERATION

• Selection of the remote connector for stick (SMAW) modes. The customer can select between the 12-pin or the 14-pin connector for the remote potentiometer input when in the “remote” switch position for stick (SMAW) modes. The default from the factory will be the 12-pin connector. The left display will show “Pot”, “12P” (Figure B.7) and the right display will show “Pot”, “14P” (Figure B.8). This setting is stored in system memory and will be remembered between machine power cycles. This selection will only be visible for stick (SMAW) modes.

B-5

ANTAGE

FIGURE B.9 FIGURE B.10

FIGURE B.11

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• Test Modes for grid load testing. The left display will show “tESt” nd “LoAd” alternately at 0.5 second intervals. The right display

a will show “CC” (mode 200)(Figure B.9), “CV” (mode 201)(Figure B.10) or “OFF” (normal operation)(Figure B.11). This setting is not remembered between machine power cycles and will default

o OFF at each power on. Moving the position of the weld process

t selection rotary switch Item 10 will reset the setting back to OFF.

OPERATION

EXITING

HIDDEN MENU BUTTON

Pressing and holding the hidden reset push button for 5 seconds will cause certain stored values to be reset to defaults. The stored hot start values will return to a default setting of 5 on the display (0 at the attribute). The work point values will all be reset to the minimum from the weld table for each respective weld mode. The alternate CV mode selection will revert back to the Flux-Cored Arc Welding-Self Shielding (FCAW-SS) setting. The remote pot connector choice will revert back to the 12-pin connector. When the reset occurs, the left display will show “ deF”, and the right display will show “AuLt” for 3 seconds until the machine exits the menu system.

B-6

ANTAGE

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OPERATION

7. WELD TERMINALS ON SWITCH

utput is enabled when in the ON position. Output is remotely controlled

O when in the REMOTE position. This control is not active in

modes.

ArcLink

8. DOOR LATCH

9. ARC CONTROL

The ARC CONTROL knob is active in the CV-WIRE and CC-STICK modes, and has different functions in these modes. This control is not active in the TOUCH START TIG mode or in

CC-STICK mode: In this mode, the ARC CONTROL knob sets the short circuit current (arc-force) during stick welding. 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 set to the minimum number without electrode sticking. Start with a setting at 0.

DOWNHILL PIPE mode: In this mode, the ARC CONTROL knob sets the short circuit current (arc-force) during stick welding to adjust for a soft or a more forceful digging arc (Crisp).

ArcLink®mode.

13. 12-PIN CONNECTOR

®

For attaching optional remote control equipment. The

2909-1 (12-pin to 6-pin) adapter cable is included for

K attaching to accessories requiring the 6-pin connector.

14. 14-PIN CONNECTOR

For attaching wire feeder control cables. Includes contactor closure circuit, work senselead remote control circuit, and 120VAC and 42VAC power.

15. WELD OUTPUT TERMINALS “+” POSITIVE AND “-” NEGATIVE

These 1/2” - 13 studs with flange nuts provide welding connection points for the electrode and work cables. For positive polarity welding the electrode cable connects to the “+” positive terminal and the work cable connects to this “-” negative terminal. For negative polarity welding the work cable connects to the “+” positive terminal and the electrode cable connects to this “-” negative terminal.

16. LOCAL/REMOTE SWITCH:

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.

10. WELD MODE SELECTOR SWITCH:

(Provides six selectable welding modes) CV-WIRE DOWNHILL PIPE CC-STICK TOUCH START TIG ARC GOUGES ARC LINK

11.

42V / 115V WIRE FEEDER VOLTAGE SWITCH:

Toggles output of 14-pin connector to voltage requirement of Wire Feeder. (Located above 14-pin connector.)

In the LOCAL position, machine output control is set by the Output Control knob on the front of the machine. In the REMOTE position, the machine output control is set by the remote inputs. This control is not active in

ArcLink® modes.

17. POLARITY SWITCH:

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

11a. 42V and 115V WIRE FEEDER BREAKERS

12. 5-PIN CONNECTOR

For attaching an

ArcLink®Wire Feeder control cable.

B-7

ANTAGE

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18.

19. 50A 240V

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20A 120V AUXILIARY BREAKERS

3 PHASE BREAKER

20. BATTERY 20A BREAKER

21.

240VAC THREE PHASE RECEPTACLE

This is a 240VAC (15-50R) receptacle that provides 240VAC three phase auxiliary power. This receptacle has a 50 amp rating.

22. 120/240 VAC SINGLE PHASE RECEPTACLE

This is a 120/240VAC (14-50R) receptacle that provides 240VAC or can be split for 120VAC single phase auxiliary power. This receptacle has a 50 amp rating. Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about this receptacle. Also refer to the AUXILIARY POWER OPERATION section later in this chapter.

OPERATION

26. DIAGNOSTIC PLUG

his is used by Field Service shops to connect and trou-

T bleshoot engine error codes and is found on the firewall inside the machine on the service side. (Figure B.12)

IGURE B.12

F

26

Items 27 thru 30 are found inside the machine by removing the right side panel facing the front.

(Figure B.13)

27. GLOW RELAY / BREAKER (70A)

28. FUEL RELAY / BREAKER (20A)

29. IDLE RELAY

30. ECU (Electronic Control Unit) BREAKER (30A)

23. 10A 42V/40V ARCLINK BREAKERS

CIRCUIT BREAKERS

24.

These circuit breakers provide separate overload current protection for each 120V circuit at the 240V single phase receptacle, each 120V single phase receptacle, the 240V three phase receptacle, the 120VAC in the 14-Pin connector, the 42VAC in

the 14-Pin connector and battery circuit overload protection.

25. GROUND STUD

Provides a connection point for connecting the machine case to earth ground. Refer to “MACHINE GROUNDING” in the Installation chapter for proper machine grounding information.

FIGURE B.13

29

27

30

28

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31. STATUS LED

(See Table B.1) Status

The status LED indicates system status. Normal operation is a steady green light. Note: During normal power-up, the LED may flash red

and/or green as the equipment performs self tests.

TABLE B.1

OPERATION

LED condition

Steady green Blinking green.

Blin k ing gree n , fast

Blinking green followed by blinking red.

Definition

System is communicating normally. Occurs during a reset and indicates the power source is identifying each component in the system. This is normal for up to 15 seconds after power-up, or if the system configuration is changed during operation. Indicates that one or more pieces of ArcLink equipment are not mapping properly.

Non-recoverable system fault. If the power source or wire feeder status LED is flashing any combination of red and green, errors are present in the system. Read the error code before the machine is turned off.

Instructions for reading the error code are detailed in the Service Manual. Individual code digits are flashed in red with a long pause between digits. If more than one code is present, the codes will be separated by a green light.

To clear the error, turn the power source OFF, and then back ON to reset.

B-9

VANTAGE® 600 SD

OPERATION

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.

STICK WELDING MODE

The

VANTAGE®600 SD

electrodes.

The MODE switch provides two stick welding settings as follows:

CC-STICK MODE

The CC-STICK position of the MODE switch is designed for horizontal, vertical-up and over head welding with all types of electrodes, especially low hydrogen. The OUTPUT CONTROL knob adjusts the full output range for stick welding.

The ARC CONTROL knob sets the short circuit (arc-force) current during stick welding. 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 set to the minimum number without electrode sticking. Start with the knob set at 0.

DOWNHILL PIPE MODE

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 knob adjusts the full output range for pipe welding.

The ARC CONTROL knob 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.

can be used with a broad range of DC stick

TOUCH START TIG MODE

The ing applications.

The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the OUTPUT CONTROL knob 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, avoids tungsten contamination. Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.

To stop the arc, simply lift the TIG torch away from the work piece. When the arc voltage reaches approximately 30 volts, the arc will go out and the machine will automatically reset to the touch start current level. The tungsten may then be retouched to the work piece to restrike the arc. The arc may also be started and stopped with an Amptrol or Arc Start Switch.

The ARC CONTROL is not active in the TIG mode.

In general the ‘Touch Start’ feature avoids tungsten contamination without the use of a Hi-frequency unit. If the use of a high frequency generator is desired, the K930-2 TIG Module can be used with the VANTAGE®600 SD

The cuitry for the connection of high frequency generating equipment.

The VANTAGE®600 SD and any high frequency generating equipment must be properly grounded. See the K930-2 TIG Module operating manuals for complete instructions on installation, operation, and maintenance.

When using the TIG Module, the OUTPUT control on the VANTAGE RENT CONTROL on the TIG Module Amptrol.

VANTAGE®600 SD

®

600 SD is used to set the maximum range of the CUR-

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

. The settings are for reference.

is equipped with the required R.F. bypass cir-

TYPICAL FUEL CONSUMPTION

Refer to Table B.2 for typical fuel consumption of the Engine for various operating scenarios.

(Deutz TD 2.9 L4) Fuel Consumption

High Idle Low Idle 100A 24V 200A 28V 300A 32V 400A 36V 500A 40V Aux power 12,000VA single phase Aux power 20,000VA three phase

VANTAGE®600 SD

Table B.2

GAL/HR

0.79

0.59

0.91

1.05

1.30

1.65

2.02

1.35

1.86

B-10

Liters/Hr

3.01

2.24

3.44

3.98

4.92

6.25

7.63

5.11

7.03

HRS @ 25 GAL(94.6L)

31.48

42.37

27.54

23.76

19.23

15.15

12.40

18.51

13.46

ANTAGE

Tr im . 50

Arc L en gt h Sh or t

Tr im 1 .00

Arc Length Medium

Trim 1.50

Arc L en gt h Lo ng

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OPERATION

COMMON WELDING PROCEDURES

WARNING

MAKING A WELD

The serviceability of a product or structure utilizing the welding

rograms is and must be the sole responsibility of the builder/user.

p Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of a welding program may not be suitable for all applications, and the build/user is and must be solely responsible for welding program selection.

Choose the electrode material, electrode size, shielding gas, and process (GMAW, GMAW-P etc.) appropriate for the material to be welded.

Select the weld mode that best matches the desired welding process. The standard weld set shipped with the encompasses a wide range of common processes that will meet most needs. If a special weld mode is desired, contact the local Lincoln Electric sales representative.

VANTAGE®600 SD

®

ANTAGE

V current according to settings contained in the

00 SDthen uses the WFS setting to adjust the voltage and

6

VANTAGE®600 SD

.

In non-synergic modes, the WFS control behaves like a conventional power source where WFS and voltage are independent adjustments. Therefore, to maintain proper arc characteristics, the operator must

djust the voltage to compensate for any changes made to the WFS.

a

Amps

In constant current modes, this control adjusts the welding amperage.

Volts

In constant voltage modes, this control adjusts the welding voltage.

Trim

In pulse synergic welding modes, the Trim setting adjusts the arc length. Trim is adjustable from 0.50 to 1.50. 1.00 is the nominal setting and is a good starting point for most conditions.

UltimArc™ Control

UltimArc™ Control allows the operator to vary the arc characteristics. UltimArc™ Control is adjustable from –10.0 to +10.0 with a nominal setting of 0.0.

All adjustments are made through the user interface. Because of the different configuration options your system may not have all of the following adjustments.

See Accessories Section for Kits and Options available to use with the VANTAGE®600 SD

.

DEFINITION OF WELDING MODES

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all welding process variables to be set by the operator.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity of single knob control. The machine will select the correct voltage and amperage based on the Wire Feed Speed (WFS) set by the operator.

BASIC WELDING CONTROLS

Weld Mode

Selecting a weld mode determines the output characteristics of the VANTAGE®600 SD a specific electrode material, electrode size, and shielding gas. For a more complete description of the weld modes programmed into the VANTAGE®600 SD Guide supplied with the machine.

Wire Feed Speed (WFS)

In synergic welding modes (synergic CV, GMAW-P), WFS is the dominant control parameter. The user adjusts WFS according to factors such as wire size, penetration requirements, heat input, etc. The

power source. Weld modes are developed with

at the factory, refer to the Weld Set Reference

PULSE WELDING

Pulse welding procedures are set by controlling an overall “arc length” variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known. Voltage or Trim can be adjusted.

Trim adjusts the arc length and ranges from 0.50 to 1.50 with a nominal value of 1.00. Trim values greater than 1.00 increase the arc length, while values less than 1.00 decrease the arc length. (See Figure B.14)

FIGURE B.14

B-11

Lincoln Electric VANTAGE 600 SD Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

INSTALLATION

OPERATION