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    90 views104 pages

    k3242 1a H - Manual

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    Sgly Zemog

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    © All Rights Reserved
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    ani22024 Operator’s Manual ee TE For uso with machines having Code Numbars: 11984 Register your machine: Need Help? Call 1.888.935.3877 ERA vancanclocne conregstor totak toa Sonica Reon Authorized Service and Distributor Locator: Lit www.lincoinelectric.com/locator Hours of Operation: {8:00 AM to 6:00 PM (ET) Mon, thru Fi ‘Save for future reference After hours? Use “Ask the Experts” at licolnelectri.com AA Lincoln Service Representative will contact you Date Purchased no later than the following business day. For Service outside the USA: Cade fax TORE Emait globalservice@lincolnelactric.com ‘Serge (GE UTOROE ESAS) ‘THE LINCOLN ELECTRIC COMPANY 22801 St Cl Avenue « levetand, OH # 44117-1189 « USA IM10179 | sedate Junie * Phone: +1.216.481.8100 » www.linoolnelectric.com © Lincoln Global, nc. All Rights lseved. hitps:imanualzz.comidoc!22695562 ani22024 THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELECTRIC. PLEASE EXAMINE CARTON AND EQUIPMENT FOR, DAMAGE IMMEDIATELY ‘When tis equipment i shipped, tte passes tothe purchaser upon receipt by the carer. Consequently, Claims for material damaged in shipment must be made bythe purchaser against the transportation company atthe time the shipment is received ‘SAFETY DEPENDS ON YOU Lincoin are wong and cutting equipment is designed an bul with safety in mind. However, your overall safety canbe increased by prope instalation .. 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 important, think before you act and be caret This statement appears where the information must be followed exactly to avoid serous personal injury or loss of ie Co Nite) This statement appears where the information must be followed to avoid minor persona injury or damage to this equipment. hitps:imanualzz.comidoc!22695562 KEEP YOUR HEAD OUT OF THE FUMES. DON'T get to close tothe ar. Use coroctielenses if necessary to stay a reasonable distance avay ‘rom the ae READ and obey the Matera Safety Data Sheet (MSDS) and the warning labal that appears onal containers of welding material USE ENOUGH VENTILATION or exhaust atthe ae, or both, to keep the fumes and gases fram your breathing zone and the general rea IN ALLARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you kep your head out of the fumes (See below) USE NATURAL DRAFTS or fans to keep the fumes away from your face Ht you develop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system shouldbe checked WEAR CORRECT EVE, EAR & BODY PROTECTION PROTECT your eyes and face wth welding let oper ted an with proper ard of itr pat {Gee ANSI 249.1), PROTECT your bod rom welding pater and are fash wit protective cong including woolen clting, fame-proo apron and goes leather Tagingg nd high bots. PROTECT others from slater, lsh, and lr wth proactive seeens or bas IN SOME AREAS, protection rom noise may be sponte BE SURE protective equpmentisin god enon ‘Also, wear safety glasses in work area AT ALL TIMES. — om” SPECIAL SITUATIONS. 1DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous cubstances unless they are properly cleaned, This fs extremely dangerous 1DO NOT WELD OR CUT painted or patod pats unless special precautions with venblation have been taken, They can release highly toxic umes or gases. Additional precautionary measures PROTECT compressed gas oyndors from excessive heat, mechanical shocks, and aes; fasten cylinders so they cannot fll BE SURE cylinders are never ounded or part ofan electrical ccuit REMOVE al potential fre hazards from welding area ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT. ani22024 SAFETY SECTION A: 1.4. Koop al equipment satey guards, covers and . : . devices in poston and in god real Keep = hans, Kr, etn ane tos away rom WARNINGS Vt a ns an a oer eng as ‘when starting, operating or repaing CALIFORNIA PROPOSITION 65 WARNINGS olen Diesel Engines 1.2, some cases it may be necessary to remove safety guards to peri requred martnance.Remave guards only wan Diesel engine exhaust and some ofits constituents are known econo thee ten wha be eokdoune regia, tothe State of Calfornia to cause cancer, ith defects, and other er clk cam MecqomecFapedalion ene, reproductive harm, working near moving pas Gasoline Engines, 1. Do notput your hands near the engine fan. Do ot attempt o The engine exhaust from this product contains chemicals known ‘verti the governor or itl by pushing on the trate caiol to the State of Calfonia to cause cancer, bith defects, or other rods whl the engine is runing. reproductive harm, 119. To prevent accidental stating gasoline engines while turing ‘ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACE- 1 MAKER WEARERS SHOULD CONSULT WITH THEIR, DOCTOR BEFORE OPERATING. Read and understand the following safety highlights, For addtional safety informatio, tis strongly recommended that you purchase @ copy of “Safty in Welding & Cutting - ANS! Standard 249.1" fom the ‘American Welding Society, P.0. Box 351040, Miami, Florida 33135 or (CSA Standard W17-2-1874. A Fee copy of “Arc Welding Safety” booklet £205 is available trom the Lincoln Electric Company, 22801 St Clair Avenue, Cleveland, Ohio 44117-1198. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. 2a, 2b. FOR ENGINE POWERED EQUIPMENT. 1.2. Tum the engine off before troubleshooting ‘and maintenance work unless the ‘maintenance work resi tobe running, om ‘Operate engines in open, ell-ventated areas or vt the engine exhaust fumes outdoors, ‘Do nota the fuel near an open flame welding arc or when the engine is running Slop the engine and allow io cool before ly refueling to prevent spied fue ftom ‘vaporizing on contact with hot engine pats and igniting, Do not spl fuel when ling tank. fuels sped, Wipe it up and donot start engine unl fumes have been eliminated. hitps:imanualzz.comidoc!22695562 the engine or welding generator during maintenance work, disconnect the sparkplug wires, cstibutor cap or magneto wire as appropriate To avoid scalding, donot remove the radiator pressure cap wien the engin shot ELECTRIC AND a MAGNETIC FIELDS MAY = BE DANGEROUS =r Eerie curentfowing though any conductor causes localzed Electric and Magni Fields (EMF). Welding curent creates EMF fils around welding cables and welding machines EM feids may intrfre with some pacemakers, and welders having a pacemaker should ccnsul their physician before ‘welding Exposure to EME fds in welding may have other health effects ‘which are now nat known. ‘Al welders should use the following procedures inorder to minimize exposure to ENF feds from the welding ccuft 241. Route the electrode and work cables together - Secure ‘them with tape when possible Never col the electrode lead around your body. Do not place your body betven the electrode and work cables. the eloctrode cabo Ison your right sito, the ‘work cable should also be on your right sie. ‘Connect te work cable to the workpiece as clase as pas sible tothe area being welded Do not work not to welding power source, 22. 23. 2a, ani22024 i 3a 3b. 36. 36 3e 3h 39, 3n 3i 34 ELECTRIC SHOCK CAN KILL. The electrode and work (or ground) cuts are electrical “hot” wien the welder i on. Do not touch these “ho” parts wih your bare skin or wet cating Wear dr, hole-tree gloves to insulate hands. Insulate yours from work and ground using dry insuation, ‘Make certan the insulation i large enough to cover your ful area of physical cantact with work and ground. In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or whi wearing wet clothing; on metal structures such as ‘floors, gratings or scaffolds; when in cramped. positions such as sitting, kneeling or lying, if there 2 high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment: * Semiaulomatic DC Constant Voltage (Wir) Welder. + DC Manual (Stick Welder. * AC Welder uth Reduced Voltage Control. In semiautomatic or automate wre welting he electrode, electrode rea, welding ead, nozzle of semiautomatic welding gun are also electrically “hot” ‘Aways be sure the work cable makes a good electrical ‘conection with the metal being welded. The connection should be s close as possible to the area being welded. Ground the work or metal fo be welded o a good electrical earth) ground. ‘Maintain the electrode holder, work clamp, welding cable and welding maine in god, safe operating condition, Replace damaged insuation. Nove dip the electrode in water for cooing, "Never simultaneously touch electrically “ho” pars of electrode holders connected to wo weldrs because voltage between the ‘wo can be the total of the open circuit voltage ofboth welders, When wotking above floor lel, use safety belt to protect yourself rom a fal should you get a shock. ‘so see tems 6. and 8 hitps:simanualaz.comidoc!22695562!sir-vantage-®-500-s6 A ARC RAYS CAN BURN. 4a 4b. 4c i Use a shield with the proper iter and cover plates to protect your eyes from sparks andthe ray ofthe are when welding or ‘observing open arc welding, Headshied and iter lens should conform to ANSI 787. standards I WN Use suitable clothing mace from durable ame-resstant material to protect your sin and that of your holpors fom the arc rays. Protec oer nearby personnel vith suitable, non-flammable Screening and/or wam them not to watch the arc nor expose ‘thamselves tothe arc rays ort hot spatter or metal A Bie AND GASES a ‘AN BE DANGEROUS. a S.a. Welding may produce fumes and gases hazardous to heath void breathing these fumes and gases ‘nen welsing, Keep your head out ote fumne, Use encugh _ventlation andor exhaust atthe acto keep fumes and gases away trom 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. ‘The operation of welding fume control equipments affected by ‘various factors including proper use and pestoning ofthe equipment, maintenance ofthe equipment and the speci ‘welding procedure and application moved. Worker exposure level shouldbe checked upon nstaltion and periodically thereafter tobe certain it's within applicable OSHA PEL and ‘AGGIH TLY Umit. 5b, 5.0, Do not weld in actions near chlorinated hydrocarbon vapors coming from degreasing, cleaning o praying operations. The heat and rays ofthe arc can react wrt soNet vapors to frm phosgene highly one gas, and othe inating products. ‘5. Sbiceing gaves used for are welding can displace ar and cause injury or death. Alvays use enough ventilation, especially in confined areas, to insure breathing ai is sata, 5.2, Read and understand the manufacture’ instructions fo this equipment and the consumables to be used, including the ‘material safety data sheet (MSDS) and follow your empoyer’s safely practies. MSDS forms are avilable from your welding distributor or from the manufacturer. 51. Aso soe tom 1. 408 ani22024 ™ SPARKS CAN CAUSE WELDING AND CUTTING > = FIRE OR EXPLOSION. 6. Remove fe hazards rm the welding area. 6. 66. 6a be Br 60 6h, 6. 8) this sno possible, cover them to prevent the welding sparks ‘tom starting ate, Remember tha welding sparks and hot ‘materi rom welding can easly go through small racks and ‘openings to adjacent areas. Avoid welding near tydraulc nes, Have ate extinguisher readily valabl. ‘here compressed gases are to be used atthe ob ste, special precautions shouldbe used to prevent hazardous situations. Refer a *Safety in Welding and Cutting (ANSI Standard 749.1) and te operating informatio fhe equipment being sed. \When not wong, make certain no part ofthe electrode crcl Is toueting te work or ground, Accidental contact can cause ‘overheating and create athe hazard. ‘Dorothea. cut or weld tanks, drums or containers unl the rope sleps have beso taken fo nsure al suc. procedures wil fol cause flammable or tic vapes from substances inside ‘They can cause an explosion even though they have been “cleaned For information, purchase “Recommended Safe Practices for he Preparation for Welding and Dating of Containers and Piping That Have Held Hazardous Substances”, AWS F4. rom te American Welding Sockey (see address above). Vent hallow castings or contsiness before healing, cing or welding. They may explode. ‘Sparks ad spatter are throw fromthe welding arc. Weer a ree tective garments suc as feather cloves, heavy shirt, cuffs {rouse hight shoes and a cap over your hi. Wear earplugs ‘when welding out of postion orn cntined places. Aways Wear sately glasses with sie shields when in a welding area Connect the work cable fo he work as closet the welding ares as practical. Work cables connected to ie building ramework oer locations avy rom te welding area increase the possibilty o the welding current passing trough ting chins, trae cals or other aemate crus. This can crete fre hazards or overneat iting chains or cables unt hey tl ‘Neo se tom I ead and flow NFPA S1B* Standard for Fre Prevention During Welding, Cutting and Other Hot Work", avaiable from NEPA, 1 Battrymarch Park, PO box 8101, Quincy, Ma 02680-9101. Do not use welding power source fr pipe thawing, hitps:simanualaz.comidoc!22695562!sir-vantage-®-500-s6 CYLINDER MAY EXPLODE IF =5) DAMAGED. 7.a, Use only compressed gas cylinders containing the corect shielding gas forthe process used and propery operating regulators designe for the gas and pressure used, Al hoses, tings, lc. shoul be suitable forthe application and. |_| ‘maintaned in good condition. 7b. Always keep oyinders in an upright position securely chine to ‘an undereamiage or xed support. 7.6, Cylinders shouldbe ovate + Away trom areas wnere ney may be stuck or subjects ‘to physical damage + safe distance from are welding o cutting operations and anyother source of heat, sparks, or fame. Never allow te electrode, electrode holder or any ober ‘tecrcally “hot parts to touch a cline 74, 7.2, Keep your hea! and face aay tom te cylinder valve outlet ‘wen opening the cylinder valve, 7.4. Valve protection caps should aways ben place and hand tht excep wen the cyinder is in use or conmected for use, 7.9, eas and flow the Insiuctions on compressed gas cylinders, associated equipment, and CGA publication Pl “Precaution for Sate Handing of Compressed Gases in Cylinders," available ‘om the Compressed Gas Association 1235 Jetferson Davis Highway, Arington, VA 22202 FOR ELECTRICALLY <, POWERED EQUIPMENT. 8. Tumoff input power using the disconect sich atte fusebox before working on the equioment {.. Install equipment in accordance wit the US. National Electrical Cd, local codes andthe manufacture’ recommendations. 8.c. Ground the equipment in accordance wit the US. Natonal Ercrcal Code andthe manufacturers recommendations Refer to http://www. lincolnelectric.com/safety for additional safe- ty information. Welding Safety Interactive Wab Guide for mobile devices BNE] Gl me ‘ete fee motile spp at http://gettag mobi 5/104 ani22024 AIR VANTAGE® 600 SD ‘TABLE OF CONTENTS Installation. ‘General Desripton.. Tectnical Specifications. Safety Precautions. VAD (Voltage Reduction Devic) Location and Venta. ‘Storing 2 StaEK. ‘Angle of Operation Liting High Altiude Operation High Temperature Operation (Col Weather Starting... ae Towing. Vehicle Mounting. saci wean es the Ging. Battery CoMneCON nnn Exhaust Outlet Pipe Spa AMESOF enn ‘Nir leaner sal re-Operation Engine and Compressor Service. One os Fuel Use Diesel Fel Fuel Cap, Engine Coca. Remote Conta Welding Terminals Welsing Ouput cabes. Pulse Welding. I Cable instalation Machine Grounding - ‘Alar PORE RECEpTECES nom Standby Power Connections. Connection to Premises Wring. Connection of Linco Electric Wire Feeders. ‘Connection of Wire Feeders with Control Cable (14 Pin. ‘Connection of Across the Arc Wir Feeders. Cate nanos ad fe et on Hela Control Cable COMMONS nn Operation. Safety instructions Recommended epiato, Controls and Settings Engine ContO5 nn . Welder Contos. = Acting & ecg Oars Stn. Control and Indicator Functionality vo Conta Stequards to improve Relabity On/Of Cutch Safeguard... Minimum Pressure Check Vale Cutch Safeguard... Welder Operation... : Duty Cycle. Sick Welaing Moae (-Stick Mode Downhl Pipe Mode Toueh Start TG Mode... ‘Typical Fuel Consumption hitps:simanualaz.comidoc!22695562!sir-vantage-®-500-s6 arog ani22024 ‘manual viewar AIR VANTAGE® 600 SD ‘TABLE OF CONTENTS (Common Welding Procedures. Making Weld... Definition of Welding Modes... Non-Symergc Welding Mode. ‘Syorgic Welding Modes, Basie Welding Conta. Wild Ide... Th. ima Cont Pulse Welding - - _AFLVANTAGE® 600 SD Setting when using K990-2 TG Modul. ‘ype cure ares Tugs Eee Cire Mot... . Constant Vtage Welding ‘synergic CV... a Non-SyMergC CV nen . . Le GOUGING en - Paralleing a ‘Aulary Power operation. ‘Simutaneous Welting and Airy Power Loads ‘Simultaneous Welding and Power Loads Table. Extension Cor Length Recommendations Tables ‘Wild Set Reference Chart. Accessories. Optional Field installed Accessorie. ~ Wire Feeder Options. se Maintenance Salety Precautions... - Routine and Periodic Maintenance. " Engine Maintenance - ‘A Fer. 2 Service Instructions A INE - Fuel Filters - Cooling System. Battery Handing = Proverting Ebctcal Bama men Charging the Battery. Nameplates / Waming Decals Maintenance Welder / Generator Maintenance. - ‘Storage... Ceaning, Brush Removal and feplacament Replacement Senice tems. Troubleshooting. sic " Section E How to use Troubleshooting Guid = EA Troublesteoting Guide. — E2-E4 Section F Wiring, Connection Diagrams and Dimension Print. Parts List... parts.lincolnelectric.com CContent/detals may be changed or updated without notice. For most current Instruction Manuals, go to parts lincolnelecric.com. hitps:simanualaz.comidoc!22695562!sir-vantage-®-500-s6 rH08 hitps:imanualzz.comidoc!22695562 ani22024 AIR VANTAGE® 600 SD NsTALLATION GENERAL DESCRIPTION COS aaa Cores eel Doseripton The AIR VANTAGE® 600 SD is a diesel engine-driven welding o ’ power source. The machine uses a brush type alterating current wa) Bee Ey Dee ‘generator for DC multi-purpose welding, for 120/240 VAC single phase and 240V three phase auiiary standby power. The welding 5 5 control system uses state of the art Chopper Technology™. The peer, (oinn Seba how product also has a belt-criven 60 CFM rotary screw compressor. High te Mode: 150 Pst 60 SCFM @ 100PSI (10.5 kg/cm) TECHNICAL eastmsec.@70Kou SPECIFICATIONS TamgresarPrateton Capacties Safety Relief Valve 1.1 gal.(4.0 liters) DES 20st CET a (Them High Temperature peat ee es ‘i 4 cylindor 64HP (48 kw) Atti Sc TD29L4 Devel Engne | Tuto Charged Water Cooled 14) EPA TIER 4 Final Compliant Diesel Engine Speed RPM Displacement High Idle 1800. 178 cu. in. (2.9L) PHYSICAL Ss Low Idle 1525 Bore x Stroke Height * €2.0'h: (1008.8 mam FullLoad 3.62" x4.33" 2mmx 110mm Wath 32.9 in, (835.7mm) ‘Stating System Capacities Dil @80in, (753mm) 12VDC battery and Starter Fuel 25 US gal (94.6L) yrox.) with Automatic Glow Plugs | Oil: 2:25 US gal (8.51) Weight 178s. (7Ag) (Aperon (1) Osta wats qt ovat anges tant pone CCR espe a ‘uta veigo win = 10% a 1 ods opal cope, When ‘oly aaa alr pone vb sal Duty Cycle | Welding Output __| Volts at Rated Amps (2 Top of Ector. Ad 16.8" 427m) for exhaust and ak cleaner. {res Door Ee 1 6am we, 100% 575Amps 43,Votts (DC multi-purpose) 60% 600 Amps 40 vals (0 multi-purpose) OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR Welding Range 30-600 Amps CCICV 20-250 Amps TIG Open Circuit Voltage 60 Max OCV @ 1800 RPM ‘Auxiliary Power 10/240 VAC 12,000 WATTS, 60 Hz., Single Phase 20,000 WATTS, 60 Hz,, Three Phase ani22024 AIR VANTAGE® 600 SD INSTALLATION ‘SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thor- ‘oughly read all operating and maintenance manuals supplied with your machine. They include important safety precau- tions, detailed engine starting, operating and maintenance instructions and parts lists. ELECTRIC SHOCK can kil, * Do not touch electrically live parts such as ‘output terminals or intemal 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 ome MOVING PARTS can injure. * Do not operate with doors open or guards off. * Stop engine before servicing. * Keep away from moving parts Only qualified personnel should install, use or sorvice this equipment. VRD (VOLTAGE REDUCTION DEVICE) ‘Tha VRD reduces the OC (Open Cicun Vorage) a the welding output {terminals while not welding to ss than 3OVDC when the resistance of the output ecu is above 2000 (ohms) ‘The VAD requires thatthe welding cable connections be kept in good electrical condition because poor connections wil contribute to poor starting. Having good electrical connections also limits the possibity of ‘other stay issues such as nea- generated damage, bums and tres. “The machine is shipped wit the VRD swatch inthe “OF” positon. To fun “On” or “OF ‘Tum the engine “ofr ‘ Disconnect the nagatve attoy cable * Lower the Front panel by removing 4 side panel screws (Soo Figure A) Place te VAD sitchin te “On” or “OT postion, (Se Figure AN) hitps:imanualzz.comidoc!22695562 ‘wit ie VAD sich inthe *OFF" position the VAD lights are non act vale. FIGURE A.1 ON/OFF VOR swrTcH ‘TO ACCESS (VAD) swirce AG FRONT PANEL ») ROTATES AWAY FROM — THE FRONT PART OF WELDER LOCATION AND VENTILATION The welder should be located to provide an unrestricted flow of clean, coo air to the cooling air inlets and to avoid restricting the cooling ar outlets, Also locate the welder so thatthe engine exhaust fumes are property vented to an outside area DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surtace directly under station- ary oF fixed electrical equipment, that surface should be cov- ‘ered with a steel plate at least .06"(1.6mm) thick, which ‘should extend not fess than 5.90"(150mm) beyond the equip- ‘ment on all sides. ‘STORING 1. Store the machine in a coo, dry place when itis natin use. Protect it from dust and di. Keep it where it can't be acc dentally damaged from construction actives, moving vehi- cles, and other hazards 2. Drain the engin ol anc refill with fresh ol. Run the engine for about five minutes to circulate oto all the pats. See the ENGINE OPERATION section manual for detsils on changing oil 3. Remove the batery, recharge it, and adjust the electro level. Store the battery in dry, dark place, ‘STACKING "NR VANTAGE® 600 $0 machines cannot be stacked ani22024 AIR VANTAGE® 600 SD INSTALLATION ANGLE OF OPERATION To achieve optimum engine performance the ARVANTAGE® 00 $0 should be run ina level position. The maximum angle of operation for the Deutz engine is 30 degrees inal directions. When operat- ing the welder at an angle, provisions must be made for checking and maintaining the oil evel atthe normal (FULL) oil capacity. Also the effective fuel capacity will be slightly less than the specified 25 gal (046 rs) wil be ight less than the amount specified. LIFTING Tho AIR VANTAGE® 600 weighs approximately 1911s. (886kg,) with a fll tank of fuel and 17371bs. (787k) less fuel. lit ball is ‘mounted to the machine and shuld always be used when lifting the machine. + Lift only with equipment of adequate litt- ing capacity. + Be sure machine is stable when lifting, + Do not lift this machine using lift bale if t 1 eqlped witha heavy accessory such as trailer of gas. FALLING + Do not it machine im litt bate is EQUIPMENT can damaged. cause injury. * Do not operate machine while suspended from lift bale. HIGH ALTITUDE OPERATION Athigher altitudes, output derating may be necessary. For max ‘mum rating, derate the welder output in accordance with the Guidelines for this engine model from the manufacturer shown in Table A-1 below: TABLE A.1 DEUTZD 2.914 ALTITUDE MAXIMUM POWER: METERS FEET AVAILABLE (%) 0-750 0-2461 99 1000 3281 95 2000 6562 95 3000 9842 93, 4000 13123 88 5000 16404 74 6000 19685 60 hitps:imanualzz.comidoc!22695562 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 startin With a fully charged battery and 0W40 cil, the engine should start satisfactorily down to -15°F(-266") Ifthe engine must be tre- ‘quently started ator below OFF (-18°C), it may be desirable to install cld-startng sides. For engines with common rai injection, the mixing of petroleum or kerosene and adding of extra low ad- tives isnot permissible. Fuels in accordance with ASTM S975 Grade 1D or DIN ENS90-Arctic-Diesel may have no petroleum ‘added. Allow the engine to warm up before applying load or ‘witching to high ide. Under no conditions should ether or other starting fluids be used with this engine! r01s08 hitps:imanualzz.comidoc!22695562 ani22024 AIR VANTAGE® 600 SD INSTALLATION TOWING Use recommended air for us wih tis quent fr roa, in-plant and yard ting bya vehicle tthe user adapts @no-Lincln tral, they must assume responsi that the method of tachment and usage doesnot resin safety hazard or damage the welding equipment Same of the fac- {ost be constered are as flows: 1. Design capacity of tres, weight of Lincoln equipment an kel ad ‘ional attachments. 2. Proper supporto, and tachment othe baseo the weting equipment 90 ‘howl be no une testo the ramen 3. Prope placement of he equipment on tetra to insure stabil side to side and foto back when being moved and when tng iy itso while being peatd or seed 4 Typical cantons of, L, wave poe eughnoss of suace on which ‘hota wil be opeatd rienmentl condos; he minenance Conformance with federal, state and claws.” | xt ales sta cal repr pe reine wen pubis, VEHICLE MOUNTING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fal. * 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 tres. * Mount equipment base to metal bed or frame of vehicle. + Follow vehicle manufacturer's instructions. PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instructions supplied with this machine i WARNING + Stop engine and allow to coo! before fueling, + Do not smoke when fueling. + Fill fuel tank at a moderate rate and do not overfil, * Wipe up spilled fuel and allow fumes to clear before start- ing engine. + Keep sparks and flame away from tank. FUEL USE DIESEL FUEL ONLY- Uta low sulphur fuel only Bp «Fl the fuel tank with clean, fresh fuel. The capacity ofthe tank is 25 gals, (94.6 ltrs) When the fuel gauge reads empty the tank ‘contains approximately 2 gals. (7.6 ts) of reserve fuel. NOTE: Afuol shutoff valve is located just before the pre-fiter/s ment filter, Place the valve in the closed position when the ‘welder isnot used for extended periods of time. ENGINE COOLING SYSTEM Air to cool the engine is draum in the sie and exhausted through radiator and case back. Iti important that te intake and exhaust airs not restricted. Allow a minimum clearance of ft. (0.6m) from the case back and 16 in, (406mm) from ether side of the base to a vertical surface. (Failure to resolve these guidelines may result in an overtemp conciton resting in engine shut down). ni08 ani22024 AIR VANTAGE® 600 SD INSTALLATION BATTERY CONNECTION ‘Use caution asthe electrolyte is a strong acid that ean burn skin and ddama The AR VANTAGE® 600 Sis shipped wit the negative battery cable is connected, Make certain that the RUN-STOP switch sin the STOP post tion. Remove the two screws rom the battery tray using a sorewdriver or 22/8°(10nm) socket tach the negative battery cable to the negative battery terminal and tighten using a 1/2"([3mm) socket or wrench NOTE: This machine is furnished with a wet charged battery; it Unused for several months, the battery may require a booster charge. Be careful to charge the battery with the correct polarity. (Gee Battery in “Maintenance Section’) we GASES FROM BATTERY can explode. * Keep sparks, flame and cigarettes away from To prevent EXPLOSION when: battery. + INSTALLING A NEW BATTERY — disconnect negative cable ‘rom old battery frst 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 nega- tive cable last. Keep well ventilated. + USING A BOOSTER — connoct postive load to battery frst thon connect nogative lead to nogative battery load at engine foot & 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: 4) nstaling new batteries. b) Using a booster. Use correct polarity — Negative Ground. EXHAUST OUTLET PIPE Remove cap from DOC pipe protruding from roo. Using the clamp provided secure the outlet pipe tothe out tbe with the pipe positioned such that wil dractthe exhaust nthe desired direction away trom the air intake, Tighten using a 1/4"(6mim) internal socket or allen vrench. Torque to 106in bss, (12N-M) hitps:imanualzz.comidoc!22695562 ‘SPARK ARRESTOR Some federal, state or local laws may requie that gasoline or tiesel engines be equipped with exhaust spark arresters when they are operated in cartin locations were unarrested sparks ‘may present a fre hazard The DOC (Diesal Oxidation Catalyst) unit included with this welder ‘does not qualify as a spark arrester. When required by local regu- lations, a suitable spark arrester, such as the K3985-1 must be installed and properly maintained, An incorrect spark arrestor may lead to damage to the engine or adversely affect performance. AIR CLEANER INSTALL ‘Al parts below are shipped with the machine ina separate box attached tothe orate. (se0 Figure A) ‘Remove cap from at intake hose and DOC exhaust attached on ‘machine. Insert air leaner into bracket between the two ridges ofa lager diameter, Postion the vacuatorat3 o 6 o'clock + Remove plug and instal 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 isin place loosen ai hse ciamp slide down and tighten clamp ‘Install 2 hex head sorews, washers to mounting bracket securing air cleaner. «SERVICE INDICATOR Air cleaner service indicator provides a Go/No-Go visual indica- tion of useful filter srvice life FIGURE A2 meri. [noms wei, WH? 1\ a W\ (enacts eye: — pec) 2808 hitps:imanualzz.comidoc!22695562 ani22024 AIR VANTAGE® 600 SD INSTALLATION PRE-OPERATION ENGINE AND COMPRESSOR ‘SERVICE READ the engine and compressor operating and mainte- nance instructions supplied with this machine. A WARNING + 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 over-fil 2 up spilled fuel and allow fumes to clear before start- ing engine. ‘Keep sparks and flame away from tank, Om a The AIR VANTAGE® 600 $0 is shipped withthe engine crankcase filled with high quality SAE 10W-30 oil that meets (API class Cl-4 or beter fr ciesel engines. Check the engine and compressor oi levels before starting the engin. fits not upto the full mark on the dipstick, add il as required. Check the oil evel every four hours of running time during the frst 35 running hours. Refer to the engine and compressor Operator's Manuals for specific ol recommendations and break-in information. The oil change interval is dependent on the quality ofthe ol and the operating environment Refer tothe engine and compressor Operator's “Manuals forthe proper service and maintenance intervals. i ‘Fil he fuel tank with clean, rash diesel ful. The capacity of the fuel tank is approximately 25 gallns (95 liters). See engine Operator's Manual for spectc fue! recommendations. FUEL USE DIESEL FUEL ONLY NOTE: Before starting the engine, open the fuel shutoff valve (pointer to be in line with hose) FUEL CAP Remove the plastic cap covering from the Fuel Tank Filler nack ‘and instal the Fuel Cap. ay ENGINE COOLANT HOT COOLANT can burn skin, ‘*Do not remove cap if radiator is hot. ‘The welder is shipped wit the engine and radiator filed with 50% mixture of ethylene glycol and water. See the MAINTE NANCE section and the engine Operator's Manual for more infor- mation on coolant. ran08 ani22024 AIR VANTAGE® 600 SD INSTALLATION REMOTE CONTROL The AIR VANTAGE® 600 SD is equipped with a 12-pin and a 14- pin connector. To enable remote control capabilities, the LOCAL/REMOTE switch must bein the REMOTE position. For the DOWNHILL PIPE or CC-STICK weld mode seecior switch Positions, remote setting of the preset arc currents set through the 12, pin connector or the 14 pin connector depending on the setup menu seting (12 pin connectors the factory default seting). The OUTPUT. (CONTROL knob is used to sat the maximum arc curent preset range forthe remote input. The lf slay wil show the arc current preset. For the TOUGH START TIG weld mode seletor switch poston, remote setting ofthe preset arc current is set through the 12 pin con- rector (ypcaly using afoot Amptra). The OUTPUT CONTROL knob is sed fo set the maximum are current preset range forthe remote input. The left splay wil show the maximum setting fr the are ccurent preset range as set by the OUTPUT CONTROL knob. EXAMPLE: When the OUTPUT CONTROL on the welders set to 200 amps, the are curent preset range onthe remote control wil preset over the range ftom minimum to 200 amps, rather than the full minimum to maximum preset are current range. Any preset are curent range thats less than the fll ange provides finer are current preset resolution for more fine tuning ofthe output For the ARG GOUGING weid mode selector switch poston, remote set- ting ofthe preset are curentis set though the 12 pin connector. The ‘emote input sets the are current preset over the ful ange rom mini- ‘mum to maximum. The ft splay wil show the are current preset. For operation with a control cable wire feeder \With the GV-WIRE weld mode selector switch positon and the WELD TERMINALS ON switch in the REMOTE position, remote setting ofthe preset arc voltage is set through the 14 pin connec- tor. The remote input sot the arc voltage preset range from 10,0V to 45.0V. The right display wil 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 postion 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 emote input sets the arc voltage preset range from 10.0V to 450. The right cisoay wil show the arc voltage preset. For the ARGLINK weld mode selector switch position, remote capability is possibie only with an ArcLink comptible digital remate control through the 12 pin connector. NOTE: To connect accessories with a 6 pin connector, use the included 12-pin to 6-pin adaptor (K2908-1). WELDING TERMINALS ‘The AR VANTAGE® 600 SD is equipped with a toggle switoh for selecting “hot” welding terminals when inthe "WELD TEAMINALS ON” “cold” welding terminals when inthe "REMOTELY CONTROLLED” posi- tion This sth has no function nthe Arcink mode, WELDING OUTPUT CABLES: With the engine off, route the electro and work cables through the strain rai bracket provided onthe front ofthe base and connact othe terminals provided. These cennectons shouldbe checked periodically and tightened f necessary Listed in Table A2 ar copper cable sizes recommended forthe eed cur- rent and cut eye, Lengths stipulated are the stance trom the welder to work and back tothe welder agin, Cable sizes ae increased for rear lenaths primarily forthe purpose of minimizing cable vote cop. Table A2 Fecutlun) CABLE SZES ro MSIE NG INS OF ELECTRODE ANG WOK Joos hea" | GABLES Bb CovERD COPPER areD res DOOR [Dw Ao RIA Paw ANA [AW m|o [2f 2 2 1 rn mo [2]. o T © Ec a o | Ec A | | m [ wo | «| | © «mo [ofa | ww |» | oo [2m [20 | 2m | 200 | 220 Cs Ta ns pcan npn 1 aden. pa {OU te ya arog buon esa be TS PULSE WELDING \When puise welding, aways use 4/0 cable. The cables must be sized based upon the peak curent ofthe pulse waveform, not the average current. Do not col the electrode or work cable. Limit the combined length ofthe elecirode 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 AR VNTAGE® 60080 2s follows. 1. The engine must be OFF to install welding cables. 2. Remove the flanged nuts from the output terminals 3. Connect the electrode holder and work cables to the weld out- put terminals. The terminals are identified on the case front. 4 Tighten the flanged nuts securely. 5. Be certain thatthe metal piece you are welding (the “work") is properly connected to the work clamp and cable. 6. Check and tighten the conneotons periodically At s4i108 ani22024 AIR VANTAGE® 600 SD INSTALLATION + Loose connections will cause the output terminals to over- heat. The terminals may eventually melt, + Do not cross the welding cables atthe output terminal connec tion. Keep the cables isolated and separate from one anther. MACHINE GROUNDING Bacaus this portable engine driven welder creates is own power, itis not necessary to connects frame io an earth ground, unless the ‘machine fs connected to premises wring (home, shop, et) To prevent dangerous electric shock, other equipment powered by this engine criven welder must: 8) be grounded tote ram ofthe welder using a grounded type ig, oF 1) be double insulated, When this welde is maunteon a truck or riley, ts frame must be securely conmected to the metal rame of the vehicle, When this engine crven welder is connected to premises wiring such as that na home or shops fame must be connected othe ystom earth gourd, Sae further Connection insu in the section ened “Stand Power Connections” as wel as the atl on grounding inthe atest Nato ‘cra! Code and the local cages. In genera, ifthe mache i tobe grounded, it should be connacted with a #8 or larger capper wire toa sold earth ground such as a metal (ground stake going into the ground fora least YOFL(3.1m) orto the meta framework ofa building which has been effectively grounded, The National Electric Code fists @ number of alternate means af grounding electrical equipment, A machine grounding stud marked with the symbol @) is provided on the front of the welder. AUXILIARY POWER RECEPTACLES: Stat the engine and set the “IDLEARUN/STOP” swatch tothe “High le” moce. Voltage is now corect atthe receptaces for auxiliary power. Tis must be done belore a tripped GFCI can be rset proper: ly, See the MAINTENANCE section for more detailed information on testing and resetting the GF The auxiliary power ofthe AR VANTAGE® 600 SD consists of two 20, ‘Amnp-120 VAC (5-20R) duplex receptacles with GFCI protection, one '50 Amp 120/240 VAC (14-50R) receptacle and ona 50 Amp 24DVAC ‘Thwee-Phase (15-502) receptacle ‘The auxiliary power capacity is 12,000 Watts Continuous of 60 H2, ‘single phase power. The aulary power capacity rating in wats is equivalent to vorl-amperes at unity power factor. The max permissible currant of the 240 VAC output fs 50 amps. The 240 VAC output canbe soit fo provide two separate 120 VAC out- puts with 2 max permissible curent of 5D Amps per output to two sep- arate 120 VAC branch ort (these cuits cannot be parallec) ‘Output voltage is within + 10% a al ads up to rated capac. The Three-Phases auiiry power capacty 's 20,000 watts contin ‘us. The maximum current is 50 amps. FIGURE A.3 AUXILIARY POWER RECEPTACLES ‘ocean anes 2 oy EES aren nse sumac / ‘onc snnens 120 V DUPLEX RECEPTACLES AND GFC A GFCI protects the two 120V auxiliary power receptacles. ‘A GFO (Ground Fault iruit inlemunter isa device to protect against ‘electric shock should apiece of defective equipment connected tot ‘dovoop aground ful. his station sbould occur, the GFC! wl rp, removing voltage from the output of te receplacle. ia GF tipped ‘ee the MAINTENANCE section for detailed information on testing ad resetting tA GFCl shouldbe propery tested atleast once every month. The 120'V aucliary power receptaces should only be used with three ‘wie grounded ype plugs o approved double insulated fools with two ‘wire plugs. The curent rating ofan plug used wit the system must be at least equal to the current capacity of the associated receptacke NOTE: The 240 V receptacle has two 120 Vcreults but ae of opp0- ‘to polaris and cannot be paaleled, ‘Al auxtary powers protected by crc breakers. The 20 has 20 Amp, cirui breakers foreach duplex receptacle. Te 120/240V Single Phase and the 24(V Three-Phases have 50 Amp 3-poe Ceuft Bresker that disconnects both at eats and ll Tree Phases simuitaneousy. (Se Figure AS) Ae 151108 ani22024 AIR VANTAGE® 600 SD INSTALLATION STANDBY POWER CONNECTIONS ‘The AR VANTAGE® 600 SD issuitaba for temporary, standby or emergency power using the engine manufacturers recommended maintenance schedule, The AIR VANTAGE® 600 SO can be permanently insteled as 9 standby power unit for 240 volt-3 wire, 50 amp genic. Connections must be made by a lioansed electrician who can determine how the 120/240 VAG power can be adapted tothe particular instalation and comply with all applicable eletrioal codes, Refer tothe connection diagram shown in Figure A. +. Install the double-pote, double-throw swith between the power company meter andthe premises disconnect. Sitch rating ‘must be the same or areatr than the customer's premises dis- connect and service over current protection, 2. Take necessary steps to assure loads limited tothe capacity of the AR VANTAGE® 600 SO by installing a 50 amp, 240 VAC dou- ble poe ciruit breaker. Maximum rated load foreach leg ofthe 240 VAC auxiliary is 50 amps. Loading above the rated output wil reduce output votage below the allowable -10% of rated voltage ‘which may damage appliances or other motor-driven equipment ‘and may suf in overheating of the AIR VANTAGE® 600 SD ‘engine and /o altemate wings. 3. Install a 50 amp 120/240 VAC plug (NEMA Typo 14-50P) tothe double-pole cout breaker using No. 6, 4 conductor cable of the desired length 4. Plug this cable into the 50 Amp 120/240 Volt receptacle onthe ‘AIR VANTAGE® 600 SD case front. Figure A.4 Connection of the AiR VANTAGE® 600 $0 to Premises Wiring xoyoir t enounoeo conoucron 240 vo owen ‘avout ae some | et compar za Tavor be j were eum > He oxo DOUBLE roLe DOUBLE THROW SwerennannoTo BE THe cAME Service ovencunnent — cases atonMecy a0 = Stance = nino ovate outs ean TPE es sa ‘4 Nt =< G. NN ean \ a eegenes +2 ———___ ore: no conpen conoucron caste see TWATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE ‘SIZE RECOUMENDATIONS. 161108 hitpssimanualez.comidoc!22695562!air-v ani22024 AIR VANTAGE® 600 SD CONNECTION OF WIRE FEEDERS WITH CONTROL CABLE (14 PIN) ‘Shut off welder before making any electrical connections. CONNECTION OF LF-72, LF-74, FLEX FEED 74 HT, FLEX FEED 84, LN-25 PRO DUAL POWER TO THE AIR VANTAGE® 600 SD Shut the welder off «Set the “WIRE FEEDER VOLTMETER™ switch to either "+" or as required hy the electrode being used (See Figure AS), * For electrode Positive, connect the electrode cable othe "+" termi nal of the welder and work cable to the “~" terminal ofthe weer. For électrode Negative, connect the electrode cable "-" terminal of the welder and work cable tothe "+" terminal ofthe welder. * Set the *MIODE” swith tothe “CV-WIRE” postion * Acjustthe “ARC CONTROL" knob to desired Crispness. SOFT for IMIG and CRISP for Innersield * Sot the “WELDING TERMINALS" switch to the CONTROLLED" position. * Sot the wire feeder voltage switch to 42V, "REMOTELY * Connect the 14 pin control cable from the wire feeder to the ‘engine dive (See Figure AG). ‘ Set tho “REMOTE/LOCAL” switch to “REMOTE” if the feeder is equipped witha remote output control knob. INSTALLATION FIGURE AS Set Mode ta |] Set Weld Terminals to CyWire |] Remotely Controtied Set Polarity to Match Electrode Polarity Setto Remote Set to av FIGURE AS ENGINE WELDER 14PIN WIRE FEEDER ~ — Q_2 a y 9 ° KI797-xx CABLE oe | ELECTRODE CABLE TO WIRE FEED UNIT TOWORK as tage-6-500-56 a7is08 ani22024 ‘manual viewar AIR VANTAGE® 600 SD INSTALLATION CONNECTION OF ACROSS THE ARC WIRE FEEDERS FIGURE A7 TO THE AIR VANTAGE® 600 SD These connections instructions apply to both the LN-25 Pro and Activ8 models. The feeders havo an internal contactor and the Weld ‘electrode is not energized unt the gun trigger is closed. When the Terminals On gun trigger is closed the wire will begin to feed and the welding process is started. ‘Set Mode to Set to cvWire Local © Shut the welder off * For electrode Positive, connect the electrode cable to the "+" terminal ofthe welder and work cable tothe °-" terminal of the ‘welder. For electrode Negative, connect the electrode cable *-" ‘terminal ofthe welder and work cable to the "+" terminal ofthe welder. * Attach the single lead from the front ofthe feeder to work using the spring clip atthe end of the ead. This is @ control lead to supply current to the wire feeder motor; it does not cary weld- ing curent (See Figure A) * Sot the MODE switch to the "GV-WIRE" postion Gee Figure A). * Sot the “WELD TERMINALS" switch to "WELD TERMINALS ON" * Sat the "ARC CONTROL” knob to "O" initially and adjust to suit * Sot the “REMOTE/LOCAL” switch to “LOCAL” control FIGURE AS 14 PIN CONNECTOR 12PIN ENGINE TREN EETOR OPTIONAL welbea __ re) Sawer 0 rp] ct a WIRE FEEDER 2909-1 12 PIN TO 6 PIN —— ¢ ADAPTER CABLE ~ WORK CLIP LEAD = 10 To Work WORK ELECTRODE CABLE rars08 ani22024 AIR VANTAGE® 600 SD INSTALLATION CABLE INDUCTANCE AND ITS EFFECTS ON WELDING Excessive cable inductance wil cause the welding performance to degrade. There are several factors that contribute to the overall inductance ofthe cabling system including cable size, and loop tea. The loop areas defined by the separation distance between the electrode and work cables, andthe overall welding loop length The welding lop length is defined 2s the total of length of the electrode cable (A) + work cable (B) + work path (C) (See Figure A), ‘To minimize inductance always use the appropriate size cables, and whenever possible, run the electrode and work cables in close proximity to one anather to minimize the loop area. Since tha most significant factor in cable inductance fs the welding loop length, avoid excessive lengths and do not col excess cable, For long work piece lengths, a siding ground should be considered to keep the total welcing loop length as short as possible, Electrode Voltage Sensing The remote ELECTRODE sense lead (67) is bul into the pin ArcLink contol cable snd is aluays connected tothe wie dive feed plate when an ArcLink wie feeder is present. Enabling or dlsabling electrode voltage sensing is application specific, and auomaticaly configured by the active weld mode. \oltage sense leads requirements are based on the weld process (Gee Table A) TABLE A. | Process | Electrode Voltage Sensing 67 lead [GMAW _| e7lead FCAW 7 lead | GTAW Voltage sense at studs (SMAW | Voltage sense at studs (9) The electrode votage sense lead (67) fs automaticaly enabled by the weld process, and integral to the 5 pin AreLnk contol cable (15439) or K2BEB nx CONTROL CABLE CONNECTIONS General Guidelines Genuine Lincaln contol cables should be used tal times (xcept ‘where noted otherwise}. Lincoln cables are specifically designed forthe communication and power needs ofthe Engine Welder and Power Feed” systems. Most are designed tobe connected end to end for ease of extension. Generally, itis recommended thatthe total lenath not exceed 200ft (60.960m). The use of non-standard cables, especially in lengths Greater than 25 fee, can lead to communication prablems (system shutdowns), poor motor accel eration (poor ar: starting), and low wire driving force (wire feeding problems). Always use the shortest length of contro cable possi- ble, and DO NOT coil excess cable, Regarding cable placement, best results wil be obtained when control cables are routed separate from the weld cables. This min- imizes the possibilty of interference between the high currents flowing through the weld cables, and the low level signals inthe control cables. Product specific Installation Instructions Connection Between AIR VANTAGE® 600 SD and ArcLink® Compatible Wire feeders (K1543, K2683 — ArcLink® Control Cable) The Sin AvcLink® convo cable connects the AR VANTAGE® 600 SD tothe wire feeder. The conial cable consists of two power leads, one ‘twisted pair for digital communication, and one lead fr voltage sens ing. The 5pinArcink® connection on the AR VANTAGE® 600 SD is located on canrl panel. The cons cable is keyed and polarized to Brevent improper connection. Best resus wil be obtained wien con- ‘tol cables are rauted separate rom the wel! cables, especial i ong tistance applications, The recommended combined length ofthe ‘AcLink® conto cable netwerk shoud not exceed 200f. (60. 960m). FIGURE AQ ‘AIR VANTAGE® 600 SD 91108 ani22024 AIR VANTAGE® 600 SD OPERATION ‘SAFETY INSTRUCTIONS Read and understand this entire section before operating your AIR VANTAGE® 600 SD. Do not attempt to use this equipment until you have thor- ‘oughly read all operating and maintenance manuals supplied with your machine. They include important safety precau tions, 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 witing. «Insulate yourself from the work and ground. “+ Always wear dry insulating gloves, ENGINE EXHAUST can kill. D+ Use in open, well ventilated areas or vent exhaust outside ‘= Do not stack anything near the engine. MOVING PARTS can ‘Do not operate with doors open or guards off, + Stop engine before servicing. + Keop away from moving parts Only qualified personnel should operate this equipment. 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 airflow. hitps:/imanualzz.comidoc(22605562/air-vantage--600-s0 RECOMMENDED APPLICATIONS WELDER The AIR VANTAGE® 600 SD provides excellent constant current DC welding output for stick (SMAW) and TIG (GTAW) welding. The ‘AIR VANTAGE® 600 SO also provides excellent constant voltage DC welding output for MIG (GMAW), Innershiold (FCAW), COutershicld (FCAW-6) and Metal Gore (GMAW-C) welding, In addi- tion the AIR VANTAGE® 600 SD can be used for Arc Gouging with carbons up to 1/2"(13mm) in diameter. ‘The AIR VANTAGE® 600 SD is not recommended for pipe thaw ing, GENERATOR The AIR VANTAGE® 600 SD provides smooth 120/240 VAC single pase and 240V three phase output for auxllary power and emergency standby power. 2o/104 ani22024 AIR VANTAGE® 600 SD OPERATION CONTROLS AND SETTINGS A welder and engine controls are located on the case front pane Refer to Figure B.3 and the explanation tha follow. Figure B.3 Case Front Panel Controls ENGINE CONTROLS Itis extremely important to have the compressor system ppowor switch (Item 36) in the “OFF” position when starting the engine. Failure to observe this may result in loss of clutch life. 4. STOP © / (LOW IDLE/RUN) & / (HIGH IDLE/RUN) SWITCH ‘Togaling the switch to the RUN position energizes the fuel sole ‘noid 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 postions as fllows: 1) in the “High” position & the engine runs atthe high idle speed controll by Ye governor. ee hitps:imanualzz.comidoc!22695562 2Inthe“auto’ / folow: 3 <> ‘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. ®, When the electrode touches the work or power i drawn for lights or toosfaproximtly 100 Wat's minimum) the engine accelerates and operates at ull speed c. When welding ceases and the AC power lad is turned of, a fixed time delay of approximately 12 seconds stars. 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 ow idle speed. ®. Te engine wil automaticaly return thigh ide speed when ‘the welding load or A.C. power load is reapplied. Position, the idler operates as 204 ani22024 AIR VANTAGE® 600 SD OPERATION ‘ler Operational exceptions \When the WELDING TERMINALS switch isin the “Remotely Controlled” position the idler will operate 2s follows: «a. When the triggering device Amptrl, Ae Start Site, etc. is pressed the engine will accelerate and operat at full speed Drovided a welding load is applied within approximately 12. seconds. * I the triggering device remains pressed but no welding load is applied within approximately 12 seconds the engine may return to low idle speed «ithe tiggering device is released or welding ceases the engine vill tum to low idle speed after approximataly 12 seconds 2. START SWITCH 8 Energizes the starter motor to crank the engine. With the engine “Run / Stop” switch in the "Run" position, push and release the ‘tart bution 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 wil 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 switeh it will light up when there are faults with the engine. (Chock engine light comes on) Field Service Shop will need to connect to diagnostic plug to read error codes. 3. DASH BOARD GAUGE The dash board gauge displays 5 gauges: 3a, OIL PRESSURE The gauge displays the engine ol pressure when the engine is running. ‘3b, ENGINE TEMPERATURE ‘The gauge displays the engine coolant temperature. 3e. HOUR METER ‘The hour meter displays the total time that the engine thas been running. This meter is a useful indicator for scheduling preventive maintenance. 3d, FUEL LEVEL Displays the level of diese 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 propery. es 4, OUTPUT CONTROL- The OUTPUT cial is used to preset the ‘output voltage or current as displayed onthe digital meters for the five welding modes. 5. VRD (Voltage Reduction Device) INDICATOR LIGHTS- (Gn tho front panel fhe AR VANTAGE? 600 SD are no incor ight. ed lightwhen tndcates OC\Onen Cret Vota equal tor rater han