Lincoln Electric IM826-A manual BREAK-IN Period, Welder Operation

B-6 OPERATION B-6

BREAK-IN PERIOD

The engine used to supply power for your welder is a heavy duty, industrial engine. It is designed and built for rugged use. It is very normal for any engine to use small quantities of oil until the break- in is accomplished. Check the oil level twice a day during the break-in period. In general this takes 50 to 100 hours of operation.

IMPORTANT

IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNIT SHOULD BE SUBJECTED TO HEAVY LOADS, WITHIN THE RATING OF THE MACHINE. AVOID LONG IDLE RUNNING PERIODS.

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.

TYPICAL FUEL CONSUMPTION

Refer to Table B.2 for typical fuel consumption of the AIR VANTAGE® 500 Engine for various operating scenarios.

Table B.2

Cummins B3.3 Engine Fuel Consumption

	Cummins B3.3	Running Time for
	56HP(42Kw)	25GAL.(94.6L)
	@1800 RPM	(Hours)
Low Idle -	.59 Gal./hour	42.4
no load 1425 RPM	(2.2 L/hour)
High Idle -	.87 Gal./hour	28.7
no load 1900 RPM	(3.3 L/hour)
DC CC Weld	2.10 Gal./hour	11.9
Output 500	(7.9 L/hour)
Amps @ 40 Volts
Auxiliary Power	1.44 Gal./hour	17.4
12,000 VA	(5.5 L/hour)
Auxiliary Power	2.02 Gal./hour	12.4
20,000 VA	(7.6 L/hour)
Air Compressor	1.29 Gal./hour	19.4
60 CFM @ 100 PSI	(4.9 L/hour)
Air Compressor
60 CFM @ 100 PSI	2.46 Gal./hour	10.2
and DC, CC Weld	(9.3 L/hour)
Output 500 Amps
@40 Volts
Air Compressor
60 CFM @ 100 PSI	1.94 Gal./hour	12.9
and Auxiliary Power	(7.3 L/hour)
12,000 VA

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 AIR VANTAGE® 500 can be used with a broad range of DC stick electrodes.

The MODE switch provides two stick welding settings as follows:

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.

TOUCH START TIG MODE

The AIR VANTAGE® 500 can be used in a wide variety of DC TIG welding 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 AIR VANTAGE® 500. The settings are for reference.

The AIR VANTAGE® 500 is equipped with the required R.F. bypass circuitry for the connection of high frequency generating equipment.

The AIR VANTAGE® 500 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 AIR VANTAGE® 500 is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module.

AIR VANTAGE® 500 CUMMINS