Lincoln Electric COMMANDER 500 Operator's Manual
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Lincoln Electric COMMANDER 500 Operator's Manual

Lincoln Electric COMMANDER 500 Operator's Manual

Lincoln electric welder user manual
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Download this manual See also: Service Manual
For use with machines having Code Numbers:
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
READING THIS MANUAL AND
THE
SAFETY
PRECAUTIONS
CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN MENU
Commander
10837, (Standard),
10838, (Deluxe)
WITHOUT
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
™
500
Copyright © 2002 Lincoln Global Inc.
IM699
April, 2002

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Summary of Contents for Lincoln Electric COMMANDER 500

  • Page 1 Commander For use with machines having Code Numbers: 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...

  • Page 2: California Proposition 65 Warnings

    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.

  • Page 3: Electric Shock Can Kill

    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.
  • Page 4 WELDING 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 from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

  • Page 5: Safety

    PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...

  • Page 7: Table Of Contents

    Remote Control ...A-5 Welding Terminals ...A-5 Welding Output Cables ...A-6 Machine Grounding ...A-6 Auxiliary Power Receptacles ...A-6 Standby Power Connections...A-6,A-7 Connection of Lincoln Electric Wire Feeders...A-8,A-9 Operation ...Section B Safety Instructions ...B-1 General Description...B-1 Recommended Applications...B-1 Design Features and Advantages...B-1 Welding Capability ...B-2...
  • Page 8 Cooling System...D-3 Cooling Blower Belt ...D-3 Battery Handling ...D-3 Nameplate / Warning Decal Maintenance...D-4 Welder / Generator Maintenance ...D-4 Engine Maintenance Components ...D-4 Troubleshooting ...Section E Wiring,Connection Diagrams and Dimension Print...Section F Parts Lists ...P386Series TABLE OF CONTENTS COMMANDER 500...

  • Page 9: Installation

    TECHNICAL SPECIFICATIONS - Commander 500 (K1639-1 & -2) Make/Model Description Deutz 3 cylinder F3L 912 44 HP(33 kw) Diesel Engine @ 1800 RPM Duty Cycle Welding Output 500 Amps (DC multi-purpose) 100% 550 Amps (DC multi-purpose) 575 Amps (DC multi-purpose)

  • Page 10: Safety Precautions

    Commander 500 machines cannot be stacked. ANGLE OF OPERATION To achieve optimum engine performance the Commander 500 should be run in a level position. The maximum angle of operation for the Deutz engine is 30 degrees fore and aft, 40 degrees right and 45 degrees left.

  • Page 11: Lifting

    For maximum rating, derate the welder output 5% for every 300 meters (984 ft.) above 1500 meters (4920 ft.). For output of 500A and below, derate the welder output 5% for every 300 meters (984 ft.) above 2100 meters (6888 ft.).

  • Page 12: Pre-Operation Engine Service

    25 gallons (94.6 liters). See engine Operator’s Manual for specific fuel recommendations. The Commander 500 Deluxe is protected by a low fuel shutdown to prevent the engine from running out of fuel. The machine will indicate a low fuel condition by turning on the low fuel light.

  • Page 13: Muffler Outlet Pipe

    INSTALLATION REMOTE CONTROL OUTPUT The Commander 500 is equipped with a 6-pin & 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control (Optional) or in the case of TIG welding applications, with the foot or hand Amptrol (K870 or K963-1 respectively).

  • Page 14: Welding Output Cables

    AUXILIARY POWER RECEPTACLES The auxiliary power capacity of the Commander 500 is 12,000 watts of 60 Hz, single phase power. The auxil- iary power capacity rating in watts is equivalent to volt- amperes at unity power factor.
  • Page 15 -10% of rated voltage which may damage appliances or other motor-driven equipment and may result in overheating of the Commander 500 engine. Figure A.2 Connection of the Commander 500 to Premises Wiring 240 VOLT POWER 240 Volt 60 Hz.

  • Page 16: Connection Of Lincoln Electric Wire Feeders

    CONNECTION OF THE LN-25 TO THE COMMANDER 500 The LN-25 with or without an external contactor may be used with the Commander 500. See the appropri- ate connection diagram in the DIAGRAMS section. NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the Commander 500.
  • Page 17 CONNECTION OF AN NA-3 AUTOMATIC WELDING SYSTEM TO THE COMMANDER For connection diagrams and instructions for connect- ing an NA-3 Welding System to the Commander 500, refer to the NA-3 Welding System instruction manual. The connection diagram for the LN-8 can be used for connecting the NA-3.

  • Page 18: Operation

    OPERATION GENERAL DESCRIPTION The Commander 500 is a diesel engine-driven welding power source. The machine uses a brush type alter- nating current generator for DC multi-purpose welding and for 120/240 VAC auxiliary standby power. The welding control system uses state of the art Chopper Technology.

  • Page 19: Welding Capability

    WELDING CAPABILITY The Commander 500 is rated at 500 amps, 40 VDC at 100% duty cycle and 575 amps, 36 VDC at 50% duty cycle. The maximum open circuit voltage at 1900 RPM is 80 volts.

  • Page 20: Controls And Settings

    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. ENGINE CONTROLS (Items 1 through 8) STOP SWITCH When placed in the “RUN” position, this switch ener- gizes the fuel solenoid and other electric accessories.
  • Page 21 Check engine cooling blower belt. Also, check to be sure that the welder loads are within the rating of the welder. The light will remain on when the engine has been shut down due to an over- temperature condition.

  • Page 22: Welder Controls

    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. COMMANDER 500...

  • Page 23: Engine Operation

    STOPPING THE ENGINE 1. Switch the RUN/STOP switch to “STOP”. This turns off the voltage supplied to the shutdown solenoid. A backup shutdown can be accomplished by shut- ting off the fuel valve located on the fuel line. COMMANDER 500...

  • Page 24: Break-In Period

    Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc. The Commander 500 can be used in a wide variety of DC Tungsten Inert Gas (TIG) welding applications. In general the “Touch Start” feature allows contamination free starting without the use of a Hi-Freq unit.
  • Page 25 (5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures and high duty cycles. Commander 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT •...

  • Page 26: Wire Feed (Constant Voltage) Welding

    WIRE FEED (CONSTANT VOLTAGE) WELD- Connect a wire feeder to the Commander 500 and set welder controls according to the instructions listed earlier in this section. The Commander 500 in the ”CV-WIRE” position, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding).

  • Page 27: Extension Cord Length Recommendations

    B-10 TABLE B.4 Commander 500 Simultaneous Welding and Power Welding Welding Output Output Range Setting 500A/40V 30-575 500A/40V 350A/30V 200A/28V 150A/27V 90A/25V * Each duplex receptacle is limited to 20 amps. ** Not to exceed 50 A per 120 VAC branch circuit when splitting the 240 VAC output.

  • Page 28: Accessories

    Has convenient plug for easy connection to the welder. The Commander 500 is equipped with a 6 pin connec- tor for connecting the remote control.

  • Page 29: Recommended Optional Equipment

    HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi-Freq Unit and the K930-ALL TIG Modules are suitable for use with the Commander 500. The Commander is equipped with the required R.F. bypass circuitry for the connection of high frequency generat- ing equipment.

  • Page 30: Maintenance

    6. Dry element before reuse with warm air at less than F (71 C). Do not use a light bulb to dry the ele- ment. COMMANDER 500 CAUTION least one inch away from element. 40 psi maximum without nozzle.

  • Page 31: Fuel Filters

    • Keep naked lights away, do not smoke ! • Do not spill fuel ! ------------------------------------------------------------------------ The Commander 500 is equipped with a Fuel Pre- Filter/Water Separator Assembly located before the lift pump and a Secondary Fuel Filter located after the lift pump and before the fuel injectors.

  • Page 32: Cooling System

    The following procedure should be followed to replace the cooling blower belt: 1. Allow the machine to cool. 2. Unfasten and slide the battery holder out from the welder. 3. Disconnect the negative battery cable. 4. Remove engine case side.

  • Page 33: Nameplate / Warning Decal Maintenance

    Do not attempt to polish slip rings while the engine is running. ------------------------------------------------------------------------ MAKE Donaldson Lincoln Gates Deutz Purolator Napa Fram Deutz Purolator Napa Fram Lincoln Stanadyne Lincoln Stanadyne COMMANDER 500 WARNING PART NUMBER P181052 A302C T13536-3 7585 1174418 PER2168 1820 PH3776 1174423 PC42 3358 P4102 M16890-C 31572 M16890-B 29575...

  • Page 34: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 35: Troubleshooting

    Replace if neccessary. 3. High oil temperature (Indicator light lit). Check engine cooling system. (Consult engine service dealer. 1. Faulty battery. Replace CAUTION COMMANDER 500 RECOMMENDED COURSE OF ACTION Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance.
  • Page 36 1. Auxiliary power load is less than 100 watts. Idler may not respond with less than a 100 watt load. Set Idler to “High” CAUTION COMMANDER 500 RECOMMENDED COURSE OF ACTION Contact your Local Lincoln Authorized Field Service Facility for technical...
  • Page 37 Refer to Auxiliary Connections in the Installation and Operation chapters. 2. Faulty connections to auxiliary receptacles. Check connections. 3. Faulty auxiliary circuit wiring. CAUTION COMMANDER 500 RECOMMENDED COURSE OF ACTION Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance.
  • Page 38 G4357 50MV=400AMPS DIAGRAMS COMMANDER 500 G3834 GND-J 281A 115A 118A 101A 105A 116A 260A 261A 232W 208B SELECT MACHINE PROGRAMMING...
  • Page 39 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 500...
  • Page 40 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 500...
  • Page 41 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 500...
  • Page 42 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 500...
  • Page 43 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 500...
  • Page 44 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 500...
  • Page 45 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 500...
  • Page 46 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 500...
  • Page 47 F-10 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 500 F-10...
  • Page 48 F-11 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 500 F-11...
  • Page 49 F-12 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 500 F-12...
  • Page 50 F-13 CONNECTION DIAGRAM: DIAGRAMS COMMANDER 500 F-13...
  • Page 51 F-14 F-14 DIAGRAMS DIMENSION PRINT COMMANDER 500...
  • Page 52 NOTES COMMANDER 500...
  • Page 53 |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Account No. AMERICAN EXPRESS MasterCard AMERICAN EXPRESS USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 BOOKS OR FREE INFORMATIVE CATALOGS Lincoln Welding School (ED-80) Seminar Information (ED-45)
  • Page 54 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● German ● WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 55 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 56 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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