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Lincoln Electric COMMANDER IM544-B Operator's Manual

Lincoln electric welding system user manual
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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
WITHOUT
READING THIS MANUAL AND
THE
SAFETY
PRECAUTIONS
CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
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
RETURN TO MAIN MENU
Commander
9978, 10580 (Stick Model),
9979, 10581 (Stick and Wire Model)
OPERATOR'S MANUAL
™
400
Premier Manufacturer of Industrial Motors
IM544-B
June, 1998

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Summary of Contents for Lincoln Electric COMMANDER IM544-B

  • 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 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. 3.b.
  • 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

    Safety ...i-iv Installation...Section A Technical Specifications ...A-1 Safety Precautions ...A-2 Location/ Ventilation ...A-2 Stacking...A-2 Angle of Operation ...A-2 Lifting ...A-2 High Altitude Operation ...A-3 Towing ...A-3 Pre-Operation Engine Service ...A-3 Oil ...A-3 Fuel...A-3 Fuel Cap...A-4 Engine Cooling System ...A-4 Battery Connection...A-4 Muffler Outlet Pipe...A-4 Spark Arrester ...A-4 Electrical Output Connections ...A-4...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - Commander 400 Make/Model Description Deutz 3 cylinder F3L 912 Diesel 44.2 HP(33kw) Engine @ 1800 RPM Duty Cycle Welding Output 400 amps (DC Constant Current) 100% 400 amps (DC Constant Voltage) 500 amps (DC Constant Current) 500 amps (DC Constant Voltage) OUTPUT - WELDER AND GENERATOR Welding Range 40 - 575 Amps...

  • Page 9: Safety Precautions

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine. They include impor- tant safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.

  • Page 10: High Altitude Operation

    HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary. As a rule of thumb, derate the welder output 5% for every 400 meters (1312 ft.) above 1000 meters (3280 ft.). Contact a Deutz Service Representative for any engine adjustments that may be required for high altitude operation.

  • Page 11: Fuel Cap

    FUEL CAP Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap. ENGINE COOLING SYSTEM The Deutz engine is air cooled by a belt driven axial blower. The oil cooler and engine cooling fins should be blown out with compressed air or steam to maintain proper cooling (See the engine Owners Manual for pro- cedures and frequency).

  • Page 12: Welding Output Cables

    WELDING OUTPUT CABLES With the engine off, route the electrode and work cables thru the strain relief bracket provided on either side of the base and connect to the terminals provided. These connections should be checked periodically and tightened if necessary. Listed in Table A.1 are copper cable sizes recom- mended for the rated current and duty cycle.
  • Page 13 2. Take necessary steps to assure load is limited to the capacity of the Commander by installing a 45 amp, 240 VAC double pole circuit breaker. rated load for each leg of the 240 VAC auxiliary is 45 amperes. Loading above the rated output will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motor-driven equipment and may result in...

  • Page 14: Operation

    OPERATING INSTRUCTIONS Read and understand this entire section before operat- ing your Commander 400. SAFETY INSTRUCTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine. They include impor- tant safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.

  • Page 15: Welding Capability

    • Selection of “hot” or “cold” output terminals with a tog- gle switch on the control panel. This feature can also be controlled by installing a remote output terminal control cable designed to open and close the #2 and #4 leads in the amphenol receptacle. FOR AUXILIARY POWER •...

  • Page 16: 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) RUN- STOP SWITCH When placed in the “RUN” position, this switch ener- gizes the fuel solenoid and other electric accessories.
  • Page 17 4. ENGINE TEMPERATURE GAUGE AND LIGHT The gauge displays the engine oil temperature. The yellow temperature light remains off under normal operating temperatures. If the light turns on, the engine protection system will shut down the engine. Check for restrictions at the engine cooling air inlets and outlets (consult the engine Operator’s Manual).

  • Page 18: Welder Controls

    WELDER CONTROLS (Items 9 through 14 ) 9. OUTPUT RANGE SWITCH & OUTPUT CONTROL These two controls allow you to select between various welding output slopes and adjust the desired welding output. Refer to Table B.1 for a description of how these two controls work.

  • Page 19: Engine Operation

    17. 120VAC RECEPTACLES These two 120VAC (5-15R) receptacles with GFCI pro- tection provide 120VAC for auxiliary power. These receptacles have a 20 amp total rating. Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about these receptacles.

  • Page 20: Typical Fuel Consumption

    TYPICAL FUEL CONSUMPTION Refer to Table B.2 for typical fuel consumption of the Commander 400’s Engine for various operating sce- narios. Table B.2 Deutz F3L 912 Engine Fuel Consumption Deutz F3L 912 44.2 Hp @ 1800 RPM Low Idle - No .30 gallons/hour Load 1350 RPM (1.36 liters/hour)
  • Page 21 Table B.3 TYPICAL CURRENT RANGES DCEN (-) Tungsten Electrode 1%, 2% Diameter Thoriated in. (mm) Tungsten 0 .010 (.25) 2-15 0.020 (.50) 5-20 0.040 (1.0) 15-80 1/16 (1.6) 70-150 3/32 (2.4) 150-250 (3.2) 250-400 5/32 (4.0) 400-500 3/16 (4.8) 500-750 (6.4) 750-1000 (1) When used with argon gas.

  • Page 22: Wire Feed (Constant Voltage) Welding

    15 seconds unless welding is resumed. STICK AND WIRE MODEL CONNECTION TO NA-3 For connection diagrams and instructions for connecting an NA-3 Welding System to the Commander Stick & Wire, refer to the NA-3 Welding System instruction manual. COMMANDER 400...

  • Page 23: Auxiliary Power Operation

    B-10 AUXILIARY POWER OPERATION Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings, if no welding current is being drawn.. The auxiliary power of the Commander consists of two- 120VAC (5-15R) duplex receptacles with GFCI protec- tion and one 120/240 VAC (14-50R) receptacle.

  • Page 24: Accessories

    OPTIONAL FIELD INSTALLED ACCESSORIES K802R POWER PLUG KIT - Provides a plug for each receptacle. K857 28 ft. (8.5 m) or K857-1 100 ft. (30.4 m) REMOTE CONTROL - Portable control provides same dial range as the output control on the welder from a location up to the specified length from the welder.

  • Page 25: Maintenance

    SAFETY PRECAUTIONS WARNING •Have a qualified technician do the maintenance and troubleshooting work. •Turn the engine off before working inside the machine. •Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. •Always use the greatest care when working near moving parts.
  • Page 26 7. Inspect for holes and tears by looking through the element toward a bright light. Check for damaged gas- kets or dented metal parts. Do not reuse damaged ele- ments. Protect element from dust and damage during drying and storage. 8.

  • Page 27: Battery Handling

    4. Slide the new element onto the grommet post on the bottom of the filter header until the element no longer easily moves up into the filter header. Now rotate the element (may take almost 1 full turn) with a slight upward pressure until the element begins to further engage the header.
  • Page 28 Table D.1 Engine Maintenance Components ITEM Air Cleaner Element Cooling Blower Belt Oil Filter Element Fuel Filter Element Water Separator Element Fuel Pre-Filter Screen Battery MAINTENANCE MAKE Donaldson Lincoln Gates Deutz Purolator Napa Fram Deutz Purolator Napa Fram Lincoln Stanadyne Lincoln Stanadyne COMMANDER 400...

  • Page 29: 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 30: Troubleshooting

    Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. Engine will not “crank”. Engine will “crank” but not start. Engine shuts down shortly after starting. Battery does not stay charged. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 31 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine will not idle down to low speed. Engine will not go to high idle when attempting to weld. Engine will not go to high idle when using auxiliary power. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 32 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) No welding power output. Welder has output and no control. No auxiliary power. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 33 WIRING DIAGRAM: DIAGRAMS HARNESS CONTROL GREEN COMMANDER 400 BLACK BLACK BLACK BLACK GREEN GREEN BLACK WHITE...
  • Page 34 WIRING DIAGRAM: 300W R3-12 R2-12 R1-50 DIAGRAMS BLACK GREEN GREEN GREEN COMMANDER 400 BLACK BLACK WHITE BLACK BLACK...
  • Page 35 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 400...
  • Page 36 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 400...
  • Page 37 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 400...
  • Page 38 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 400...
  • Page 39 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 400...
  • Page 40 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 400...
  • Page 41 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 400...
  • Page 42 F-10 F-10 DIAGRAMS CONNECTION DIAGRAM: COMMANDER 400...
  • Page 43 F-11 F-11 DIAGRAMS DIMENSION PRINT COMMANDER 400...
  • Page 44 F-12 F-12 NOTES COMMANDER 400...
  • Page 45 MasterCard ® ® |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Account No. 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) Educational Video Information (ED-93) James F.
  • Page 46 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
  • Page 47 ● ● Keep your head out of fumes. Turn power off before servicing. ● Use ventilation or exhaust to remove fumes from breathing zone. ● Los humos fuera de la zona de res- ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...

  • Page 48: Limited Warranty

    Equipment manufactured for the Lincoln Electric Company is subject to the warranty period of the original manufacturer. All engines and engine accessories are warranted by the engine or engine accessory manufacturer and are not covered by this warranty.

This manual is also suitable for:

Commander 400

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