Lincoln Electric IM644-A manual Welding Capability, For Auxiliary Power, Other Features

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B-2

 

OPERATION

 

B-2

 

 

 

 

 

100% duty cycle at 500 amps output and 50% duty cycle at 575 amps output.

Dual 3-digit output meters are provided (optional on K1639-1) for presetting the weld amperage or voltage and displaying the actual amperage and voltage during welding. The meters use superbrite L.E.D.'s for improved readability in full sunlight.

Standard remote control capability with 14 pin and 6 pin connectors for easy connection of Lincoln remote con- trol accessories.

An internal "Solid State" contactor allows for the selec- tion of "hot" or "cold" output terminals with a toggle switch on the control panel.

“Arc Control”potentiometer in Wire and Stick modes for precise adjustment of arc characteristics.

Advanced circuitry to prevent pop-outs in the five slope modes.

FOR AUXILIARY POWER

12,000 watts of 120/240 VAC, 60Hz auxiliary power.

Power for tools, 120/240 VAC lights, electric pumps and for standby emergency power.

Drive a 5 HP motor (provided it is started under no load).

Two 20 amp 120 VAC duplex receptacles for up to 40 amps of 120 VAC power.

One 50 amp, 120/240 VAC dual voltage receptacle for up to 50 amps of 240 VAC, and up to 50 amps per side to separate branch circuits (not in parallel) of 120 VAC single phase auxiliary power. Allows easy con- nection to premises wiring.

Weld and AC auxiliary power at the same time (with- in machine total capacity).

OTHER FEATURES

Deutz 3-cylinder, air/oil cooled diesel engine. Designed for long life, easy maintenance and excel- lent fuel economy.

Engine protection system shuts the engine down for low oil pressure, high oil temperature or a broken fan/engine alternator belt.

Gauges for oil pressure, oil temperature, engine alter- nator output and fuel level.

Indicator lights for low oil pressure, high oil tempera- ture, engine alternator low output/broken belt and low fuel level (on K1639-2 only).

Automatic low fuel shutdown before running out of fuel (K1639-2 only).

Engine hour meter standard on all models.

Extended range 25 gallon (94.6 l) fuel tank.

Automatic idler reduces engine speed when not weld- ing or drawing auxiliary power. This feature reduces fuel consumption and extends engine life.

Compact size fits crosswise in full size pick-up truck.

Single side engine service.

Copper alternator windings and high temperature insulation for dependability and long life.

New paint system on case and base for outstanding corrosion protection.

K1639-1 Commander 500 Standard Model

The K1639-1 is the standard version of the Commander 500, and has all the features of the K1639-2 Deluxe version except that there are no gauges, low fuel light nor dual output meters. This version does have fully functional engine protection for low oil pressure, high oil temperature, and alter- nator output with associated lights.

A field installed Dual Output Meter and Gauge Kit (K- 1596-2) is available for the K1639-1 Commander 500.The kit includes dual output meters, oil pressure gauge, oil temperature gage, and alternator amme- ter.

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 90 volts. The weld current is variable from 30 to 575 amps.

COMMANDER 500

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Contents Safety Depends on You CommanderCalifornia Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéThank You Table of Contents Section F Section CSection D Section EBore x Stroke InstallationWelding Range Open Circuit Voltage Auxiliary Power1 HEIGHT2 Width Depth WeightStacking Safety PrecautionsLocation / Ventilation StoringTowing High Temperature OperationLifting High Altitude OperationFuel USE Diesel Fuel only PRE-OPERATION Engine ServiceEngine Cooling System Battery Connection OILHigh Frequency Generators for TIG Applications Remote ControlWelding Terminals Machine Grounding Auxiliary Power ReceptaclesStandby Power Connections Welding Output CablesPower Connection of the LN-25 to the Commander Connection of Lincoln Electric Wire FeedersConnection of LN-7 or LN-8 to the Commander Connection of AN LN-23P Wire Feeder to the Commander Operating Instructions Safety InstructionsDesign Features and Advantages OperationWelding Capability For Auxiliary PowerOther Features K1639-1 Commander 500 Standard ModelFuel Level Gauge and Light Controls and SettingsRUN- Stop Switch Start PushbuttonHour Meter Idler SwitchOIL Pressure Gauge K1639-2 Std., K1639-1 Opt. and Light Idler Operational exceptionsAuxiliary Power Controls Starting the Engine Engine OperationStopping the Engine Stick Welding Welder OperationBREAK-IN Period Typical Fuel ConsumptionCommander 500 Settings When Using the K930-1 TIG Module Commander 500 Settings When Using the K799 HI-FREQ UnitTable B.3 Typical Current Ranges 1 for Tungsten ELECTRODES2 Wire Feed Constant Voltage WELD- ING Auxiliary Power OperationSimultaneous Welding and AUXIL- Iary Power Loads Table B.4 Commander 500 Simultaneous Welding and Power Loads Optional Field Installed Accessories AccessoriesRecommended Optional Equipment Routine and Periodic Maintenance MaintenanceEngine Maintenance Fuel PRE-FILTER/WATER Separator ASSEM- BLY Fuel FiltersWater Separator Element Cooling System Cooling Blower Belt Battery HandlingBrush Removal and Replacement Nameplates / Warning Decals MaintenanceWelder / Generator Maintenance CleaningHOW to USE Troubleshooting Guide TroubleshootingPossible Areas SymptomsCourse of Action Function Problems Output Problems Commander 500 Wiring Diagram DiagramsConnection Diagram To Work Electrode Cable To Wire Feed Unit Commander / K867 / K775 / LN-7 Connection DiagramElectrode Cable Connection DiagramRemote Control To Wire Feed UnitCommander to K867 Adapter Connection Diagram Connection DiagramCommander / K867 / LN-8 Connection Diagram Remove the Three Screws Shown and USE PIN Amphenol To LN-8 Input Cable Plug K595 Control Cable Commander / LN-8 Connection DiagramTo Work To Work PIN Commander / K930 TIG Module / Connection Diagram To LN-742 Input Cable Plug K592 Control Cable Commander / LN-742 Connection Diagram24.97 Dimension Print$700.00 Basic CoursePrecaucion Aviso DE