Lincoln Electric IM544-B manual Operation, Operating Instructions, Safety Instructions

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B-1

OPERATION

B-1

 

 

 

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.

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such as output terminals or internal wiring.

•Insulate yourself from the work and ground.

•Always wear dry insulating gloves.

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ENGINE EXHAUST can kill.

•Use in open, well ventilated areas or vent exhaust outside

•Do not stack anything near the engine.

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MOVING PARTS can injure.

•Do not operate with doors open or guards off.

GENERAL DESCRIPTION

The Commander is a diesel engine driven welding power source. The machine uses a brushless asyn- chronous alternating current generator for DC stick electrode welding and for 120/240 VAC auxiliary stand- by power. As a generator it can supply up to 10,000 watts of 120/240 volt AC power. As a welder it provides up to 400 amps of DC constant current output in six slope-controlled ranges. In addition a seventh general purpose welding range provides up to 575 amps of constant current welding output.

The engine is a 44.2 Hp (33kw), 3-cylinder air/oil cooled diesel made by Deutz. This naturally aspirated, 4 cycle engine features direct injection, a Bosch in-line injection pump and a Bosch mechanical governor.

This machine is controlled by a high quality microcon- troller. The microcontroller provides high speed control of the weld process as well as the engine protection features.

RECOMMENDED APPLICATIONS

WELDER

The Commander 400 (Stick model) provides excellent con- stant current DC welding output for stick (SMAW) welding. The Commander 400 (Stick & Wire model) also provides excellent constant voltage DC welding output for MIG (GMAW) and Innershield (FCAW) welding.

GENERATOR

The Commander 400 provides smooth 120/240 VAC output for auxiliary power and emergency standby power.

DESIGN FEATURES AND ADVANTAGES

(All Models)

•Stop engine before servicing.

•Keep away from moving parts

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Only qualified personnel should operate this equip- ment.

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door closed and the side panels in place as these provide maxi- mum protection from moving parts and insure proper cooling air flow.

FOR STICK WELDING

Excellent DC constant current output for stick weld- ing applications.

40 to 400 amps output in six slope controlled ranges for out-of position and pipe electrodes and 50 to 575 amps constant current output in one general purpose welding range.

3 digit display is provided for presetting the weld amperage and displaying the actual amperage during welding. The display uses superbrite L.E.D.’s for improved readability in full sunlight.

Remote control capability standard on all models.

COMMANDER 400

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Contents Commander Safety Depends on YouSafety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcThank You Table of Contents HEIGHT2 Width Depth Weight InstallationWelding Range Open Circuit Voltage Auxiliary Power1 Bore x StrokeStacking Safety PrecautionsLOCATION/VENTILATION Angle of OperationTowing PRE-OPERATION Engine ServiceHigh Altitude Operation OILFuel CAP Engine Cooling System Battery ConnectionElectrical Output Connections Muffler Outlet PipeWelding Output Cables Auxiliary Power ReceptaclesStandby Power Connections Machine GroundingPower Operating Instructions Safety InstructionsOperation General DescriptionOther Features Additional Design FeaturesFor Auxiliary Power For Wire WeldingStart Pushbutton Controls and SettingsRUN- Stop Switch Engine Alternator Ammeter and Light Engine Temperature Gauge and LightIdler Switch Idler Operational exceptionsAuxiliary Power Controls Starting the Engine Wire Feeder Mode ControlsEngine Operation Stopping the EngineStick Welding Welder OperationTypical Fuel Consumption TIG WeldingTable B.3 Typical Current Ranges 1 for Tungsten ELECTRODES2 Commander 400 Settings When Using the K799 HI-FREQ UnitCommander 400 Settings When Using the K930-1 TIG Module Stick and Wire Model Connection to LN-23P Wire Feed Constant Voltage WELD- INGStick and Wire Model Connection to LN-25 Stick and Wire Model Connection to NA-3Auxiliary Power Operation Simultaneous Welding and AUXIL- Iary Power LoadsRecommended Equipment AccessoriesOptional Field Installed Accessories Engine Maintenance MaintenanceRoutine and Periodic Maintenance Water Separator Element Fuel FiltersFuel PRE-FILTER/WATER Separator ASSEM- BLY Battery Handling Cooling System Cooling Blower BeltMake Part Number Troubleshooting HOW to USE Troubleshooting GuideCourse of Action SymptomsPossible Areas Function Problems Output Problems Diagrams Commander Diagrams K488 / K487 Spool GUN Connection DiagramDiagram Commander 400 Stick & Wire / LN-23P Connection DiagramAmphenol 14 PIN Commander 400 Stick & Wire / K867 / LN-8 Connection Diagram Electrode Cable To Wire Feed Unit LN-7 Connection Diagram Electrode Cable Commander 400 Stick & Wire / LN-8 Connection Diagram Dimension Print Commander Basic Course $700.00Precaucion Aviso DE Conditions of Warranty Statement of Limited WarrantyWarranty Period 1 2 Warranty Limitations