Lincoln Electric IM544-B Welder Operation, Typical Fuel Consumption, Stick Welding, TIG Welding

B-7 OPERATION B-7

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	Running Time for
	44.2 Hp	25 gallons
	@ 1800 RPM	(Hours)
Low Idle - No	.30 gallons/hour	83.3
Load 1350 RPM	(1.36 liters/hour)
High Idle - No	.78 gallons/hour	32.1
Load 1900 RPM	( 3.55 liters/hour)
DC CC Weld	1.84 gallons/hour	13.6
Output 400	( 8.36 liters/hour)
Amps @ 40 Volts
Auxiliary Power
10,000 VA	1.32 gallons/hour	18.9
	(6.00 liters/hour)

WELDER OPERATION

STICK WELDING

The Commander 400 can be used with a broad range of DC stick electrodes.

The OUTPUT RANGE switch provides six overlapping slope controlled current ranges. The OUTPUT CON- TROL adjusts the current from minimum to maximum within each range. Open circuit voltage is also con- trolled by the OUTPUT CONTROL in the slope con- trolled setting. These slope controlled settings are intended for “out-of-position” welding, including pipe where the operator would like to control the current level by changing the arc length.

setting and lower open circuit voltage. For example: to obtain 175 amps and a forceful arc, set the to the “230 MAX” position and then adjust the OUTPUT CON- TROL to get 175 amps.

GENERAL WELDING

The seventh position of the OUTPUT RANGE switch is designed for horizontal welds with all types of elec- trodes especially low hydrogen. The OUTPUT CON- TROL adjusts the full range of 50 to 575 amps. This setting provides a soft, constant current arc. If a more forceful arc is desired, then select the proper range from the slope controlled current ranges.

TIG WELDING

The Commander 400 can be used in a wide variety of DC Tungsten Inert Gas (TIG) welding applications for DC TIG welding up to 400A at a 20% duty cycle, 300A at a 60% duty cycle and 250A at a 80% duty cycle. Refer to Table B.3 for recommended output setting depending on the tungsten electrode size. The Commander can be used without a TIG module or Hi- Freq Unit for scratch start DC TIG welding. Using a K799 Hi-Freq Unit or K930-1 TIG Module enables DC TIG welding without having to scratch start. The end of this section also details Commander 400 settings when using either of these units for DC TIG welding. Also refer to the Accessories chapter for recommend- ed equipment for TIG welding.

ARC GOUGING

Set the output range switch to the General purpose position (50-575). For current setting, refer to The Procedure Handbook of Arc Welding, section on arc gouging (13.5) or the consumable manufacturer’s rec- ommended current rating.

PIPE WELDING

When using a sloped range, high open circuit voltage setting provides the softest arc with best resistance to pop-outs. To get this characteristic, set the OUTPUT RANGE switch to the lowest setting that still provides the current you need and set the OUTPUT CONTROL near maximum. For example: to obtain 175 amps and a soft arc, set the OUTPUT RANGE switch to the “180 MAX” position and then adjust the OUTPUT CON- TROL for 175 amps.

When a forceful “digging” arc is required, use a higher

COMMANDER 400