Lincoln Electric 500 manual Operation, Safety Instructions, General Description

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B-1

OPERATION

B-1

 

 

 

Read and understand this entire section before operat- ing your Commander 500.

SAFETY INSTRUCTIONS

Do not attempt to use this equipment until you have thoroughly read all operating and mainte-

WARNING

nance manuals supplied with your machine. They include important 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.

------------------------------------------------------------------------

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.

•Stop engine before servicing.

•Keep away from moving parts

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Only qualified personnel should operate this equipment.

ADDITIONAL SAFETY PRECAUTIONS

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

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. The Commander 500 is not recom- mended for pipe thawing.

The generator has a single sealed bearing for mainte- nance free service. The rotor is a copper wound design with two slip rings and brushes. The stator is wound entirely with heavy gauge copper wire and insulated with NEMA class F insulation material. The stator is then impregnated with three layers of high quality var- nish. After the stator is assembled using tie bars, the entire assembly covered with an environmentally pro- tective coating. These measures insure trouble-free operation in the harshest environments.

The fuel tank is made from high density polyethylene and holds 25 gallons of diesel fuel. This will provide enough fuel to run for more than 12 hours at full load.

The Deutz F3L-912 engine is equipped with a stan- dard, heavy duty, combination fuel filter/water separa- tor element.

RECOMMENDED APPLICATIONS

WELDER

The Commander 500 provides excellent constant current DC welding output for stick (SMAW) and TIG welding. The Commander 500 also provides excellent constant voltage DC welding output for MIG (GMAW) and Innershield (FCAW) welding.

GENERATOR

The Commander 500 provides smooth 120/240 VAC output for auxiliary power and emergency standby power.

DESIGN FEATURES AND ADVANTAGES

K1639-2 Commander 500 Deluxe Model Features

For Welding:

•Excellent DC multi-purpose welding for stick, MIG, TIG, cored wire and arc gouging applications.

•30 to 500 amps output in five slope controlled ranges for out-of position and pipe electrodes, one constant current output range for general purpose welding, one constant voltage range for MIG wire and cored wire welding and one 20-250 amp range for “Touch Start” TIG welding.

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

COMMANDER 500

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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 Section E Section CSection D Section FHEIGHT2 Width Depth Weight InstallationWelding Range Open Circuit Voltage Auxiliary Power1 Bore x StrokeStoring Safety PrecautionsLocation / Ventilation StackingHigh Altitude Operation High Temperature OperationLifting TowingOIL PRE-OPERATION Engine ServiceEngine Cooling System Battery Connection Fuel USE Diesel Fuel onlyRemote Control High Frequency Generators for TIG ApplicationsWelding Terminals Welding Output Cables Auxiliary Power ReceptaclesStandby Power Connections Machine GroundingPower Connection of Lincoln Electric Wire Feeders Connection of the LN-25 to the CommanderConnection of LN-7 or LN-8 to the Commander Connection of AN LN-23P Wire Feeder to the Commander Remotely ControlledOperation Safety InstructionsDesign Features and Advantages General DescriptionK1639-1 Commander 500 Standard Model For Auxiliary PowerOther Features Welding CapabilityStart Pushbutton Controls and SettingsRUN Stop Switch Fuel Level Gauge and LightIdler Switch Engine Alternator Ammeter K1639Hour Meter Auxiliary Power Controls Engine Operation Starting the EngineStopping the Engine Typical Fuel Consumption Welder OperationBREAK-IN Period Stick WeldingCommander 500 Settings When Using the K799 HI-FREQ Unit Table B.3 Typical Current Ranges 1 for Tungsten ELECTRODES2Auxiliary Power Operation Table B.4 Commander 500 Simultaneous Welding and Power Loads Accessories Optional Field Installed AccessoriesK899-1 Spark Arrestor KIT Easily mounts to standard muffler Stick Wire Feed Welding OptionsRecommended Optional Equipment TIGMaintenance Routine and Periodic MaintenanceEngine Maintenance Fuel Filters Fuel PRE-FILTER/WATER Separator ASSEM- BLYWater Separator Element Battery Handling Cooling System Cooling Blower BeltCleaning Nameplates / Warning Decals MaintenanceWelder / Generator Maintenance Brush Removal and ReplacementTroubleshooting HOW to USE Troubleshooting GuideSymptoms Possible AreasCourse of Action Function Problems Output Problems Commander 500 Wiring Diagram for 10838 and below Diagrams Connection DiagramConnection Diagram Diagrams Diagrams Commander / K867 / LN-8 Connection Diagram Diagrams Diagrams Engine Welders /LN-8 Connection Diagram DiagramElectric Shock can kill ConnectionConnection Diagram Diagrams Diagrams M18962 Commander Basic Course $700.00Precaucion Aviso DE
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500 specifications

The Lincoln Electric 500 is a hallmark of innovation in arc welding technology, designed to cater to the rigorous demands of both industrial applications and serious hobbyist projects. This powerful machine is known for its reliability, versatility, and user-friendly design, making it an essential tool for professional welders and those looking to tackle various welding tasks with ease.

One of the standout features of the Lincoln Electric 500 is its robust power output. With a capability of up to 500 amps, it can handle a wide range of welding processes, including Stick, TIG, and MIG welding. This flexibility allows welders to use the machine for different types of metals, including steel, stainless steel, and aluminum, making it suitable for diverse applications from automotive to construction industries.

The machine's digital interface enhances user experience by providing precise control over the welding parameters. The intuitive display allows for easy adjustments of voltage and wire speed, ensuring optimal welding conditions are achieved. This feature is especially beneficial for beginners who may require additional support as they learn the intricacies of welding.

The Lincoln Electric 500 is also equipped with advanced technologies that enhance efficiency and welding quality. One such technology is the inverter system, which optimizes the power source for superior arc stability and improved penetration. This results in cleaner welds with minimal spatter, reducing the need for post-welding cleanup. Furthermore, the machine’s duty cycle is impressive, meaning it can operate for extended periods without overheating, a critical factor in high-production environments.

Another significant characteristic of the Lincoln Electric 500 is its portability. Weighing in at a manageable level and designed with built-in carrying handles, it’s easy to transport between job sites. This feature is particularly valuable for mobile welders who need to work in various locations.

Safety is paramount in welding operations, and the Lincoln Electric 500 integrates various safety features designed to protect the user. Overload protection and thermal overload indicators help prevent damage to the machine and injury to the operator, ensuring a reliable and safe working environment.

Overall, the Lincoln Electric 500 stands out not only for its performance but also for its thoughtful engineering that prioritizes user safety, comfort, and versatility. It is a dependable choice for anyone looking to produce high-quality welds while enjoying the benefits of advanced welding technology.
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