Lincoln Electric 500 Welder Operation, BREAK-IN Period, Typical Fuel Consumption, Stick Welding

B-7 OPERATION B-7

BREAK-IN PERIOD

The engine used to supply power for your welder is a heavy duty, industrial engine. It is designed and built for rugged use. It is very normal for any engine to use small quantities of oil until the break-in is accom- plished. Check the oil level twice a day during the break-in period (about 200 running hours).

IMPORTANT

IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNIT SHOULD BE SUBJECTED TO HEAVY LOADS, WITHIN THE RATING OF THE MACHINE. AVOID LONG IDLE RUNNING PERIODS.

TYPICAL FUEL CONSUMPTION

Refer to Table B.2 for typical fuel consumption of the Commander 500’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	.47 gallons/hour	53.2
Load 1475 RPM	(1.77 liters/hour)
High Idle - No	.66 gallons/hour	37.9
Load 1900 RPM	( 2.50 liters/hour)
DC CC Weld	1.94 gallons/hour	12.9
Output 500	( 7.34 liters/hour)
Amps @ 40
Volts
	1.31 gallons/hour	19.1
Auxiliary Power	(4.96 liters/hour)

WELDER OPERATION

STICK WELDING

The Commander 500 can be used with a broad range of DC stick electrodes.

The “WELD MODE” switch provides five overlapping slope controlled current ranges. The OUTPUT adjusts the current from minimum to maximum within each range. Voltage is also controlled by the OUTPUT in the slope controlled setting. These slope controlled set- tings are intended for “out-of-position” welding, includ- ing pipe welding, where the operator would like to con- trol the current level by changing the arc length.

PIPE WELDING

The Commander 500 is equipped with special circuitry to minimize pop-outs in the five slope modes at any open circuit voltage.

For a soft arc characteristic, set the "WELD MODE" Switch to the lowest setting that still provides the cur- rent you need and set the "OUTPUT" near maximum. For example: to obtain 140 amps and a soft arc, set the " WELD MODE" Switch to the "150 MAX" position and then adjust the "OUTPUT" for 140 amps.

When a forceful "digging" arc is required, use a higher setting and lower the open circuit voltage. For exam- ple: to obtain 140 amps and a forceful arc, set the “ WELD MODE” to the "250 MAX" position and then adjust the "OUTPUT" to get 140 amps.

CONSTANT CURRENT (CC) WELDING

The CC - STICK position of “30 to 575", the "WELD MODE" Switch is designed for horizontal welds with all types of electrodes especially low hydrogen. The "OUTPUT" adjusts the full range of 30 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.

In the CC mode, sticking can be prevented by adjust- ing the “ARC CONTROL”. Turning this control clock- wise, increases the short circuit current, thus prevent- ing sticking. This is another way of increasing arc force.

TIG WELDING

The most clockwise position of the WELD MODE switch is for TIG welding in the range of 20 amps to 250 amps, with a “Touch Start” feature. To initiate a weld, the OUTPUT is first set to the desired current and the tungsten is touched to the work. During the

time the tungsten is touching the work there is very little voltage or current and, in general, no tung- sten contamination. Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.

The Commander 500 can be used in a wide variety of DC Tungsten Inert Gas (TIG) welding applications. In general the “Touch Start” feature allows contamination free starting without the use of a Hi-Freq unit. But the K930-1 or -2 TIG module or K799 Hi-Freq unit, can be used with the Commander 500. The settings for these follow the tungsten current range table.

COMMANDER 500