Lincoln Electric IM644-A Welder Operation, BREAK-IN Period, Typical Fuel Consumption, TIG 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	.37 gallons/hour	67.6
Load 1400 RPM	(1.40 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
Auxiliary Power	1.31 gallons/hour	19.1
12,000 VA	(4.96 liters/hour)

WELDER OPERATION

STICK WELDING

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

The SELECTOR switch provides five overlapping slope controlled current ranges. The CONTROL adjusts the current from minimum to maximum within each range. Voltage is also controlled by the CON- TROL in the slope controlled setting. These slope con- trolled settings are intended for “out-of-position” weld-

ing, including pipe welding, where the operator would like to control 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 "SELECTOR" Switch to the lowest setting that still provides the cur- rent you need and set the "CONTROL" near maximum. For example: to obtain 140 amps and a soft arc, set the " SELECTOR" Switch to the "150 MAX" position and then adjust the " CONTROL" for 140 amps.

When a forceful "digging" arc is required, use a higher setting and lower the open circuit voltage. For example: to obtain 140 amps and a forceful arc, set the “ SELEC- TOR” to the "250 MAX" position and then adjust the " CONTROL" to get 140 amps.

CONSTANT CURRENT (CC) WELDING

The STICK-CC position of “30 to 575", the "SELEC- TOR" Switch is designed for horizontal welds with all types of electrodes especially low hydrogen. The

"CONTROL" 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 SELECTOR switch is for TIG welding in the range of 15 amps to 200 amps, with a “Touch Start” feature. To initiate a weld, the CON- TROL is first set to the desired current and the tung- sten is touched to the work. During the time the tung- sten is touching the work there is very little voltage or current and, in general, no tungsten contamination. Then, the tungsten is gently lifted off the work in a rock- ing 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