Lincoln Electric SVM153-A manuals
Power Tools > Welding System
When we buy new device such as Lincoln Electric SVM153-A we often through away most of the documentation but the warranty.
Very often issues with Lincoln Electric SVM153-A begin only after the warranty period ends and you may want to find how to repair it or just do some service work.
Even oftener it is hard to remember what does each function in Welding System Lincoln Electric SVM153-A is responsible for and what options to choose for expected result.
Fortunately you can find all manuals for Welding System on our side using links below.
Lincoln Electric SVM153-A Service Manual
156 pages 4.78 Mb
SVM153-A Commander 500September, 2002 SERVICE MANUALSafety Depends on YouCALIFORNIA PROPOSITION 65 WARNINGS FOR ENGINE powered equipment. 2 WARNINGELECTRIC AND MAGNETIC FIELDS may be dangerous 3 ARC RAYS can burn.ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. 4 FOR ELECTRICALLY powered equipment.CYLINDER may explode if damaged. WELDING SPARKS can cause fire or explosion. 5 PRCAUTIONS DE SRETPRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS -7 - INSTALLATION SECTION -15 - OPERATION SECTION -27 - ACCESSORIES SECTION -36 - MAINTENANCE SECTION -- THEORY OF OPERATION SECTION -ENGINE ROTOR STATO RWELDWINDING MECHANICAL ROTATION STARTER ALTERNATOR ANALOG POWER SUPPLY BOARD WELD CONTROL BOARDPWM SIGNALS (2) VOLTMETER AMMETER PERIPHERAL BOARD THREE-PHASE RECTIFIER WORK TERMINAL ELECTRODE TERMINAL + + 47 COMMANDER 500(2) (2) 80 VDC (2) 20 VDC GENERAL DESCRIPTION BATTERY, ENGINE, ROTOR, STATOR, PULLCOIL BOARD AND PERIPHERAL BOARD ENGINE PROTECTIONENGINE ROTOR STATO R WELD CONTROL BOARD + 48 COMMANDER 500WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACKENGINE ROTOR STATO R WELD CONTROL BOARD + 49 COMMANDER 500ANALOG CONTROL POWER SUPPLY BOARD AND WELD CONTROL BOARDNOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. E-4 E-4 FIGURE E-4 ANALOG CONTROL POWER SUPPLY BOARD AND WELD CONTROL BOARD FOR WIRE FEEDER IGBT CHOKE AUXILIARY WINDINGS COMMANDER 500 ENGINE ROTOR STATO RWELDWINDING MECHANICAL ROTATIO N STARTER ALTERNATOR ANALOG POWER SUPPLY BOARD WELD CONTROL BOARDPWM SIGNALS (2) VOLTMETER AMMETER PERIPHERAL BOARD THREE-PHASE RECTIFIER WORK TERMINAL ELECTRODE TERMINAL + + 50 COMMANDER 500} } } } 117 }}}}118 REPLACEMENT PROCEDURE119 MODULE REMOVALAND REPLACEMENT123 OUTPUT RECTIFIER BRIDGE DIODE REMOVALAND REPLACEMENT125 OUTPUT RECTIFIER BRIDGE DIODE REMOVALAND126 STATOR/ROTOR REMOVALAND REPLACEMENT127 {PREPARATION AND LEAD REMOVAL PROCEDURE 130 STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED)135 RETEST AFTER REPAIRENGINE RPM WELDER DC (STICK) OUTPUT PIPE MODES SHORT CIRCUIT CURRENT (FINE CONTROL AT MAXIMUM) WELDER CV (WIRE) OUTPUT 136 RETEST AFTER REPAIR (CONTINUED)TOUCH START TIG MODE OUTPUT AUXILIARY POWER OUTPUT G-1 137 ELECTRICAL DIAGRAMSG-1 TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- 138 ELECTRICAL DIAGRAMS WIRING DIAGRAM - COMMANDER 500+AMPHENOL 2 I232F 232G 232E I AMPHENOL 1 PCB3261A 260 260A P52 J52HOT START PINCH MISC CONTROL POWER 206S J43 POWER SUPPLYAM METER VOLT METER CONTROL POT MODE AMPHENOL GND STUD ON RIGHT SIDE BACK OF CONTROL BOXW4 W1 W2 (VIEWED FROM REAR) INSULATED STUDGND. SCREW ON CONTROL PANEL GROUND STUD ON OUTPUT PANEL PINCH POT CONTROL OUTPUT - +COMMANDER 500 WIRING DIAGRAMSTART BUTTON IDLE 247 246 245 232L 232M 232K 232N 232A 243 12VDC 12V BATTERY ELECT. +W2 W3 W3 STATOR WELD WINDINGS W5 W4 W5 W1 W6 W6 S5 R1 -BATTERY BOARD PULL COIL BD. PERIPHERAL BD. WELD BOARD10K261THERMAL P51 RIGHT SIDE 300 AMP MODULE HEATSINK D4 P50 LEFTSIDE 300 AMP MODULE HEATSINK D3 +204S DENOTES ITEMS INCLUDED ON DELUXE MODELS ONLY PCB2 PCB1 PCB4 PCB8 WORK VOLTMETER AMMETERJ A D C H B K E F G A B C D E FON STANDARD MODELS, LEADS 242D & 229 ARE TO BE TAPED G-2 139 ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE - COMMANDER 500G3834AMPHENOL + + + NONE 11-22-99 GDATE: SCALE: SUBJECT: EQUIPMENT TYPE: DRAWING No.: COM. CONTROL COMMANDER 300 & 500 MACHINE SCHEMATICPOSITIVE OUTPUT TERMINAL NEGATIVE OUTPUT TERMINAL WELD CONTROL ANALOG POWER PC BOARD BATTERY PERIPHERAL PULL COIL _A M P S V O L T D I S P L A Y SA B C D E F J A D C H B K E F G I G-3 G4357 141 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY- BATTERY PC BOARD LSUBJECT: DATE:DO NOT SCALE THIS DRAWING EN-168 SCALE: EQUIPMENT TYPE: DRAWING No.: MISC. BATTERY PC BD. ASSEMBLYBUY PER E3867 TEST PER E3868-1BUY AS IDENTIFICATION CODE G-5 142 ELECTRICAL DIAGRAMS SCHEMATIC - CHOPPER PC BOARD4-14-2000 PWM INPUTLABELS THE LINCOLN ELECTRIC CO. M19462 CHOPPER, 300 AMP SCHEMATIC to heatsink 15 to 32 Vacto + cap NONE CLEVELAND, OHIO U.S.A. to heatsink M 19462 G-6 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY- CHOPPER PC BOARD.105 EYELET DETAIL L11315-1B0 BLANK PART NO. L11315-B L 143 }}.275 .285 FOR PARTS ORDERS: INCLUDE (1) L11167 PRINT AND (1) T12837-1 G-7 145 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY- PERIPHERAL PC BOARDBr V PART NO.3PROGRAM ITEM 55 WITH ITEM 7 . NO COMPONENTS ON BOTTOM SIDE OF PC BOARD. OTHER PERMANENT MARKING IN AREA SHOWN. N.B. 3662-1 GSUBJECT: DATE:DO NOT SCALE THIS DRAWING EN-170 SCALE: EQUIPMENT TYPE: DRAWING No.: COMMON ANALOG CONTROL PERIPHERAL CONTROL PCB ASSEMBLY BUY PER E3867 TEST PER E3869-PN.F. N.G. NOTES:CONNECTOR TOP SURFACE. N.C. SECURE PC BOARD ASSEMBLY IN PLACE WITH ITEM (4). (2 PLACES) N.F. IDENTIFY COMPLETE ASSEMBLY WITH A PRINTED LABEL OR N.G. N.H. 4 N.C.UNLESS OTHERWISE SPECIFIED: RESISTANCE = OHMS BUY AS G3662-1B1 IDENTIFICATION CODESCHEMATIC REFERENCE - G3663 G-9 MPC BOARD ASSEMBLY- POWER SUPPLY (ANALOG) PC BOARD SCHEMATIC REFERE NCE M19422 PART NO. M19423-1B04 2 (6.14) (3.64) 1:1 2/23/99SUBJECT: DATE:DO NOT SCALE THIS DRAWING SCALE: EQUIPMENT TYPE: DRAWING No.: COMMON ANALOG CONTROL ANALOG POWER SUPPLY PCB ASSEMBLYBUY PER E3867 TEST PER E3861NOTES: N.D. N.E. 3 N.C. BUY AS IDENTIFICA TION CO DE 147 }{ vG-11 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY- PULL-COIL PC BOARDN.A. N.B. 2 N.D. 3 N.C. (6.14) L11384-1B0 SCHEMATIC REFERENCE L11383 PART NO. LSUBJECT: DATE:DO NOT SCALE THIS DRAWING EN-168 EXPERIMENTAL DRAWINGSCALE: EQUIPMENT TYPE: DRAWING No.: ENGINE WELDERS PULL COIL P.C. BOARD ASSEMBLYBUY PER E3867 TEST PER E3883BUY AS IDENTIFICATION CODEUNLESS OTHERWISE SPECIFIED: CAPACITORS = MFD/VOLTS RESISTORS = 1/4W/OHMS INDUCTANCE = HENRYS 149 vPULL COIL L11384-1 (3.64) NOTES: G-13 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY- WELD CONTROL PC BOARD109 S25002-2000SMT 8 RESISTOR,SMD,200OHMS,1/3W,MF,1%,S1210 129 S25001-2001SMT 9 RESISTOR,SMD,2K,1/4W,1206,1%,TR 133 S15128-4SMT 8 OP-AMP,SMD,QUAD, GEN-PURPOSE,224D 134 S15128-18SMT 10 IC,OP-AMP,SMT,QUAD,HIGH-PERF,33074D 136 S15018-6SMT 9 IC,SMD,CMOS,SWITCH,ANALOG,QUAD, 4066B N.F.62 S25001-1000SMT 6 RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR 70 S25000-1500SMT 7 RESISTOR,SMD,METAL FILM,1/10W,150OHMS 71 S25000-3011SMT 12 RESISTOR,SMD,METAL FILM,1/10W,3.01K,1 82 S25000-5110SMT 7 91 S25008-1002SMT 16 RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.5% VSCHEMATIC REFERENCE -G3661_2C3 PART NO. 3660-2 GMAP ILD APM SUBJECT: DATE:ON 3 PLACE DECIMALS IS .002 DO NOT SCALE THIS DRAWING EN-170 SCALE:DRAWN BY: Chg. Sheet No. ENGINEER: EQUIPMENT TYPE: DRAWING No.: COMMON ANALOG CONTROL WELD CONTROL PCB ASSEMBLYREFERENCE: G3660-1"X" INFO. 7-7-2000 8-4-2000P UNLESS OTHERWISE SPECIFIED: RESISTANCE = OHMS FOR PARTS ORDERS SEND:BUY AS IDENTIFICATION CODE G3660-2C4 155 }}N.B. 3 4 N.C.(4.84) (7.84) N.G. N.H.RESISTOR,SMD,METAL FILM,1/10W,511OHMS 86 S25004-2430SMT 10 RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.1% 61 S25000-28R7SMT 6 RESISTOR,SMD,METAL FILM,1/10W,28.7OHM NOTE: G3990-2 MUST BE REVIEWED WHEN MODIFYING THIS BOARD. BUY PER E3867 TEST PER E3869-C G-19 156 SVM ERROR REPORTING FORM
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