Lincoln Electric IM644-A manual Diagrams, Commander 500 Wiring Diagram

COMMANDER 500 WIRING DIAGRAM

WIRING

-F1

6A

6A

3

67

3

3

6A

AUXILIARY WINDINGS

W2

CORRESPONDING SETTINGS FOR TAP NUMBERS

GND-E

6E

AUXILIARY POWER

STATOR

3

W2

(AS VIEWED FROM THE FRONT)

"INSULATED STUD"

W3

250A

35 0A

AUXILIARY POWER

6D

6

LEFT

J12

W3

SELECTOR SWITCH

150A

5

6

5A

ON BOTTOM LEFT

500A

GND. SCREW ON

6C

OF CONTROL BOX

DIAGRAM:

4

1

15

(VIEWED FROM REAR)

4

7

5A

3

IGBT

CAP.

23A

STICK CONTROL PANEL

5

2

16

W2

W3

STATOR

S5

GND-D

5

DRIVER

25A

217

90A

3

8

30-575A

PCB1

6

3

WELD

6 5

216

GND-B

W4

WINDINGS

W1

218

7

WIRE

6A

4

215

2

TIG

CB1

BOLTED

W4

W1

219

A

30-575A

15-250 A

CB5

20A

W5

W6

8

3

214

3B

LEADC 203 TO

261

TO

W3

GND-B

W5

EMPTY

EMPTY

15A

PASS THRU TOROID

260

HEATSINK

CAP.

MULTI-LEAD

W2

W6

220

9

2

213

EMPTY

EMPTY

8

ONE TIME

HEAT SINK

222

6C

31

+

GND-C

3A

CB3

RED

J40

P40

3

CHOKE

OPTIONAL

50A

SILVER

GND-C

R2

BLACK

6A

W6

WITH 42V

11

L1

25 watts

W6

1

VAC KIT

AUXILIARY

J11

115/230V

11

3

W1

2

6E

NEUTRAL STUD

3

W1

43

CB6

GND-D

-

3

10A

BACK OF CONTROL

CB2

203

6A

RIGHT

4

BOX "LEFT SIDE"

HOT (GOLD)

RECTIFIER BRIDGE

BLACK

5

20A

6A

IGBT

CAP.

MULTI-LEAD

ohms250

RED

6

5D

5F

9

SILVER

67

DRIVER

41

GND-E

12

PCB2

J13

OPTIONAL

42B

5D

J11

67A

LEADS 3 & 6A

13

SHUNT

5G

42VAC KIT

5B

6B

CB4

4

1

ELECT.

PASS THROUGH

3

23

50MV=400AMPS

13

18

15

6E

50A

5C

5

2

14

17

16

42

5E

6D

5

TOROID TWICE

25

-

+

14

6A

HOT (GOLD)

IN OPPOSITE

BOLTED

6

3

P16

12

DIRECTIONS

6A

TO

CAP.

1

2

6 7 8

5C

5B

HEATSINK

P14

J14

3

4

5

5

5E

J16

BYPASS PCB

22

1

22A

21A

Y

Y

R

R

BR BR BK BK

CONTROL

5C

HEAT SINK

21

4

TRANSFORMER

5

2

3

RED

YELLOW

BROWN

6A

200B

WORK

5F

42VAC

18

13 30VAC 14

15 30VAC 16

3

201

200A

200D

12

17

PCB

POWER MODULE

POWER

CONTROL

CONTROL

BRUSH

BRUSH

200E

+

200E

16

200A

200C

21B

120VAC

3200MFD

201B

15

201A

PRIMARY

HOT(BLACK)

300V

6D

200C

14

200D

ROTOR

201B

-

3

NEUTRAL (BLACK)

201A

5H

13

5P

HARNESS

6D

12

6H

6A

POSITIVE BRUSH CONNECTED

200

11

200B

TO SLIP RING NEAREST

201

5P

226

10

226A

TO THE LAMINATION

6F

SWITCH SHOWN IN

237

9

237A

67A

CONTROL HARNESS

224A

8

224

POSITIVE POLARITY

31

31

DIAGRAMS

COMMANDER 500

262A

7

262B

+

POSITION

32

32

ENGINE

234A

6

234

42

42

228A

5

228

POLARITY

21C

5G

233A

4

233

SWITCH

41

41

241A

3

241

-

281A

2

281

2C

2B

IDLER

WELDING

CONTROL

239A

1

239

J30

P30

4C

4B

HOUR

CONTROL

SOURCE

SWITCH

J

31

SHOWN IN

SHOWN IN

115VAC

75B

OUTPUT

VIEWED

METER

"HIGH" POSITION

"ALWAYS ON" POSITION

A

32

CONTROL HARNESS

CONTACTOR

CONTROL

FROM

76C

77C

+

256

248

D

4E

RF BYPASS PCB

BACK

-

CCW

PINCH POT

HIGH

237A

226A

C

2E

ALWAYS ON

R1

REMOTE

4

58

50K

WORK

H

21C

76C

75A

HOLD

S6

77

AUTO

REMOTELY

COIL

E

75B

REMOTE

77E

VIEWED

77B

CONTROLLED

232L

PULL

227

2C

75

76

LOCAL

COIL

F

76E

J61

FROM

76B

278A

263

264

IDLE

SOL.

242E

242

CONTROL

4C

BACK

277

278

G

75E

77C

77B

SWITCH SHOWN IN

32

I

41

76B

232M

PULL

262

42VAC

TOROID

1

"LOCAL" POSITION

COIL

K

42

START BUTTON

SHUTDOWN

SOL.

GROUND

B

242H

3

6

HOLD

COIL

AMPHENOL 1

76E

CONTROL HARNESS

224

262B

75E77E

J62

236A

236C

238

232B

232C

236

2E

LEADS 238 & 236C TO BE

229B

242

236B

OIL PRESSURE SWITCH & SENSOR

4E

BOLTED TOGETHER AND

BATT.

OIL

OIL

5G

5H

231

228

234

1

4

TAPED ON STANDARD

CHRG.

PRESS.

TEMP

FUEL

RUN/STOP

RUN

SENSOR

SWITCH

TOROID

228A 229A

12VDC

MODEL.

242B

242D

SWITCH

G

A

S

S

S

SHOWN IN

STOP

WK

77D

3

6

243

247

246

245

REMOTE

241A

229

INSULATED

5L

5J

"RUN" POS.

OIL TEMP. SENSOR & SWITCH

CONTROL

B

76D

76D

P18

GOLD

GOLD

GOLD

GOLD

STUD

232L

232A

232H

232D

233

241

C

75D

77D

J60

242A

SENSOR

75D

1 2

3

4

ALT.

LOW

TEMP.

LOW

242C

5K

232J

SWITCH

ENHANCED

D

2D

2D

J18

PRESS.

FUEL

232M

238

GND. STUD ON

5K

CONTACTOR

OPTIONAL ON

242B

229C

229

E

4D

4D

232G

232K

BOTTOM RIGHT OF

232D

FUEL LVL.

1

4

SILVER

SILVER

SILVER

SILVER

STANDARD MODEL

241B

232K

229B

CONTROL BOX

GROUND

F

242I

242I

228B 229B

232E

232F

232G

232P

232F

228B

262

242D

SENSOR

242H

241B 229C

227

AMPHENOL 2

232E

232A

236C

32

232 238

236

WELD STUD ON

232N

229

236C

231

OUTPUT PANEL

TOROID

232

232N

5R

TOROID

STARTER

SOLENOID

B4

B3

B2

B1

DIAGRAM

STARTING

(+)

12V BATTERY

MOTOR

101A

107A

106A

STUD ON ENGINE

18 67

277 22

75 77

222

217

105A

103A

102A

107A

232

90

SENSE

EXC 281

MOUNTING FOOT

216

213

90

91

239

(-)

STUD ON ENGINE

LEFT SIDE

101A 104A

106A

5L

MOUNTING FOOT

1725A 23A 23 25 278

21

76

215218219214 220

91

108A

109A 110A

2B 237 4B 232D

263 264 262A 226 224A

260

245 261 247 234A 243 239A 5J

233A 248 229A

256

POS

NEG

RIGHT SIDE

1

3

1

6

1

8

ALTERNATOR

+

-

1

8

1

5

1

4

1

108A 109A 110A

3

20012

281A

5K

105A

102A

246

5N

104A

103A

32

5S

238

242I

239

GROUNDING BOLT

5

J8

1

5

J9

1

5F

ON ENGINE BLOCK

FRAME

4

6

4

6

7

9

16

242H

9

J3

16

6

10

5

8

DISPLAY PCB

J5

J6

J7

5R

GND STUD ON RIGHT SIDE

5M ENGINE GROUND

J4

J2

J1

CONTROL PCB

OPTIONAL ON STANDARD MODEL

ENGINE PROTECTION PCB

BACK OF CONTROL BOX

5M

XE

G3583

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-

F-1

gram for your particular machine is pasted inside the machine on one of the enclosure panels.