CommanderTM | Lincoln Electric SVM153-A instruction

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SVM153-A

September, 2002

CommanderTM 500

For use with machines having Code Numbers: 10837 (Standard), 10838 (Deluxe)

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be in- creased by proper installation . . .

and thoughtful operation on your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS

EQUIPMENT WITHOUT

READING THIS MANUAL AND

THE SAFETY PRECAUTIONS

CONTAINED THROUGHOUT.

And, most importantly, think before you act and be careful.

SERVICE MANUAL

Copyright © 2002 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Lincoln Electric SVM153-A service manual CommanderTM

Contents

CommanderTM California Proposition 65 Warnings Safety Electric Shock can kill Iii Welding Sparks can cause fire or explosion Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Commander 500 K1639-1 Installation Location / Ventilation Safety PrecautionsStoring Stacking Lifting High Temperature OperationTowing High Altitude Operation PRE-OPERATION Engine Service Spark Arrester Muffler Outlet Pipe Standby Power Connections Auxiliary Power ReceptaclesWelding Output Cables Machine Grounding Company Table of Contents Operation Section Operation Safety InstructionsOperating Instructions General Description Recommended Applications Design Features and Advantages K1639-1 Commander 500 Standard Model Controls and SettingsWelding Capability Idler Switch RUN/STOP SwitchStart Pushbutton Fuel Level Gauge and Light Welding Terminals Switch Weld Mode Output ControlTable B.1 Weld Mode and Output Control Functions Hour Meter Auxiliary Power Controls Starting the Engine Engine OperationBREAK-IN Period Typical Fuel Consumption Stick Welding Welder OperationConstant Current CC Welding TIG Welding Commander 500 Settings When Using the K930-1 TIG Module Commander 500 Settings When Using the K799 HI-FREQ UnitTable B.3 Typical Current RANGES1 for Tungsten ELECTRODES2 TIG Torch Wire Feed Constant Voltage Welding Auxiliary Power OperationSimultaneous Welding and Auxiliary Power Loads ARC Gouging Permissible Permissible Auxiliary Extension Cord Recommendations Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesField Installed Options Stick Welding Accessories Connection of Lincoln Electric Wire Feeders Semiautomatic Welding AccessoriesOther Wire Feeders for the Commander High Frequency Generators for TIG Applications To Work Electrode Cable To Wire Feed Unit ING CV ING CV ING CV Figure C.5 Commander 500/LN-23P Connection Diagram ING Terminals Always on Table of Contents Maintenance Section Routine and Periodic Maintenance MaintenanceEngine Maintenance Daily Figure D.1 OIL Drain and Refill Fuel Filters Figure D.2 Fuel PRE-FILTER/WATER Separator Assembly Figure D.3 Secondary Fuel Filter AIR Filter Maintenance Table D.2 Engine Maintenance Parts Manufacturer Part Number Frequency Maintenance Required Connecting a Battery Charger Battery Maintenance WELDER/GENERATOR Maintenance Figure D.5 Major Component Locations Table of Contents Theory of Operation Section Commander Theory of Operation Commander Weld WINDINGS, RECTIFIER, Power Modules and Feedback Analog Control Power Supply Board and Weld Control Board Insulated Gate Bipolar Transistor Igbt Operation 6E-6 Pulse Width ModulationMinimum Output Maximum Output Chopper Technology Fundamentals External DC Solid State Inductor ARC Source Switch Diode70-80VDC Troubleshooting & Repair Section Table of ContentsSection F-1 HOW to USE Troubleshooting Guide Troubleshooting & Repair PC Board can be damaged by static electricity PC Board Troubleshooting Procedures Observe Safety Guidelines Troubleshooting GuideDetailed in the beginning of this manual Perform the Rotor Resistance Justment Test Function Problems Charging Circuit Test Engine Problems Shutdown Perform the Idler Solenoid Symptoms Misadjustments Course of Action Problems Possible Areas Engine Starting Diagnostic Chart Return START-UP and OCV Diagnostic Chart Description Case Cover Removal and Replacement ProcedureMaterials Needed Procedure Case Cover Removal Replacement Procedure Figure F.1 Removal Case Front Knobs Removal and Replacement Procedure Power Module Capacitor Discharge Procedure Procedure Test Description Idler Solenoid Test Figure F.5 Idler Solenoid Leads Test Procedure Shutdown Solenoid Test Figure F.6 Shutdown Solenoid Lead Terminals Engine Throttle Adjustment Test Strobe-tach Method Figure F.7 Strobe Mark Location Mark Blower Paddle Here Locking NUT Frequency Counter Method 28F-28Oscilloscope Method Rotor Resistance Test Test Procedure Flashing and Rotor Voltage Test Lead # 201A 10 11 12 13 14 15 Troubleshooting & Repair Stator Voltage Test Figure F.13 Front Control Panel Removal Screws Troubleshooting & Repair Auxiliary Leads #5B, #5E, #8, #9, #11, #12 Auxiliary Power and Weld Windings TestBehind Panel Weld Winding Lead Connections W6W1 Analog Power Supply PC Board Voltage Test 40F-40 Control Circuit Input PowerJ41 Test Points Component Tested Voltage Reading Analog Control Power Supply PC Board Test Output Rectifier Bridge Test Perform the Power Module Capacitor Discharge Procedure Troubleshooting & Repair Figure F.20 Diode Lead Removal Power Module Test Power Module PC Board Diode Lead D4 Positive + Strap Temperature SwitchW10 Check Igbt For Shorts Check Diode Module When all tests are complete Charging Circuit Test #239 #281 #238 Figure F.24 Engine Alternator Location Normal Open Circuit Voltage Waveform 115VAC Supply Scope SettingsHigh Idle no Load 15.8 ms Volts 50V5ms MAX TAP MAX Control POT High Idle no Load Normal Open Circuit Voltage Waveform StickVolts 50V5ms Machine Loaded to 500 Amps AT 40 Volts Normal Weld Voltage Waveform Stick CCVolts 20V0.1ms Normal Weld Voltage Waveform Wire CV Loaded to 200A 16 Volts Normal TIG Mode Voltage WaveformVolts 10V50ms MAX Control POT High Idle no Load Normal Open Circuit Voltage Waveform Wire CV TAP Shutdown Solenoid Removal and Replacement Figure F Shutdown Solenoid Lead Connections Figure F Shutdown Solenoid Linkage ARM Assembly Reassembly Description Control Panel Removal Screws Front Green Ground Lead Figure F Power Module Capacitor Lead Removal Troubleshooting & Repair Replacement Procedure Description Figure F.30 Power Module PC Board Power Module PC Board Removal Power Module PC Board Replacement Diode Module Removal Diode Module Replacement Output Rectifier Bridge Diode Removal and Replacement Refer to Figure F.32 Turn the engine off Diode Stud Size Foot Pounds Inch Pounds Return Section TOC STATOR/ROTOR Removal and Replacement Leads #229 #242D Preparation and Lead Removal ProcedurePlug Fuel Lines Bolts Filter Field Diode Capacitor #200D #5P #201 #201A #232M Figure F.35 Brush Holder and Lead Removal Figure F.37 Alternator Shroud Removal Screws Acoustical Foam Figure F.38 Lift Frame and Associated Component Removal Figure F.39 Stator Removal Stator Removal Procedure Reassembly Notes Rotor Removal Procedure Engine Lead Reconnection ChecklistOutput Panel and Control BOX Retest After Repair Welder CV Wire OutputEngine RPM Welder DC Stick Output Auxiliary Power Output Touch Start TIG Mode Output Table of Contents Electrical Diagrams Section Electrical Diagrams Electrical Diagrams G3834 Schematic Complete Machine Commander Schematic Battery PC Board Return to Section PC Board Assembly Battery PC Board PWM Input Schematic Chopper PC Board Return to Section Return to Section TOC PC Board Assembly Chopper PC Board Schematic Peripheral PC Board Return to Section PC Board Assembly Peripheral PC Board Schematic Power Supply Analog PC Board PC Board Reference QTY Designators Description PC Board Assembly Power Supply Analog PC Board Schematic PULL-COIL PC Board MOSFET/HEATSINK ASBLY,T12704-82&S1810 PC Board Assembly PULL-COIL PC Board Schematic Weld Control PC Board Sheet Electrical Diagrams Electrical Diagrams Electrical Diagrams Electrical Diagrams RESISTOR,SMD,METAL FILM,1/10W,150OHMS PC Board Assembly Weld Control PC Board SVM Error Reporting Form