Lincoln Electric SVM153-A service manual Schematic Complete Machine Commander, G3834

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G-3

ELECTRICAL DIAGRAMS

G-3

SCHEMATIC - COMPLETE MACHINE - COMMANDER 500

G4357

D3

G3834

IGBT

IGBT MODULE - EMMITTER

IS COMMON TO HEATSINK

E

C

NOTE: COMMANDER 500

GATE SIGNAL

2400uf

USES (2) 300 AMP

2400uf

100vdc

100vdc

CHOPPER MODULES &

DIODE

CHOPPER

(J50-3) 18

+20V

MODULE

(J50-1) 17

COMMANDER 300 USES

PC BOARD

(2) 200 AMP CHOPPER

(J50-7) 25

23 (J50-9)

MODULES.

+12V

+12 INS. STUD

IGBT MODULE - EMMITTER

232K

IS COMMON TO HEATSINK

13

D4

SHUNT

L1 CHOKE

14

POSITIVE

IGBT

232C

232B

50MV=400 AMPS

OUTPUT

E

C

W1

W6

OIL

TERMINAL

204S

CURRENT LEVEL

W1

W6

FUEL

TEMP.

PRESS.

GATE SIGNAL

206S

FEED BACK SIGNAL

S

S

S

206B

206A

2400uf

2400uf

DIODE

(J51-3) 16

CHOPPER

+20V

100vdc

100vdc

W2

STATOR

BY-PASS

WIREFEEDER

MODULE

PC BOARD

(J51-1) 15

THREE PHASE

W2

WELD

FOUR POLE 1800 RPM ALTERNATOR

PC BOARD

VOLTMETER

RECTIFIER

242A

242C

W3

WINDINGS

21

228A

POLARITY

(J51-7) 25A

23A (J51-9)

W3

208

SWITCH

241A

208A

NEGATIVE

+12V

229A

W4 W4

W5

OUTPUT

W5

T

T

T

W

W

TERMINAL

I

I

I

W

S

S

S

41

T

T

E

E

T

208B

E

D

D

42 VOLT AC

D

ROTOR FIELD

P

P

WIRE FEEDER

P

A

A

I

I

I

POWER

SLIP RINGS

232J (J31-4)

A

17 (J42-3)

R

R

R

ANALOG

200B

(J32-10) 229A

18 (J42-8)

5T (J31-9)

23

25A

23A

POWER PC

42

200A

160 VDC

OIL PRESSURE

25

+

PERIPHERAL

15 (J42-1)

206S (J6-2)

(J12-1)(J12-2)

(J12-3) (J12-4)

BOARD

(J32-6) 234A

16 (J42-6)

3

PC BOARD

5V

3200uf

SENSOR

204S (J6-1)

(J13-3) 105A

105A (J42-2)

SWITCH

300vdc

ARC VOLTAGE FEEDBACK

15V

208B (J12-16)

(J13-1) 115A

115A (J42-5)

TEMPERATURE

COM

120 V AC

(J13-2) 101A

101A (J42-7)

AC AUX.

(J32-5) 233A

15V

201

10 V

WELD CONTROL

(J13-4) 116A

116A (J42-9)

POWER

77 (J7-1)

15V TO GND.

ROTOR RESISTANCE= 25- 27 OHMS

SWITCH

SENSOR

(J13-5) 118A

118A (J42-10)

OUTPUT

0-10 V

PC BOARD

240 V AC

5

R1

76 (J7-2)

0 V

CONTROL 10K

(J12-8) 257

239A (J32-8)

FUEL LVL.

0 V

IDLER SWITCH

5J (J42-4)

5A

(J32-9) 229

75 (J7-3)

(J12-7) 256

13 (J41-1)

14 (J41-2)

405 (J31-11)

SENSOR

15 V

120 V AC

10 V

77A (J10-1)

2A

(TO AMPHENOL)

+

SHUT DOWN HOLD COIL

(J10-5) 2

15 V

271 (J32-7)

REMOTE

-15 V (W/O POT.)

WELD TERMINALS SWITCH

(TO AMPHENOL)

76A (J10-2)

(J10-4) 4

6

270 (J31-8)

(J31-5) 224A

21Ω

262

CONTROL 10K

0 V

(TO AMPHENOL)

120 VOLT AC

0 V

75A (J10-3)

4A

403 (J31-3)

(J31-6) 262B

POWER FOR

279 (J9-3)

(J2-1) 213

CV

6F

ROTOR FIELD CIRCUIT

(J32-12)

(J32-1)

(J32-3)

(J32-2)

(J32-4)

90A PIPE

232P

262A

ARC

(J2-2) 214

247

245

246

243

_

278 (J9-2)

(J2-3) 215

150A PIPE

5P

+

CONTROL 10K R2

OUTPUT

277 (J9-1)

(J2-4) 216

250A PIPE

SELECTOR

80V DC INPUT POWER

LOW

LOW

HOUR METER

(J2-5) 217

350A PIPE

SWITCH

HIGH

ALT.

TOROID-

PRESS.

FUEL

TEMP.

(J2-6) 218

500A PIPE

232R

SENSES AC POWER &

260A (J12-9)

CC

"TRIGGER" CURRENT

+12 VOLTS FROM THE BATTERY VIA

FROM LN25 TO

261A (J12-10)

(J2-7) 220

TIG

THE RUN / STOP SWITCH.

ACTIVATE IDLER

(J2-8) 222

232F

232P

232G

232E

ROTOR

(232D, 232T & 232W

(J43-11) 200

FLASHING

232A

MULTI LEAD)

281A (J43-3)

(J43-14) 271

403 (J65-3)

PULL COIL

232T

232W (J12-14)

(J11-5) 250

THERMOSTATS ON

(232D,

232 (J43-5)

PC BOARD

+12 INS. STUD

232S

249 CHOPPER MODULES

232T &

232

(J43-8) 270

IDLE SOL.

0 - .1V WHEN ON

+12

232W

226 (J12-15)

NORMALLY CLOSED

405 (J65-5)

PULL COIL

21Ω

(J11-4) 251

INSULATED

MULTI

232J

IDLER HOLD COIL

.3 Ω

232L

STUD

LEAD)

BATTERY

(J43-15)401

401 (J65-1)

227 (B1)

5G (J13-7)

THERMAL

(J11-1) 252

RUN-STOP SWITCH

PC BOARD

402 (J65-2)

(J4-1 THRU 10)

(J5-1 THRU 10)

(J11-6) 253

SHUTDOWN

SHOWN IN RUN POS.

START

J43-16) 402

SHUT DOWN

236B

PULL COIL

M1 THRU M10

M1 THRU M10

(J12-12) 404

EXC.

BUTTON

(J43-9) 5L

5S (B4)

265 (B3)

.3 Ω

232M

SENSE

SWITCH

POS

236A

404 (J65-4)

232N (B2)

+12 INS. STUD

NEG

ENGINE

ALTERNATOR +

232D

236

232A

D

A

+

-

232H

231

M

238

236C

I

P

S

S

P

BATT

+

ENGINE

CHRG.

L

METER

12 VOLT

STARTER

A

V

SOLENOID

BATTERY

Y

O

L

ENGINE

S

T

FRAME

STARTER

GROUND

115VAC

J

31

A

32

404

INPUT TO

42VAC

I

41A

AMPHENOL

K

42A

A

WORK

H

21

REMOTE

77B

E

77A

B

76B

REMOTE

77B

CONTROL

F

76A

C

75B

CONTROL

76B

G

75A

D

2B

CONTACTOR

75B

D

4A

4B

E

4B

C

2A

F

GND-B

2B

GROUND

GROUND

B

GND-A

AMPHENOL

AMPHENOL

THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.

UNLESS OTHERWISE SPECIFIED TOLERANCE

"X" INFO.

Chg. Sheet No.

DESIGN INFORMATION

REFERENCE: EQUIPMENT TYPE:

COM. CONTROL COMMANDER 300 & 500

MANUFACTURING TOLERANCE PER E2056

SOLIDEDGE

ON 2 PLACE DECIMALS IS ± .02

5000762

DRAWN BY: DP

ON 3 PLACE DECIMALS IS ± .002

XA

SUBJECT:

MACHINE SCHEMATIC

EN-170

ON ALL ANGLES IS± .5 OF A DEGREE

ENGINEER: DP

SUPERSEDING:

MATERIAL TOLERANCE ("t") TO AGREE

XC-UF

SCALE:NONE

DATE:11-22-99

DRAWING No.: G 3834

DO NOT SCALE THIS DRAWING

APPROVED:

WITH PUBLISHED STANDARDS.

XB-UF

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

COMMANDER 500