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Lincoln Electric SVM153-A service manual Table of Contents Operation Section

Models: SVM153-A

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Section B-1	Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation	Section B
Operating Instructions	B-2
Safety Instructions	B-2
General Description	B-2
Recommended Applications	B-3
Design Features and Advantages	B-3
Welding Capability	B-4
Controls and Settings	B-4
Engine Controls	B-5
Welder Controls	B-6
Auxiliary Power Controls	B-7
Engine Operation	B-8
Starting the Engine	B-8
Stopping the Engine	B-8
Break-In Period	B-8
Typical Fuel Consumption	B-8
Welder Operation	B-9
Stick Welding	B-9
Pipe Welding	B-9
Constant Current (CC) Welding	B-9
TIG Welding	B-9
Wire Feed (Constant Voltage) Welding	B-11
Auxiliary Power Operation	B-11
Simultaneous Welding and Auxiliary Power Loads	B-11
Arc Gouging	B-11
Paralleling	B-11
Extension Cord Recommendations	B-12

COMMANDER 500

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Lincoln Electric SVM153-A service manual Table of Contents Operation Section

Contents

CommanderTM California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Commander 500 K1639-1 InstallationStacking Safety PrecautionsLocation / Ventilation StoringHigh Altitude Operation High Temperature OperationLifting TowingPRE-OPERATION Engine Service Spark Arrester Muffler Outlet PipeMachine Grounding Auxiliary Power ReceptaclesStandby Power Connections Welding Output CablesCompany Table of Contents Operation Section General Description Safety InstructionsOperation Operating InstructionsRecommended Applications Design Features and AdvantagesControls and Settings K1639-1 Commander 500 Standard ModelWelding Capability Fuel Level Gauge and Light RUN/STOP SwitchIdler Switch Start PushbuttonHour Meter Weld Mode Output ControlWelding Terminals Switch Table B.1 Weld Mode and Output Control FunctionsAuxiliary Power Controls Typical Fuel Consumption Engine OperationStarting the Engine BREAK-IN PeriodTIG Welding Welder OperationStick Welding Constant Current CC WeldingTIG Torch Commander 500 Settings When Using the K799 HI-FREQ UnitCommander 500 Settings When Using the K930-1 TIG Module Table B.3 Typical Current RANGES1 for Tungsten ELECTRODES2ARC Gouging Auxiliary Power OperationWire Feed Constant Voltage Welding Simultaneous Welding and Auxiliary Power LoadsPermissible Permissible Auxiliary Extension Cord RecommendationsTable of Contents Accessories Section Stick Welding Accessories AccessoriesOPTIONS/ACCESSORIES Field Installed OptionsHigh Frequency Generators for TIG Applications Semiautomatic Welding AccessoriesConnection of Lincoln Electric Wire Feeders Other Wire Feeders for the CommanderTo 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 Daily MaintenanceRoutine and Periodic Maintenance Engine MaintenanceFigure D.1 OIL Drain and Refill Fuel Filters Figure D.2 Fuel PRE-FILTER/WATER Separator AssemblyFigure D.3 Secondary Fuel Filter AIR Filter Maintenance Table D.2 Engine Maintenance Parts Manufacturer Part Number Frequency Maintenance RequiredConnecting a Battery Charger Battery MaintenanceWELDER/GENERATOR Maintenance Figure D.5 Major Component Locations Table of Contents Theory of Operation Section CommanderTheory of Operation CommanderWeld WINDINGS, RECTIFIER, Power Modules and Feedback Analog Control Power Supply Board and Weld Control Board Insulated Gate Bipolar Transistor Igbt Operation Maximum Output Pulse Width Modulation6E-6 Minimum OutputExternal DC Solid State Inductor ARC Source Switch Diode Chopper Technology Fundamentals70-80VDC Table of Contents Troubleshooting & Repair SectionSection F-1 HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board can be damaged by static electricity PC Board Troubleshooting ProceduresTroubleshooting Guide Observe Safety GuidelinesDetailed 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 AreasEngine Starting Diagnostic Chart Return START-UP and OCV Diagnostic ChartCase Cover Removal and Replacement Procedure DescriptionMaterials Needed Procedure Case Cover Removal Replacement ProcedureFigure F.1 Removal Case Front Knobs Removal and Replacement ProcedurePower Module Capacitor Discharge Procedure Procedure Test Description Idler Solenoid TestFigure F.5 Idler Solenoid Leads Test ProcedureShutdown 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 HereLocking NUT 28F-28 Frequency Counter MethodOscilloscope Method Rotor Resistance Test Test Procedure Flashing and Rotor Voltage Test Lead # 201A 10 11 12 13 14 15Troubleshooting & Repair Stator Voltage Test Figure F.13 Front Control Panel Removal Screws Troubleshooting & Repair Auxiliary Power and Weld Windings Test Auxiliary Leads #5B, #5E, #8, #9, #11, #12Behind Panel Weld Winding Lead Connections W6W1Analog Power Supply PC Board Voltage Test Control Circuit Input Power 40F-40J41 Test Points Component Tested Voltage Reading Analog Control Power Supply PC Board TestOutput Rectifier Bridge Test Perform the Power Module Capacitor Discharge Procedure Troubleshooting & Repair Figure F.20 Diode Lead Removal Power Module Test Temperature Switch Power Module PC Board Diode Lead D4 Positive + StrapW10 Check Igbt For Shorts Check Diode Module When all tests are completeCharging Circuit Test #239 #281 #238 Figure F.24 Engine Alternator Location15.8 ms Volts 50V5ms Scope SettingsNormal Open Circuit Voltage Waveform 115VAC Supply High Idle no LoadNormal Open Circuit Voltage Waveform Stick MAX TAP MAX Control POT High Idle no LoadVolts 50V5ms Normal Weld Voltage Waveform Stick CC Machine Loaded to 500 Amps AT 40 VoltsVolts 20V0.1ms Normal Weld Voltage Waveform Wire CV Normal TIG Mode Voltage Waveform Loaded to 200A 16 VoltsVolts 10V50ms MAX Control POT High Idle no Load Normal Open Circuit Voltage Waveform Wire CV TAPShutdown Solenoid Removal and Replacement Figure F Shutdown Solenoid Lead Connections Figure F Shutdown Solenoid Linkage ARM Assembly ReassemblyDescription 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 RemovalPower Module PC Board Replacement Diode Module Removal Diode Module ReplacementOutput Rectifier Bridge Diode Removal and Replacement Refer to Figure F.32 Turn the engine off Diode Stud Size Foot Pounds Inch Pounds Return Section TOCSTATOR/ROTOR Removal and Replacement Preparation and Lead Removal Procedure Leads #229 #242DPlug Fuel Lines Bolts Filter Field Diode Capacitor #200D #5P #201 #201A#232M Figure F.35 Brush Holder and Lead RemovalFigure F.37 Alternator Shroud Removal Screws Acoustical Foam Figure F.38 Lift Frame and Associated Component Removal Figure F.39 Stator Removal Stator Removal ProcedureReassembly Notes Rotor Removal ProcedureLead Reconnection Checklist EngineOutput Panel and Control BOX Welder DC Stick Output Welder CV Wire OutputRetest After Repair Engine RPMAuxiliary Power Output Touch Start TIG Mode OutputTable of Contents Electrical Diagrams Section Electrical DiagramsElectrical Diagrams G3834 Schematic Complete Machine CommanderSchematic Battery PC Board Return to Section PC Board Assembly Battery PC BoardPWM Input Schematic Chopper PC BoardReturn to Section Return to Section TOC PC Board Assembly Chopper PC BoardSchematic Peripheral PC Board Return to Section PC Board Assembly Peripheral PC BoardSchematic Power Supply Analog PC Board PC Board Reference QTY Designators Description PC Board Assembly Power Supply Analog PC BoardSchematic PULL-COIL PC Board MOSFET/HEATSINK ASBLY,T12704-82&S1810 PC Board Assembly PULL-COIL PC BoardSchematic 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 BoardSVM Error Reporting Form