Table of Contents Operation Section | Lincoln Electric 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 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 Stacking Safety PrecautionsLocation / Ventilation Storing High Altitude Operation High Temperature OperationLifting Towing PRE-OPERATION Engine Service Spark Arrester Muffler Outlet Pipe Machine Grounding Auxiliary Power ReceptaclesStandby Power Connections Welding Output Cables Company Table of Contents Operation Section General Description Safety InstructionsOperation Operating Instructions Recommended Applications Design Features and Advantages Controls and Settings K1639-1 Commander 500 Standard ModelWelding Capability Fuel Level Gauge and Light RUN/STOP SwitchIdler Switch Start Pushbutton Hour Meter Weld Mode Output ControlWelding Terminals Switch Table B.1 Weld Mode and Output Control Functions Auxiliary Power Controls Typical Fuel Consumption Engine OperationStarting the Engine BREAK-IN Period TIG Welding Welder OperationStick Welding Constant Current CC Welding TIG 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 ELECTRODES2 ARC Gouging Auxiliary Power OperationWire Feed Constant Voltage Welding Simultaneous Welding and Auxiliary Power Loads Permissible Permissible Auxiliary Extension Cord Recommendations Table of Contents Accessories Section Stick Welding Accessories AccessoriesOPTIONS/ACCESSORIES Field Installed Options High Frequency Generators for TIG Applications Semiautomatic Welding AccessoriesConnection of Lincoln Electric Wire Feeders Other Wire Feeders for the Commander 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 Daily MaintenanceRoutine and Periodic Maintenance Engine Maintenance 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 Maximum Output Pulse Width Modulation6E-6 Minimum Output External 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 & Repair PC Board can be damaged by static electricity PC Board Troubleshooting Procedures Troubleshooting 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 Areas Engine Starting Diagnostic Chart Return START-UP and OCV Diagnostic Chart Case Cover Removal and Replacement Procedure DescriptionMaterials 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 28F-28 Frequency Counter MethodOscilloscope 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 Power and Weld Windings Test Auxiliary Leads #5B, #5E, #8, #9, #11, #12Behind Panel Weld Winding Lead Connections W6W1 Analog Power Supply PC Board Voltage Test Control Circuit Input Power 40F-40J41 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 Temperature Switch Power Module PC Board Diode Lead D4 Positive + StrapW10 Check Igbt For Shorts Check Diode Module When all tests are complete Charging Circuit Test #239 #281 #238 Figure F.24 Engine Alternator Location 15.8 ms Volts 50V5ms Scope SettingsNormal Open Circuit Voltage Waveform 115VAC Supply High Idle no Load Normal 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 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 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 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 Lead Reconnection Checklist EngineOutput Panel and Control BOX Welder DC Stick Output Welder CV Wire OutputRetest After Repair Engine RPM 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