Lincoln Electric SVM153-A service manual Commander, Theory of Operation

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E-2 E-2

THEORY OF OPERATION

FIGURE E.2 - BATTERY, ENGINE, ROTOR, STATOR, PULL COIL BOARD

AND PERIPHERAL BOARD – ENGINE PROTECTION

				THREE-PHASE						WORK
COMMANDER 500									TERMINAL
				RECTIFIER						__
								TO WELD
								CONTROL
								BOARD
				+	(2)	(2)		POWER MODULES
								(2)	ELECTRODE
								IGBT	TERMINAL
					80 VDC
								CHOKE		+
									SHUNT
			W							F
										E
		D	I
										E
	L		N
							(2)	PWM		D
			D
E					ANALOG					B
			I				20 VDC
W			N	POWER SUPPLY				SIGNALS (2)		A
			G							C
					BOARD					K

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ENGINE

STARTER

ALTERNATOR
RUN/STOP
SWITCH							ENGINE
		BATTERY			S		SENSORS
					H
		BOARD			U	I		1/2
					T
						D		BATTERY
					D	L		BD
					O
120				10	W	E
	VDC			VDC	N	R
BATTERY						SOL
		PULL
		COIL				TO WELD
		BOARD			SOL	CONTROL
						BOARD
			10
			VDC

PERIPHERAL

BOARD

			WELD
MECHANICAL	ROTOR	TO	CONTROL
ROTATION		HOLD	BOARD
		IDLE
	SLIP	COIL		VOLTMETER
	RINGS			AMMETER
	STATOR	THERMAL	ARC OUTPUT	PROCESS/RANGE
			CONTROL CONTROL SELECTOR
		LIGHT
		42 VAC TO 14 PIN AMPHENOL
	AUXILIARY WINDINGS	FOR WIRE FEEDER
	1
	2
	0	240VAC
	V	RECEPTACLE

A

C

120VAC RECEPTACLES (2)

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GENERAL DESCRIPTION

The Commander 500 is a diesel engine-driven welding power source capable of producing 500 amps at 40VDC at a 100% duty cycle. The engine is coupled to a brush-type alternating current generator. This AC output is rectified and controlled by Chopper Technology to produce DC current for multi-purpose welding applications. The Commander 500 is also capable of producing 12,000 watts of AC auxiliary power at 100% duty cycle.

BATTERY, ENGINE, ROTOR, STATOR, PULL COIL BOARD AND PERIPHERAL BOARD – ENGINE PROTECTION

The 12VDC battery powers the engine starter motor and also supplies power to the Battery PC board, Pull Coil PC board, Peripheral PC board and associated circuitry. When the engine, which is mechanically cou- pled to the rotor, is started and running, the 12 VDC

battery voltage is fed through the Battery PC board to the rotor field coil via a brush and slip ring configura- tion. This excitation or "flashing" voltage magnetizes the rotor lamination. This rotating magnet induces a voltage in the stationary windings of the main alterna- tor stator. The stator houses a three-phase weld wind- ing, a 120/240VAC single-phase auxiliary winding, and a 42VAC wire feeder power winding.

The engine alternator supplies charging current for the battery circuit. The Peripheral board monitors the engine sensors and will shut the engine off in the event of low oil pressure, engine over temperature, malfunc- tion of the engine’s alternator system or a low fuel con- dition. The idler solenoid is mechanically connected to the engine’s throttle linkage. If no welding or auxiliary current is being drawn from the Commander 500, the Pull Coil board activates the idler solenoid, which then brings the engine to a low idle state. When output cur- rent is sensed, either weld or auxiliary, the Weld Control PC board deactivates the idler solenoid, and the engine returns to high RPM.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

COMMANDER 500