Instruction/ maintenance manual of the product SVM153-A Lincoln Electric
Go to page of 156
SVM153-A September , 2002 Safety Depends on Y ou 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 .
CALIFORNIA PROPOSITION 65 W ARNINGS i i SAFETY FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.
ii ii SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
iii iii SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.
iv iv SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les p.
v v - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - COMMANDER 500 Page Safety .................................................................................................................................................i-iv Installation ...........
Installation ................................................................................................................... ..........Section A T echnical Specifications ............................................................................
A-2 A-2 INST ALLA TION COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma.
Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.
LIFTING The Commander lift bale should be used to lift the machine. The Commander is shipped with the lift bale retracted. Before attempting to lift the Commander , secure the lift bale in a raised position. Secure the lift bale as follows: a. Open the engine compartment door .
A-5 A-5 INST ALLA TION COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRE-OPERA TION ENGINE SER VICE READ the engine operating and maintenance instruc- tions supplied with this machine.
IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster Use correct polarity — Negative Ground. The Commander is shipped with the negative battery cable disconnected.
WELDING OUTPUT CABLES With the engine off, route the electrode and work cables through the strain relief bracket provided on the front of the base and connect to the terminals provided. These connections should be checked periodically and tightened if necessary .
1. Install the double-pole, double-throw switch between the power company meter and the premises disconnect. Switch rating must be the same or greater than the cus- tomer ’s premises disconnect and service over current protection.
Operation ............................................................................................................................... Section B Operating Instructions ................................................................................
B-2 B-2 OPERA TION COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TING INSTRUCTIONS Read and understand this entire section before operat- ing your Commander 500.
RECOMMENDED APPLICA TIONS WELDER The Commander 500 provides excellent constant cur- rent DC welding output for stick (SMA W) and TIG weld- ing. The Commander 500 also provides excellent con- stant voltage DC welding output for MIG (GMA W) and Innershield (FCA W) welding.
K1639-1 COMMANDER 500 ST ANDARD MODEL • The K1639-1 is the standard version of the Commander 500 and has all the features of the K1639-2 Deluxe version except that there are no gauges, low fuel light, nor dual output meters.
ENGINE CONTROLS (Items 1 through 8) 1. RUN/STOP SWITCH When placed in the RUN position, this switch energizes the fuel solenoid and other electric accessories. When placed in the STOP position, the flow of fuel to the injection pump is stopped to shut down the engine.
Idler Operational Exceptions When the WELDING TERMINALS switch is in the “Welding T erminals Remotely Controlled” position, the idler will operate as follows: a.
12. 6 - PIN CONNECTOR (AMPHENOL) The 6-pin amphenol located on the control panel allows for connection of interfacing equipment. 13. WELD OUTPUT TERMINALS + AND - These 1/2 - 13 studs with flange nuts provide welding connection points for the electrode and work cables.
ENGINE OPERA TION ST ARTING THE ENGINE 1. Open the engine compartment door and check that the fuel shutoff valve located to the left of the fuel fil- ter housing is in the open position (lever to be in line with the hose). 2. Check for proper oil level on the oil dipstick.
T able B.2 – DEUTZ F3L 912 ENGINE FUEL CONSUMPTION Deutz F3L 912 Running Time 44.2 Hp for 25 gallons @ 1800 RPM (Hours) Low Idle - No .47 gallons/hour 53.2 Load 1475 RPM (1.77 liters/hour) High Idle - No .66 gallons/hour 37.9 Load 1900 RPM (2.50 liters/hour) DC CC Weld 1.
COMMANDER 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the 20-250 setting (TIG). • Set the IDLER switch to the HIGH position. • Set the WELDING TERMINALS switch to the WELD TERMINALS ON position. This will close the solid state contactor and provide an always “hot” electrode.
WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the Commander 500 and set welder controls according to the instructions listed ear- lier in this section.
B-12 B-12 OPERA TION COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE B.
Accessories .................................................................................................................... ......Section C Options/Accessories ......................................................................................
OPTIONS/ACCESSORIES The following options/accessories are available for your Commander 500 from your local Lincoln Distributor . FIELD INST ALLED OPTIONS K802N POWER PLUG KIT - Provides a plug for each receptacle. K857 25 ft. (8.5 m) or K857-1 100 ft.
SEMIAUT OMA TIC WELDING ACCESSORIES LN-7 OR LN-8 WIRE FEEDERS - Semiautomatic, con- stant speed wire feeders. For CV operation only . LN-23P WIRE FEEDER - This portable wire feeder is capable of CV operation. K350-1 Adapter Kit is required. LN-25 WIRE FEEDER - The LN-25 with or without an external contactor may be used with the Commander 300.
CONNECTION OF THE LN-7 TO THE COMMANDER 500 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-7 to the “+” terminal of the welder . Connect the work cable to the “-” terminal of the welder .
C-5 C-5 ACCESSORIES COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECTION OF THE LN-7 TO THE COMMANDER 500 USING K584 OR K594 INPUT CABLE ASSEMBL Y (SEE FIGURE C.
C-6 C-6 ACCESSORIES COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECTION OF THE LN-8 TO THE COMMANDER 500 USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.
C-7 C-7 ACCESSORIES COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECTION OF THE LN-8 TO THE COMMANDER 500 USING K595 INPUT CABLE ASSEMBL Y (SEE FIGURE C.
C-8 C-8 ACCESSORIES COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECTION OF THE LN-23P TO THE COMMANDER 500 USING K350-1 ADAPTER (SEE FIGURE C.
C-9 C-9 ACCESSORIES COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECTION OF THE LN-25 TO THE COMMANDER 500 “ ACROSS THE ARC ” (SEE FIGURE C.
Maintenance .................................................................................................................... ......Section D Safety Precautions .......................................................................................
SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete.
CHANGE THE OIL FIL TER: Change the oil filter the first time between 25 and 50 hours of operation. Then, under normal operating conditions, change the oil filter after every 250 hours of operation. If the engine is operated under heavy load or in high ambient tem- peratures, change the oil filter more frequently .
FUEL FIL TERS: When working on the fuel system: • Keep naked lights away , do not smoke ! • Do not spill fuel ! The Commander 500 is equipped with a Fuel Pre- Filter/W ater Separator Assembly located before the lift pump and a Secondary Fuel Filter located after the lift pump and before the fuel injectors.
4. Slide the new element onto the grommet post on the bottom of the filter header until the element no longer easily moves up into the filter header . Now rotate the element (it may take almost 1 full turn) with a slight upward pressure until the element begins to further engage the header .
BLEEDING THE FUEL SYSTEM: In the event the engine is operated until it runs out of fuel, you will need to bleed the fuel system in order to start the engine. Refer to the engine operation manual. AIR FIL TER: Excessive air filter restriction will result in reduced engine life.
COOLING SYSTEM: The cooling system of the Deutz engine needs to be checked and cleaned periodically . Consult the engine Operation Manual for the proper frequency and procedure. COOLING BLOWER BEL T : The following procedure should be followed to replace the cooling blower belt: 1.
D-8 D-8 MAINTENANCE COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE D.1 DEUTZ ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Starting Engine • Fill fuel tank.
BA TTER Y MAINTENANCE GASES FROM BA TTERY can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when working near a battery . Follow the instructions printed on the battery .
WELDER/GENERA TOR MAINTENANCE STORAGE: Store the Commander 500 in clean, dry , protected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air .
D-11 D-11 MAINTENANCE COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 12 10 8 7 9 6 5 4 3 2 1 11 FIGURE D.5 – MAJOR COMPONENT LOCA TIONS 1.
General Description .......................................................................................................................E-2 Battery , Starter , Engine, Rotor , Stator , Pull Coil Board and Peripheral Board – Engine Protection ....
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 T echnology to produce DC current for multi-purpose welding applications.
WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK The three-phase stator weld windings are connected to a three-phase rectifier bridge. The resultant DC volt- age is applied to four paralleled capacitors incorporat- ed within each of the two power modules.
ANALOG CONTROL POWER SUPPL Y BOARD AND WELD CONTROL BOARD The Analog Power Supply PC board, which is powered by 80 VDC derived from the filter capacitors on the Power Modules, supplies various regulated DC volt- ages to operate the Weld Control PC board circuitry .
INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT s are semicon- ductors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow .
PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION is used to describe how much time is devoted to conduction in the cycle. Changing the pulse width is known as MODU- LA TION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.
CHOPPER TECHNOLOGY FUNDAMENT ALS The new era of welding machines such as the Commander 500, employ a technology whereby a DC source is turned on and off (chopped up) at high speed, then smoothed through an inductor to control an arc. Hence the name “ Chopper .
Tr oubleshooting & Repair Section ......................................................................................Section F How to Use T roubleshooting Guide ...................................................................................
This T roubleshooting Guide is provided to help you locate and repair possible machine malfunc- tions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “ PROBLEM ” (SYMP- TOMS).
ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T urn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
TROUBLESHOOTING & REP AIR F-13 COMMANDER 500 ENGINE ST ARTING DIAGNOSTIC CHART F-13 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Does the PULL COIL read .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 COMMANDER 500 ST ART -UP AND OCV DIAGNOSTIC CHART F-14 No LOW IDLE.
TROUBLESHOOTING & REP AIR F-15 F-15 COMMANDER 500 CASE COVER REMOV AL AND REPLACEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-16 F-16 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROP R OD LEFT FRONT P ANEL RIGHT FRONT P ANEL DOOR ASSEMBL Y ROUND HEAD SCREW LOCA TION FIGURE F .
TROUBLESHOOTING & REP AIR F-17 F-17 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FRONT CONTROL P ANEL SCREWS SCREW FIGURE F .
TROUBLESHOOTING & REP AIR F-18 F-18 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CASE FRONT KNOBS - REMOV AL AND REPLACEMENT PROCEDURE Replacement Removal Flat Rounded Replacement: 1.
TROUBLESHOOTING & REP AIR F-19 F-19 COMMANDER 500 POWER MODULE CAP ACITOR DISCHARGE PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-20 F-20 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE CAP ACITOR TERMINALS FIGURE F .
TROUBLESHOOTING & REP AIR F-21 F-21 COMMANDER 500 IDLER SOLENOID TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-22 F-22 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master.
TROUBLESHOOTING & REP AIR F-23 F-23 COMMANDER 500 SHUTDOWN SOLENOID TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-24 F-24 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master.
TROUBLESHOOTING & REP AIR F-25 F-25 COMMANDER 500 ENGINE THROTTLE ADJUSTMENT TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-26 F-26 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MARK BLOWER P ADDLE HERE FIGURE F .
TROUBLESHOOTING & REP AIR F-27 F-27 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) FIGURE F .
TROUBLESHOOTING & REP AIR F-28 F-28 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) 6.
TROUBLESHOOTING & REP AIR F-29 F-29 COMMANDER 500 ROT OR RESIST ANCE TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-30 F-30 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SLIP RINGS BRUSH HOLDER ASSEMBL Y ACCESS P ANEL FIGURE F .
TROUBLESHOOTING & REP AIR F-31 F-31 COMMANDER 500 FLASHING AND ROTOR VOL T AGE TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-32 F-32 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master.
TROUBLESHOOTING & REP AIR F-33 F-33 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIL TER CAP ACITOR FIELD DIODE RECTIFIER BRIDGE FIGURE F .
TROUBLESHOOTING & REP AIR F-34 F-34 COMMANDER 500 ST A TOR VOL T AGE TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-35 F-35 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FRONT CONTROL P ANEL SCREWS SCREW FIGURE F .
TROUBLESHOOTING & REP AIR F-36 F-36 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GREEN GROUND LEAD OUTPUT P ANEL SCREWS OUTPUT LEADS (BEHIND P ANEL) FIGURE F .
TROUBLESHOOTING & REP AIR F-37 F-37 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC AUXILIAR Y LEADS #5B, #5E, #8, #9, #1 1, #12 (BEHIND P ANEL) FIGURE F .
TROUBLESHOOTING & REP AIR F-38 F-38 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WELD WINDING LEAD CONNECTIONS W6 W2 W4 W1 W3 W5 FIGURE F .
TROUBLESHOOTING & REP AIR F-39 F-39 COMMANDER 500 ANALOG POWER SUPPL Y PC BOARD VOL T AGE TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-40 F-40 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master.
TROUBLESHOOTING & REP AIR F-41 F-41 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE F .
TROUBLESHOOTING & REP AIR F-42 F-42 COMMANDER 500 OUTPUT RECTIFIER BRIDGE TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-43 F-43 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FRONT CONTROL P ANEL SCREW SCREWS FIGURE F .
TROUBLESHOOTING & REP AIR F-44 F-44 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GREEN GROUND LEAD OUTPUT P ANEL SCREWS OUTPUT LEADS (BEHIND P ANEL) FIGURE F .
TROUBLESHOOTING & REP AIR F-45 F-45 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WELD WINDING LEAD CONNECTIONS W6 W2 W4 W1 W3 W5 FIGURE F .
TROUBLESHOOTING & REP AIR F-46 F-46 COMMANDER 500 POWER MODULE TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-47 F-47 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W10 W9 DIODE LEAD D4 TEMPERA TURE SWITCH POWER MODULE PC BOARD POSITIVE (+) STRAP POSITIVE (+) STRAP FIGURE F .
TROUBLESHOOTING & REP AIR F-48 F-48 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HEA T SINK POSITIVE (+) CAP ACITOR TERMINAL CONNECTIONS FIGURE F .
TROUBLESHOOTING & REP AIR F-49 F-49 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DIODE MODULE TERMINALS HEA T SINK FIGURE F .
TROUBLESHOOTING & REP AIR F-50 F-50 COMMANDER 500 CHARGING CIRCUIT TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-51 F-51 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC #239 #281 #238 FIGURE F .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-52 F-52 COMMANDER 500 This is the typical auxiliary output voltage generated from a properly operating machine.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-53 F-53 COMMANDER 500 This is the typical DC open circuit out- put voltage generated from a properly operating machine.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-54 F-54 COMMANDER 500 This is the typical DC output voltage generated from a properly operating machine.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AI.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-56 F-56 COMMANDER 500 This is the typical TIG MODE output voltage generated from a properly operating machine.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-57 F-57 COMMANDER 500 This is the typical DC open circuit output voltage generated from a properly operating machine.
TROUBLESHOOTING & REP AIR F-58 F-58 COMMANDER 500 SHUTDOWN SOLENOID REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-59 F-59 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master.
TROUBLESHOOTING & REP AIR F-60 F-60 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PIVOT PIN SP ACER W ASHER PLAIN W ASHER RET AINING RING MOUNTING F ASTENERS FIGURE F .
TROUBLESHOOTING & REP AIR F-61 F-61 COMMANDER 500 POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-62 F-62 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FRONT CONTROL P ANEL SCREWS SCREW GREEN GROUND LEAD F .
TROUBLESHOOTING & REP AIR F-63 F-63 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC REMOVE LEADS POWER MODULE FIGURE F .
TROUBLESHOOTING & REP AIR F-64 F-64 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master.
TROUBLESHOOTING & REP AIR F-65 F-65 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBL Y REMOV AL AND REPLACEMENT (CONTINUED) Refer to Figure F .
TROUBLESHOOTING & REP AIR F-66 F-66 COMMANDER 500 POWER MODULE (CHOPPER) PC BOARD/DIODE MODULE REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-67 F-67 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PLUG J50 ALLEN HEAD SCREWS (4) COPPER SP ACERS TEMPERA TURE SWITCH HEA T SINK POWER MODULE PC BOARD DIODE MODULE FIGURE F .
TROUBLESHOOTING & REP AIR F-68 F-68 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MODULE (CHOPPER) PC BOARD/DIODE MODULE REMOV AL AND REPLACEMENT (CONTINUED) POWER MODULE PC BOARD REPLACEMENT 1.
TROUBLESHOOTING & REP AIR F-69 F-69 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SPRING WASHER PLAIN WASHER 2 TO 3 TURNS EACH 12-18 IN.
TROUBLESHOOTING & REP AIR F-70 F-70 COMMANDER 500 OUTPUT RECTIFIER BRIDGE DIODE REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel.
TROUBLESHOOTING & REP AIR F-71 F-71 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HEA TSINKS DIODE DIODE PIGT AIL LEADS FIGURE F .
TROUBLESHOOTING & REP AIR F-72 F-72 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFIER BRIDGE DIODE REMOV AL AND REMOV AL AND REPLACEMENT (CONTINUED) 8.
TROUBLESHOOTING & REP AIR F-73 F-73 COMMANDER 500 ST A TOR/ROT OR REMOV AL AND REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-74 F-74 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PLUG FUEL LINES U-BOL TS (2) LEADS #229 AND #242D { FIGURE F .
TROUBLESHOOTING & REP AIR F-75 F-75 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PLUG P/J52 #201 #201A 6F #200D #5P FIL TER CAP ACITOR FIELD DIODE RECTIFIER BRIDGE FIGURE F .
TROUBLESHOOTING & REP AIR F-76 F-76 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC #200A #200B #201 12 VDC STUD LEADS #232L AND #232M PULL COIL PC BOARD (LEADS #265 AND #227) CONTROL BOX FIGURE F .
TROUBLESHOOTING & REP AIR F-77 F-77 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 6 SCREWS SHROUD ACOUSTICAL FOAM FIGURE F .
TROUBLESHOOTING & REP AIR F-78 F-78 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CENTER P ANEL LIFT FRAME WELDMENT BASE FUEL T ANK SUPPORTS F AN BAFFLE FIGURE F .
TROUBLESHOOTING & REP AIR F-79 F-79 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master.
TROUBLESHOOTING & REP AIR F-80 F-80 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FLEX PLA TE BLOWER SEGMENT (4) ROTOR FIGURE F .
TROUBLESHOOTING & REP AIR F-81 F-81 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master.
TROUBLESHOOTING & REP AIR F-82 F-82 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master.
TROUBLESHOOTING & REP AIR F-83 F-83 COMMANDER 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master.
G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- Electrical Diagrams ........................................................................................................................G-1 Wiring Diagram ...............
ELECTRICAL DIAGRAMS G-2 COMMANDER 500 WIRING DIAGRAM - COMMANDER 500 GND-H 6D 3 GND-F 5A AUX I LI AR Y P OWE R GND-D 12 11 10 EMPT Y CB6 10A EMPTY EMPTY 42A 42 31 GND-E 42A 5J OUTPUT 31 CONTROL 32 CCW.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-3 COMM.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-4 COMMANDER 500 SCHEMA TIC - BA TTER Y PC BOARD G-4 NOTE: This diagram is for reference only .
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-6 COMMANDER 500 SCHEMA TIC - CHOPPER PC BOARD FILENAME: M19462_1BA 10.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-8 COMMANDER 500 SCHEMA TIC - PERIPHERAL PC BOARD G-8 NOTE: This diagram is for reference only .
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric.
ELECTRICAL DIAGRAMS G-10 COMMANDER 500 SCHEMA TIC - POWER SUPPL Y (ANALOG) PC BOARD G-10 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-12 COMMANDER 500 SCHEMA TIC - PULL-COIL PC BOARD G-12 NOTE: This diagram is for reference only .
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric.
ELECTRICAL DIAGRAMS G-14 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 1 G-14 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-15 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 2 G-15 NOTE: This diagram is for reference only .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-16 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 3 G-16 NOTE: This diagram is for reference only .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-17 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 4 G-17 NOTE: This diagram is for reference only .
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-18 COMMANDER 500 SCHEMA TIC - WELD CONTROL PC BOARD - SHEET 5 G-18 NOTE: This diagram is for reference only .
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric.
SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you.
An important point after buying a device Lincoln Electric SVM153-A (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric SVM153-A yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric SVM153-A - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric SVM153-A you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric SVM153-A will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric SVM153-A, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric SVM153-A.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric SVM153-A. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric SVM153-A along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
