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Lincoln Electric SVM153-A Welding System User Manual

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3. cle 5 22 199 9 o g NA Camper in Plug COIL DRIVE CIRCUIT sv con t S4 gt 0P3 NA MET a gt 0P2 7 DECIMAL PT COMMON ee u gt s m NA yy IDLE HOLD COIL MULTIARC FAN d gt 5 gt 0 2 NA 1026 07 NA 105 AMMETER IN w SHORT CIRCUIT PROTECTION Qu 50 T 1 02A Ju o AMETER PSET MODE e et WTI gt AMMETER GND f iy P FOR AUX USE PULL TO COMTO REMAIN ga fpga X3 A gt 8233 B Y 05A 2 05 END a Tak TO IDLE PULL COIL CIRCUIT AMMETER DISPLAYS PRESET T gt H 9010 ar 40V SIS 5 40V Date 1206 PULL COIL PCB
4. T cls 9 92 199 p AUS 9 TOUCH START TIG CIRCUIT Popes 45V REFERENCE SUPPLY ay nee CONTROL CIRCUI FEEDBACK DIVIDER DA esv 5 77 R178 RI R251 p VOLTAGE FEEDBACK CIRCUIT H5VA A approx 78v 20K 758 100 80 01414 ES 243 8 1 o gt 16 176 iw ES 27 gt IV 10 m Dole 1206 Dale 1206 CUR SENSE 219 5 20K I 3140 500 ref Dii 1 R301 TIG V DETECT 182 5 fpga i to TOOK Ria Oh 2 VOLTAGE FEEDBACK 2224 055 TTSK ba d 2 02A 9 6 IO0K 70V i and SHUNT IN POSITIVE 10018 05A OIW gt 2 01W TO PWM LEAD SENSE LEAD 30V 054 Low T Low T 240 a cir ON NEGATIVE STUD TE R267 R342 5 TIG_SETPOINT EIK 51K TOP BOARD 170 1 Ru 8219 o o IN 2 LAYOUT 01 oi CH V FEEDBACK us T L 50 43110 c i 6 m 182 pas CURRE
5. 6 06201 0 2242 C 10 fpga gt 5 X10 1 TIG LIMIT E R107 m y LOCAL pg R138 3 100 77 T0 POT 42 0 AN 100K 768K O D RIO X R175 1 EH nem CUR AMe 100 E O O 330740 221K 4ov 750 17 m a 3 gt uw 2 332k 8 150 A 39 2K S P5 took S I LOCAL_WIPER Sjow Sow EET Sfoiw amp amp o1w 5 C104 N 7 D Eo 2 3 9 10 Siw 2 3 9 10 ei 2700pF 10 06680 xu 06680 06680 0680 525 06680 xss 16680 xss 606680 xss 0680 o 50 40V V 3 5 6 2 3 5 6 2 Y Y Y Y n add A 8 C D A B D o gt IZIK V FEEDBACK s i B Eiig T 12 45V V 079 GND P DZ6 m Y 12 L Ls ko bs 9 2 5 12 100 8 0225 gle c N c c 0225W amp po H 2 2240 2240 224D 2240 2240 2240 2240 2240 CUR_SENSE_TIMED ae x40 x40 x40 x40 su 5 5 aV V7 ono 128 it 120 L A 28 QE 20 8 ow
6. 5 E EIZ TIIE 9 9158 olg o z E 9 _ E cic 5 5 D 4 4 n n 15 la h 3 ha 4 4 4 4 3 4 4 Vcc C75 cm il pg dcm ER ce C66 ces C64 ce ca C60 c Ly 1 c 01 91 91 01 01 01 94 91 04 01 01 01 01 01 01 01 4 01 01 50V m 50V je 50 50V xe 50V id 50V s sov uc 50V 50 ha 50V e 50V 50V 50V iud sov due 50V e 50V 50V 50V x55 50V 2240 2240 330740 330740 330230W 406680 406680 406680 406680 29010 406680 406680 2240 2240 2240 2240 29010 2240 2240 GND n i n i 10 7 7 7 7 7 ine i n n n i GND 15V 5 15V T E 01 SOV 50v aic 9 a Wi T 7 C83 L ael 4 L 4 n NA 4 150 50 01 1 m C96 cst C55 13 C82 E gis ha m i 50V 50V NA 50V NA 50V m Ol zm 4 91 AN 01 AN 01 50V 01 Lr 92 NA 95 LI X16 1 x2 6 M x52 v x56 Y 30v 20 r 2150 x ES x20 555 X24 E X36 E Pew 330740 aM 330740 oV 330740 57 330740 GND 330740 6 57 57 X47 vA x50 Gi 7 4 1 GND 74 GND 7 GND 7 GND
7. 45 2 5 volt 1 Amp control 18 C19 C23 C10 600V e P 20V 100 T 100 100 AN 01 T 20V 50V H 4 D4 C6 47 DZ2 e 2 volts 300 control was D7 1A FR 1000V 073 PM 545 15 volts 200 milliamp control INFORMATION SYMBOLS PER E1537 ELAND OHIO U S A scale NONE jn 09 02 99 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 453 20 volts 200 milliamp 24K chopper ET 20 Volts 200 milliamp 221 chopper LN 6 2 gt 15 volts 200 milliamp 121K miscellanious COLN ELECTRIC CO QUIP TYPE 1 Multi System susce _ANalog Control Power Suppl SUP S D O 19422 COMMANDER 500 9 11 PC BOARD ASSEMBLY POWER SUPPLY ANALOG PC BOARD ELECTRICAL DIAGRAMS G 11 PC
8. Return to Section Return to Master TOC KEY lt 1 MULTIWELD VOL gt DRIVER CIRCUL FUEL CONTAC 1 MUR a ORCL 3 MCTCR CIRC EM CH SENSE CIRCU DW TURNS OR CONTACTOR DN HL AT SOL TURNS ENGIN F ENG ALT OIL TEMP SWITCE OIL TEMP SWITCH gt UNDER VOLTS Return to Section TOC Return to Master TOC AT OIL_TEMP INDICATES HOT ENGINE T SHUT ENGINE DOWN INDICATES FAILED
9. y 11 8 as 4009 VE 010 NOLING H3lUVI EX na P 002 H35NVH A009 VE SNOLLJJNNOO H35NVH A007 Vi N3 OL 4g 8 vu3Hdlu3d HSV 13 SU3UNV AWOJ llyg ACT 5 HIIRM LY 1N3S38d SI AZT 145012 SI N3dO 38 M SH39NVH 04 GASVIG qd3SH3 AdH 9NI38 530010 ONDDOT8 01 dOlS ATIVILLVWOLN 3 SI i IH 10 51 JNION3 3 N Q3NIVBO LON SI AY3LLY LINJA Hsv 14 1nHS TT NSS MO S 3unSS3Hd 710 8 Q311081NO2 SI 0990 T S HSV14 SH30NVANWOJ 80 AlddNS X3 0115 0 0089 11 8 01 Zt gt 08 04 073M NO 71 OL Audllvd INVES AOTH 318100 AlddNS A0Z ANYAT A is manual d by th 0350 LON Ines covere NNVH AOTH is for reference only It may not be accurate for all mach iagram isd Thi N
10. 5 5 22 1996 9 t 1t MACHINE SELECT sv ey PESA s 25 gt T TIG SWITCH 31 93 1 029 22 SLOPE 1 CUR SENSE TIMED o PL_SWITCH vog ____ s ope_z z ENABLE NS olo P2_SWITCH 211 05 1 026 6 SLO 4 100119 019 XF AN OR LOW IDLE SERIAL_DATA mo 1l P3 SWITCH 3 1 09 10025 2 SLOPE 8 361 096 PWM_ENABLE gt c c 925 S gja A PL SWITCH 1010010 xi 8 1 0246 SLOPE 16 911 097 1 0116 16 SD MEM nios MACH_SEL_1 PS_SWITCH 121 012 1 023 23 SLOPE_32 2817098 01505 5 i 5 1 50x 2 1 50K B 1 E520 2 94 0320 14 2 515 pga Rit R157 i WIRE SWITCH 1 013 1 022 SLOPE 6L 2217099 10114 IMTS ux E D TR QUT MAH SEI TWO FDUR __fs ope_128 10111 0101 1 0113 4H nh gt MACHESELZ TIG V DETECT 191 015 1002000 TIG WELD 1021 0102 vot dH 2 109 f R12 risa 2 1 19 103 104 SK MACH 1 2 THERMAL SENSE __ 1 016 1 019 THERMAL LAMP 03 0103 1 0104 5 ca 197 MACH SEL 302 01 525070 55 525070 55 nck sack te fpga R2 RISS 253 Us 193 DIN WW qur MARE SEL a 3355 X31 pape EPN N E ia MACH SEL 1 391 039 1 062 X VOLTMETER ON 1221170122 PROGRAM E 1 T T UM ae MACH SEL 2 341 031 0061 81 _________fmeer_pset_mO0E 1231170123 1 0142 442 RL S
11. 4 5 TOWING 55 E 4 5 Pre Operation Engine Service 5 g LE 5 a A 5 f Fuel Capriana 5 Engine Cooling EEA 5 Battery Connection citri tet cien ent repaso a ne Dun End A 5 Muffler Outlet lt lt rhe ie taii oat race A 6 Spark Arr St fano snien poe ye ein vale EYED e Ede COE REA A 6 High Frequency Generators for TIG A 6 EleCthial Connections OPE A 6 Remote Control srpen a aa 6 5 Welding Terminals teet itae in 6 g Welding Output Gables 5 2 reete reet 7 8 Machine ern m A 7 E Auxiliary Power entree nnne nennt tenen nnn nes A 7 Standby Power 7 Y 4 2 8 5 A COMMANDER 500 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC
12. D En O zs e s e e 0 e vi5 e 8 s e 52 e e 592 e e on e 9 e 9 s 820 sni v na DICA um Gall rj e sj Tee we one ee ona nee ue 9 I lee esi xa e ies ole e csza e v zn es MO 6 cee eel ox s 9 00 E E
13. 2 8 Options eT C 2 E Stick Welding C 2 4 TIG Welding C 2 Semiautomatic Welding C 3 Connection of Lincoln Electric Wire C 3 Connection of the LN 7 Using K867 Universal Adapter C 4 Connection of the LN 7 Using the K584 or K594 Input Cable Assembly 5 Connection of the LN 8 Using the K867 Universal Adapter C 6 Connection of the LN 8 Using the K595 Input Cable C 7 Connection of the LN 23 P Using K350 1 C 8 Connection of the LN 25 Across the Arc C 9 Retum to Master TOC Y 4 2 8 5 4 Retum to Master COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y 4 2 8 E 5 3 Retum to Master ACCESSORIES OPTIONS ACCESSORIES The following options accessories are available for your Commander 500 from your local Lincoln Distributor FIELD INSTALLED OPTIONS K802N POWER PLUG KIT Provides a plug for each re
14. Return to Section TOC Return to Master TOC V CIR COM V V CIR_COM SHUT DOWN SOLENOID PULL COIL DRIVE IDLE SOLENOID PULL COIL DRIVE V TO SOLENOID Ds CIR COM HOLD COIL DRIVE Woon ON WELD BOARD 100V TO SHUT DOWN SOLENOID HOLD COIL DRIVE ON PERIPHERAL BOARD V 20V 401 25 amp 75 10V TO BATTERY BD Z5V REFERENCE 402 JS UN 5 405 olo e c S9 o PEN 2 2 e lt Sa x 1 V POW_COM V CIR_COM CIR_COM Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 3 COMMANDER 500 Return to Section Return to Master TOC Return to Section TOC olo o E E 5 8 FRE 0 12 2 e lt 5 3 o o Return to Section Return to Master TOC Return to Master TOC G 13 PC BOARD ASSEMBLY PULL COIL PC BOARD LINCOLN NOTE NOTES NA CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING SECURE P C BOARD ASSEMBLY IN PLACE WITH ITEM 4 2 PLACES N C IDENTIFY COMPLETE ASSEMBLY AND SERI
15. LINCOLN B MAY HAVE WEAK FUEL SOLENOID OR BAD PERIPHERAL PCB CORRECT that problem MAY HAVE ENGINE gt PROBLEMS Did 1 of the WARNING lights come on Y Did engine START Did engine REMAIN running after the 30 second INBHIT timer CORRECT that problem COMMANDER 500 a TROUBLESHOOTING amp REPAIR F 14 START UP AND OCV DIAGNOSTIC CHART 7 2 Upon starting the engine there should be only ONE display illuminated depending on which mode the machine is in The numbers in the display should increase decrease smoothly and in a linear fashion with the rotation of the Control 10K Pot Place the WELDING TERMINALS SW In the REMOTELY CONTROLLED position and place the IDLER SW in the AUTO position After about 12 seconds the engine should go to LOW IDLE Then Go to Engine Return to Section TOC Return to Master TOC Salen place the WELDING TERMINALS SW in the WELD TERMINALS position Engine should go back to HIGH har IDLE for 12 seconds and back to LOW IDLE and remain there With the machine in CV Mode you should have CONTROL PCB MAY CORRECT an OCV range 23 7 25 2V at Min and 75 0 78 0V at Max In CC Mode you should have an OCV range of 77 80V BE BAD that problem This WILL NOT change with the rotation of the Control Pot In TIG Mode you should have an OCV range of
16. LINCOLN B V com NOTES N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF UNLESS OTHERWISE SPECIFIED TOLERANCE THE LINCOLN ELECTRIC CO ON HOLES SIZES PER E 2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS O to heatsink GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 Re 220 381 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED 004 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 0 7 02 3 DIODES 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION f f FRAME CONNECTION gt EARTH GROUND CONNECTION FILENAME M19462 1BA THE LINCOLN ELECTRIC CO 1 CHOPPER 300 AMP CLEVELAND OHIO U S A SUBJECT SCHEMATIC SCALE NONE DR LC DATE 3 26 99 CHK surse 19462 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual COMMANDER 500 at ELECTRICAL DIAGRAM
17. 5 4700 50 10 525020 15 CT37 CAPACITOR SMD CERAMIC 0 022MF 50V 1 525024 75 C138 C139 CAPACITOR SMD TANTALUM A7MF 20V 10 S 825020 178MT 140 5 0 27 50 10 525040 85 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 DIODE SMD DUAL 0 200A 70V UDR CC SOT 525040 25 13 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 DIODE SMD 1A 400V DO 214BA AC 525040 55 033 034 035 036 037 038 D39 D40 D41 D42 D43 D44 D45 D46 D47 D48 DIODE SMD DUAL 0 200A 70V UFR 525049 15 D49 D50 D51 D52 D54 D55 D61 D63 D64 DIODE SMD 0 5A 30V SOD 123 SCHOTTKY 525040 45 056 057 062 DIODE SMD DUAL 0 200A 70V UFR 525049 25 058 059 DIODE SMD 1A 30V SMA SCHOTTKY 525040 35 060 DIODE SMD DUAL 6A 200V DPAK CC ULTRA 525044 55 021 072 ZENER DIODE SMD 3W 18V 5 SMB S25044 3SMT 0730740714 ZENER DIODE SMD 3W 12V 5 SMB 525045 15 IDZ5 DZ6 DZ7 DZ8 DZ9 DZ10 0211 ZENER_DIODE SMD 225mW 12V 5 SOT 23 525044 45 02120213 ZENER DIODE SMD 3W 15V 5 SMB 52504415 0215 ZENER DIODE SMD 3W 5 1V 5 SMB 518248 172 12 524020 8 2 13
18. 2 PLACE DECIMALS IS 03g ON ALL ANGLES IS 5iBF A DEGREE MATERIAL TOLERANCE TO AGREE 3PLACE DECIMALS IS 0 UNLESS OTHERWISE SPECIFIED TOLERANCE olo O o Fle 5 0 PEN 6 8 5 rp o THE LINCOLN ELECTRIC CO NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNEDBY THELINCOLN ELECTRIC CO e g M16100 39 X XX XX VENDOR CODE VCE SAT MAKE PER E1911 VGE TH ENCAPSULATE WITH E1844 1 COAT TEST PER E3846 CH Return to Section TOC Return to Master TOC 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 This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN i LINCOLN machine COMMANDER 500 G 6 ELECTRICAL DIAGRAMS G 8 SCHEMATIC PERIPHERAL PC BOARD AMP CONTACTOR_CONTROL R159 511
19. 8 9 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 32 F 32 TROUBLESHOOTING amp REPAIR FLASHING AND ROTOR VOLTAGE TEST CONTINUED FIGURE F 11 PLUG P J52 LOCATION PLUG P J52 07009 SS FILTER CAPACITOR FIELD DIODE RECTIFIER BRIDGE PLUG P J52 9 Ho 11 12 13 141506 1 1 2 3 4 5 6 7 8 LEAD 200 gt LEAD 201A TEST PROCEDURE Using the 3 8 wrench remove the sheet metal screws from the right front case side Carefully remove the right case side Set the volt ohmmeter to the DC volts position Locate Plug P J52 and leads 200A and 201A See Figure F 11 NOTE Cut any cable ties necessary to perform the test DO NOT UNPLUG PLUG P J52 5 COMMANDER 500 LINCOLN Connect the positive meter probe to lead 200A and the negative meter probe to lead 201A Start the engine and run it at high idle speed 1900 RPM Check the voltage reading on the meter t should read approximately 16 VDC Return to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 33 F 33 TROUBLESHOOTING amp REPAIR
20. 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 58 TROUBLESHOOTING amp REPAIR SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will aid the technician in the removal and replacement of the shutdown solenoid MATERIALS NEEDED 7 16 Wrench Long slot head screwdriver Needle nose pliers This procedure should take approximately 30 minutes to perform COMMANDER 500 LINCOLN F 58 59 59 TROUBLESHOOTING amp REPAIR SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT CONTINUED FIGURE F 25 SHUTDOWN SOLENOID LEAD CONNECTIONS Return to Section TOC Retum to Master TOC PULL IN COIL LARGER TERMINALS EACH SIDE 232M AND 265 SHUTDOWN SOLENOID e iv
21. HN pov Dale 1206 237 ask S 5i R343 Aoi THERMAL NA j x da me 5 GND ENGINE E 4 75K N V THERMAL EM 7920 z d LIGHT 01W amp 1 9 33k 3 R68 4 hoov low 100 R72 MULTIARC 01W Me 100 R au ARC FORCI 1 2 5V_REF lt _ 5V_REF y d gt 4 H Rol Fans CONTROL For 13 Vv T m 5 E 30140 01W TPB 392 ohm M 3 ud 5 sv pew E OPENCOER TEMP 1 8wW SM1 4206 ae 475K li j ante 2 c R326 MED R188 fpga 218 A Bax AN 01 TW 70 PM NC 50 RI S D Sov B aD OIW asv S NA Sv 70 NC NC 5 P ue ji T Ta R346 R347 ne d T 01 V FEEDBACK 50 GND 01w 172 172 m Bum m PAGE 4 OF 5 91W 1010 C137 SR NC THERMAL LAMP NE gozz GENERAL INFORMATION LAST NO USED EOTS ai ue O 5 R69 R20 fpga fpga R29 Mn Th ELECTRICAL SYMBOLS PER E1537 R 383 619 amp 766 O SOI TRA SEHE RTS 40V CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED ca He 252 GND 01 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 0 6 cle E DIODES 1A400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET Vino Ws SUPPLY SOURCE POINT E t AT THERMAL_SENSE INDICATES OVER TEMPERATURE THERMAL LAMP ACTUATOR CIRCUIT 57 COMMON CONNECTION FILENAME 5000749 G3660 2 G3900 2C 7 H F
22. 7 Engine OperatlODiz ot cete er 8 Starting lt aad 8 Stopping the ENJINS 3 rete bx EO Re B 8 ir sid B 8 Typical Fuel 8 Welder Operation etii eate cor baa fee Rn d ERA dE deat chia B 9 Stck Welding iet iia hri i eret it ean une n B 9 Pipe Welding m E M B 9 Constant Current CC 4 20440000 B 9 gea rnom B 9 Wire Feed Constant Voltage B 11 Auxiliary Power nnns en ten B 11 Simultaneous Welding and Auxiliary Power B 11 Xem Tm B 11 Fe ANCA SMP 11 Extension Cord 12 500 LINCOLN 8 Section B 1 Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION OPERATING INSTRUCTIONS Read and understand this entire section before operat
23. A 2 INSTALLATION A 2 TECHNICAL SPECIFICATIONS COMMANDER 500 K1639 1 amp 2 Make Model Deutz 3 cylinder F3L 912 Diesel Engine Duty Cycle Welding Range 30 575 Amps CC CV 20 250 Amps TIG Height 42 0 in 1966 8 mm Description 44 HP 33 kw 1800 RPM INPUT DIESEL ENGINE Speed RPM Displacement 173 cu in 2 83 L High Idle 1900 Low Idle 1475 Full Load 1800 Starting Capacities System Fuel 25 gal 94 6 L 12VDC battery amp Starter Bore x Stroke 3 94 4 72 100 120 RATED OUTPUT WELDER Welding Output 500 Amps DC multi purpose 550 Amps DC multi purpose 575 Amps DC multi purpose OUTPUT WELDER AND GENERAT Open Circuit Voltage 80 Max OCV 1900 RPM PHYSICAL DIMENSIONS Width 31 5 in 800 1 mm Depth 63 1 in 1602 7 mm Oil 9 5 Qts 9 0L Volts at Rated Amps 40 Volts 36 Volts 35 Volts OR Auxiliary Power 120 240 VAC 12 000 Watts 60 Hz 100 Duty Cycle Weight 1638 labs 743 kg Approx Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced Top of enclosure Add 8 9 226 1mm for exhaust COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 8 9 8 Return to Section TOC Retum to Master TO
24. N 2 TOOK METER WELD SIGNAL VA aa 1206 01 515 T SUPLLY ON TO AMMETER NA 0022 NA Asy Ky 022 P9 50 NA 18 LSW SMT HI BOTH METERS 3 109 HOLD DISPLAYING ACTUAL 8 9 PRESET 1 21 de al of R52 2 soo NE En Jt xi NA XT 01 A LEFT MOST DECIMAL PT LOV TSK a 006880 406680 12 8 3 gt e d d 5 SV 15 0 B lus TO IDLE HOLD OIL OR MULTIARC FAN NA SCALE 101 TPH 5 NA 01 PA 406680 NA NA 150 15 NA x 50 70 TI a2 6A 5 R153 3 NA NA NA NA XI A NA zm 01 _ y 200v sov CUR_AMP LOOK R115 R197 R228 R243 1 4 REZ gt 13 i M tv 1004 100K 301K 681K 825K NA R234 View 70V 01 01 01 010 P 406680 13 tooo H 200 En VOLTMETER 5 tI t na VOLTMETER_ON 5i GND 5 2 0 SUPPLY ON VOLTMETER jan VA NA BLINKING ate 1208 5 WS glow 0 022 E a L R561 9022 T amp 01 221K 100 A 015 V NA V no 36 OIW pE GND LL ofie 52 gt DM NA 00 06 406680 13 NA 3 090 LEFT MosT DECIMAL PT 400v SA fpga 4 3 5 S egik e R56 6 010 A BA METER_HOLD NA 01 X36 NA NA SCALE 101 50 70 n O O RIS2 1006 NA NA E 21 oci ke V FEEDBACk TOOK 8 R353 R350 EN V ono T NA SS di B ees 5 2 THRESH P pm T pan
25. On masses 3 ze s ss o 9 c sy 2020 B ore 0 e0 PART NO ary IPC BOARD REFERENCE DESIGNATORS DESCRIPTION S25000 28R7SMT R155 R156 R157 R158 R159 R160 RESISTOR SMD METAL FILM 1 10W 28 70HM G3660 C WELD CONTROL BLANK 524671 PLUG KEYING PLUG 525001 10005 R161 R162 R163 R164 R165 R166 RESISTOR SMD 1000HMS 1 4W 1206 1 TR 19436 2 POTTING TRAY 525001 12135 R167 R168R169 RESISTOR SMD 121K 1 4W 1206 195 TR 58025 80 SELF TAPPING SCREW 525000 22115 170 8171 8172 8173 8174 RESISTOR SMD METAL FILM 1 10W 2 21K 1 E2527 EPOXY ENCAPSULATING RESIN 525001 75005 R175 RESISTOR SMD 7500HMS 1 4W 1206 19 TR E3539 g EQ ELECTRICAL INSULATING COMPOUND 525001 20025MT 176 177 8178 RESISTOR SMD 20K 1 4W 1206 1 TR 524762 5 X30 SOFTWARE 525000 33215 R178 R180R181 RT82 R183 RESISTOR SMD METAL FILM 1 10W 3 32K 1 524
26. COMMANDER 500 LINCOLN F 25 F 26 F 26 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST CONTINUED FIGURE F 7 STROBE MARK LOCATION Return to Section TOC Retum to Master TOC Retum to Master TOC 5 5 B 8 ec MARK BLOWER PADDLE HERE ME 8 5 8 TEST PROCEDURE 9 g Strobe tach Method 5 1 227 ps E 2 ight on the bolt head Synchronize it to the 8 1 2 this procedure with the engine rS mark y f mE With the machine at HIGH IDLE the tach a 2 Unlatch lift and 2 s ener engine should read between 1890 and 1910 RPM service access door Perform the Case Cover Removal and Replacement With the machine at LOW IDLE the tach Procedure through Step 9 For Strobe should read between 1450 and 1500 RPM Tach method only 3 With a white or red marking pencil place a mark on one of the blower paddles See Figure F 7 for location 4 Connect the strobe tach according to the manufacturer s instructions Return to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST CONTINUED FIGURE F 8 HIGH IDLE ADJ USTMENT Return to Section TOC Retum to Master TOC LOCKING NUT ADJUSTING SCREW Retum to Master TOC Return to Section TOC 1r S HE 8 8 E cic ADJUSTING COLLAR LOCKING NUT Return to Section TOC Retum to M
27. Not to exceed 50 A per 120 VAC branch circuit when splitting the 240 VAC output EXTENSION CORD RECOMMENDATIONS An extension cord can be used with the auxiliary power outputs as long as it is of ample size Table B 5 lists permissible extension cord lengths based on conduc tor size and auxiliary power output Retum to Master TOC 5 0 B 8 E 8 8 TABLE 5 COMMANDER 500 EXTENSION CORD LENGTH RECOMMENDATIONS 5 Current Voltage Load Maximum Allowable Cord Length in ft m for Conductor Size B 4 Amps Volts Watts 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG 9 gt 15 120 1800 30 9 40 12 75 23 125 38 175 53 300 91 8 8 15 240 3600 60 18 75 23 150 46 225 69 350 107 600 183 E 20 120 2400 30 9 50 15 88 27 138 42 225 69 20 240 48010 60 18 100 30 175 53 275 84 450 137 F D 25 240 6000 90 27 150 46 225 69 250 76 30 240 7200 75 23 120 37 175 53 300 91 38 240 9000 100 30 150 46 250 76 50 240 12000 125 38 200 61 Conductor size is based maximum 2 0 voltage drop Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN 8 Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES SECTION 8 i 550 eee es Section C g Options ACCeSSOrl8S enit tini
28. 8 524020 6 33 510 511 CONNECTOR MOLEXMINI PCB 6 PIN TIN 52402010 435 CONNECTOR MOLEXMINI PCB 10 PIN TIN 524020 2G 8 CONNECTOR MOLEXMINI PCB 2 PIN GOLD 524020 4 37 38 39 CONNECTOR MOLEXMINI PCB 4 PIN TIN 524020 16 12 CONNECTOR MOLEXMINI PCB 16 PIN TIN 515000 228MT OPTOCOUPLER SMD PHOTO TRANSISTOR 70V 525050 15 01 02 03 04 05 26 07 08 09 010 011 012 014 TRANSISTOR SMD NPN 0 5A 40V SOT 23 MM 525050 25 1015 016 017 018 019 020 021 022 TRANSISTOR SMS PNP SOT23 0 5A 40V MM 525051 15 023 TRANSISTOR SMD NMF SOT 223 1 5A 100V 525051 25 024 TRANSISTOR SMD NMF D2PAK 18A 200V IRF 525000 47515 RT R24 R25 R26 R27 R28 R29 R30 R31 R32 R34 R35 R36 R37 R38 R39 R41 R42 R43 R44 R45 R46 R47 R48 R49 R382 RESISTOR SMD METAL FILM 1 10W 4 75K 1 525000 15015 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R17 R63 RESISTOR SMD METAL FILM 1 10W 1 50K 1 525000 47505 R18 R19 R20 R21 R22 R23 RESISTOR SMD METAL FILM 1 10W 4750HMS 525000 10005 R5O R51 R52 R53 R54 R55 R56 R57 R58 R59 R60 R61 R64 R65 R66 R67 R68 R69 R70 R71 R72 R73 RESISTOR SMD METAL FILM 1 10W 1000HMS 525000 82515 R62 R243 R244 R268 R361 IRESISTOR SMD METAL FILM 1 10W 8 25K 1 525001 13018MT RTARISRTG RIT RESISTOR SMD 1 3K 1
29. Retum to Section TOC Retum to Master TOC MATERIALS NEEDED Volt Ohmmeter Analog 3 8 Wrench 7 16 Wrench 3 4 Wrench This procedure should take approximately 45 minutes to perform Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN 8 9 8 Return to Section Y 4 2 3 Retum to Master F 47 F 47 TROUBLESHOOTING amp REPAIR 8 8 E 5 POWER MODULE TEST CONTINUED 9 3 g FIGURE F 21 POWER MODULE CAPACITOR LEADS LEFT SIDE AE i TEMPERATURE SWITCH 17Q POSITIVE STRAP w9 y wio 8 POWER qf SN E DIODE Q ALA LEAD D4 AV POSITIVE STRAP TEST PROCEDURE 1 Turn the engine off 2 Perform the Case Cover Removal proce dure 3 Perform the Power Module Capacitor Discharge procedure 4 Using the 7 16 wrench loosen the nuts on the positive terminals of the power capaci tors Then remove the nuts lock washers and flat washers from the terminals where the positive straps connect to the power module PC board Flip the straps out of the way Also remove diode lead D3 if working on right side power module or D4 if work ing on left side power module See Figure F 21 5 Using the 7 16 wrench remove the flex leads W9 and W10 left side or W7 and W8 right side from the Power Module PC board
30. SZ of y 2 N gt to Section Retum to Master HOLD IN COIL SMALLER TERMINALS IDLER EACH SIDE SOLENOID 224 AND 262 PROCEDURE 1 Turn engine off 2 Unlatch lift and secure the engine access door 1r SB HE 8 8 E cic 3 Locate and remove the four spade connec tors that attach the shutdown solenoid termi nals to the wiring harness leads 224 232M 265 and 262 See Figure F 25 Cut the cable tie Return to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 60 F 60 TROUBLESHOOTING amp REPAIR SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT CONTINUED FIGURE F 26 SHUTDOWN SOLENOID LINKAGE ARM ASSEMBLY PIVOT PIN SPACER PLAIN WASHER zs RETAINING RING 4 Using the 7 16 wrench remove the three nuts two bolts and three lock washers mounting the shutdown solenoid assembly to the engine See Figure F 26 5 Using the long screwdriver and needle nose pliers carefully remove the retaining ring plain washer spacer washer and pivot pin from the linkage arm assembly See Figure F 26 6 Carefully remove the solenoid assembly 7 Replace any faulty parts and reassemble the solenoid assembly y X MOUNTING FASTENERS
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32. 15 16 17 COMMANDER 500 LINCOLN W6 o W1 W2 o W3 W4 o W5 Replace any shorted or open diode as the tests indicate See the Diode Removal and Replacement Procedure Replace the pigtails and stator leads onto the correct studs Assemble the washers and nuts Replace the lower front panel and output leads Replace the upper control panel and secure Replace the front left and right case sides 46 F 46 TROUBLESHOOTING amp REPAIR POWER MODULE TEST WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum to Master TOC 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the power modules are shorted This is a resistance test not a voltage test This test will only help diagnose a problem in the power section of the module Other PC board components could be faulty
33. Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION Table 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 94 gallons hour 12 9 Output 500 7 34 liters hour Amps 40 Volts Auxiliary Power 1 31 gallons hour 19 1 12 000 VA 4 96 liters hour WELDER OPERATION STICK WELDING The Commander 500 can be used with a broad range of DC stick electrodes The WELD MODE switch provides five overlapping slope controlled current ranges The OUTPUT adjusts the current from minimum to maximum within each range Voltage is also controlled by the OUTPUT in the slope controlled setting These slope controlled set tings are intended for out of position welding includ ing pipe welding where the operator would like to con trol the current level by changing the arc length PIPE WELDING The Commander 500 is equipped with special circuitry to minimize pop outs in the five slope modes at any open circuit voltage For a soft arc characteristic set the WELD MODE switch to the lowest setting that still provides the cur rent you need and set the OUTPUT near maximum For example to obtain 140 amps and a soft arc set the WELD
34. for the items listed below Follow either the hourly or the calendar intervals whichever come first More fre quent service may be required depending on your spe cific application and operating conditions OIL Check the oil level after every 8 hours of operation or daily BE SURE TO MAINTAIN THE OIL LEVEL Change the oil the first time between 25 and 50 hours of operation Then under normal operating conditions change the oil as specified in Table D 1 If the engine is operated under heavy load or in high ambient tem peratures change the oil more frequently CHANGE THE OIL Change the oil while the engine is still warm as follows 1 Drain the oil from the drain plug located on the engine bottom as shown in Figure D 1 Examine the washer and replace it if it appears damaged 2 Replace the plug and washer and tighten firmly 3 Remove the oil fill cap and add oil until the level reaches the MAX mark on the dipstick See Use high quality oil viscosity grade 10W40 Consult the engine manual for oil specifi cations for various ambient temperatures Always check the level with the dipstick before adding more oil 4 Reinstall the oil fill cap and the dipstick COMMANDER 500 LINCOLN 8 Return to Section Return to Section TOC 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 E 5 3 Retum to Master MAINTENANCE FIGURE D
35. no TO AMMETER INPUT n id 10 Veh 3 cNTVoLT 1 172 1 909 NA R54 9 47 05A 100 6l TRIG our 2 t ES aA z AMMETER IN SA E amp 010 bl eser 81 ZV NA 5 54 iv R337 R352 E ay 70 i NA 024 gt 109 133 TPG NA gs 18 o Vio 01v 7353 gt VOLTMETER GND HI LOW IDLE ov 115 ND 100 xx NA PRESET XTT iW 5 mae 014 19 0 022 o o TO VOLTMETER INPUT J5 e a VOLTMETER IN fpga 05 35V 50V PRESET LEVEL INPU i A 9 RSS 9 NA 5 FAN OR LOW IOLE 575 40V PRESET NA p 83 1 5 V RIGHT MOST DECIMAL 044 c 17 ao NA VOLTMETER IN NA 5 UN 212 E 4066BD E PR 7 DECIMAL PT COMMON 15V 5 VMETER PSET MODE tov fI in Plug jaw w E ays preset NA METER INTERFACE CIRCUIT NOCTMETER pos eNO w BLINKING LEFT DECIMAL PT DURING HOLD E 01 R190 K gt EA GAVA aN 40V vA NA 2 METER PRESET CIRCUIT R370 SERIAL DATA MAX_POT END_PT ofi 4 A RI TTK gt NA 1V 1000A 100V s 50V 8 221 E iw Zi z TK 4 406680 x DA cin S MAX POT PRESET LEVEL PAS 10 T 252 pga 2 xz SN MAX PRESET ENABLE fpga gt 1 HI SETPOINT s i LO POT 15 AT MAX POT EET ij TM m NA CS_LIMITS TS 1000 DISPLAY M
36. 12 INS STUD NY AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO U SA QUIPMENT TYPE COM CONTROL COMMANDER 300 amp 500 re MACHINE SCHEMATIC bue emos sce Nove 1 22 99 DRAWNGNo G 3834 COMMANDER 500 G 4 60ETT 1 82 JILVWSHIS 8 11 8 3arans 251 NOLLJ3NNOJ GNNOYS HlHV3 IOLLO23NNO2 C NOLL23NNO2 NOWWOI A LNIOd 24005 ATddNS H3MOd LAN 30v170 ATadNS Y ELECTRICAL DIAGRAMS 931319345 3SIM43 031519345 ASIMYSHLO SSJINN 50890 915 Q3HSI T8nd 31925 SONVYS TOL WIYSLYW S OTHO ON amp 13A312 I 3719NV TY NO 209 OIHIJ3 19 N IOONT 1 AHL ld 53215 S3 10H NO 02 21919373 102 11 JHL TIT 60 111 3J3dS ASIMYSH1O SSA INN 30 NOISSIAH3d SS3HdX3 LNOHLIM ISN GISO7NSIG 38 01 702 318123 13 N IOONET 3 1 NOTLYWHOANT 0 SNIVINOO 132HS SIHI 1002 NOWNOS 9 9NIAVH S IOHINOJ 20 AYLINDYID HO SIN3NOdWOJ 12VX3 JH1 MOHS LON AVW WeHOVIO 08908 313 14402 9 30 ALT TISU3ONVHOH3INI 9NIL234343V 100HLIA 39NVH2 AVW 04908 1112412 Q31NIBd Y NO AHLIDOSIO YO SINSNOdWOO SONIS AQOT VT SAGOIG swyg 590151539 031519345 ASIMYSHLO 55371 NOILJWYOJNI 1953339 59 3SN3S 9NIDHVH3 AH311V8
37. 175 10V REF 30V 100 S 10 0 ZIK R140 iw 1 TOOK R239 21 2 XTE R207 2 DET TK vrer f cle xs5 A gt 8125 1 3 our e 8215 Hu x 2L 240 10 0K R171 1 z ow X8 E A out 415 3 01W pgzorapy 8 2 23K 08 4 AVE CURRENT BUFFER 023 MU iW IW R292 USE WSC 1 B 15 t 520 i Wu 8208 Rio 5 x5 y RIA el 100v 01 B SOFT START GND Z ETT TO CHOPPER MODULES 7 E 1 014 TIGLIMIT Sst 3 100K xs 8 R206 DES ED M az cas im 52 1 toga 3 4 i 016 01 a7 9 iW x 6 THK amp 75 00182501 tim 8246 2 105 AW LL E267 50 50 330230W A 2100 Em 01 02 0022 775 REF2 2 Le m ay 8 009 Ts 2 d jow 8 HI DISABLED D R168 1 9212 R180 is lt TZIK TO AMPHENOL x10 IK 33K MIN CUR DISABLE a REMOTE 5 01W 01W 5 b 50 tios 3 0710 100 2 023 1 06680 8 d 18 L 120 R248 4 K 12V Ls 12V Orr iva X19 0 0022 S 475 ES 175 02250 Ld 5 al 200 PED 77010 GND 1 2 iw 5 GND lt 01 825 TPC NV GND 406680 12 SVA amp 75 _ EWPIPEENARLE PWM_ENABLE fpga 7 tpg g e LO ENABLED Dy HI ON 3 ony LO CV without PINCH POT STICK PIPE REF2
38. 2 E SENSOR OIL TEMP SENSOR amp SWITCH O o v z 2 tc o G 2 5 o 2 5 AMPHENOL 2 3 MACHINE SELECT PCB4 STUD ON ENGINE LEFT SIDE MOUNTING FOOT RIGHT SIDE 403 2628 224A 2 WELD BOARD Dr PCB3 M N 7 CONTROL POT ALTERNATOR 232P 04 405 ag 277 257 256 238 PULL COIL BD 239 GROUNDING BOLT ON ENGINE BLOCK PCB8 FRAME GND STUD ONRIGHTSIDE ENGINE GROUND BACK OF CONTROL BOX PROGRAMMING 00000009 1 20 2 Ja 1 J HOT START PINCH MISC CONTROL 63777 Return to Section Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine 3 COMMANDER 500 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo o E E 5 8 ols 0 12 2
39. 3 2 o R euo3anuro 1 Lia 8 00 1092 pem XD tt A n loiw FIXED_HOT START 3 SAL 2 z 2 B CUR_LIMIT 30740 m gt AUX CUR SENSE x or i A22 food 100 Dale 1210 TOE _ 8403ARUL0 CUR_AMP ole 1210 E R154 zl 1 38 Sov Bee p a ie 60 R106 R204 st 30740 m 200 AUS 029 40v TZIK 30IK e J 732K 9 R329 R23 400v 400v Es paw WM amp d 32K 700 S 221K 30 8T 1 cas 010 07 START ENABLED S took R238 RT tpga R333 i ET PONT 01 721K 137 TY 581 TOROID 016 7013 50 iW OIW CUR_SENSE CONNECTION REFZ Y B sque CURRENT iz R32 0 022 81200 V 902 Bw 04 fpga 240 GND R332 HOT START ENABLE 200 015 v 212 C26 m 3 GND 5 150 19 T aa oe Va o LOO 5 jo1w 200 sov S zzi amp o1w p CUR_AMP AVERAGE CURRENT DELAY mum Ansv 12 R222 R320 RIGG IK GR a 0D 8330 n o FROM CURRENT AMP 01 014 Ew 13 0 70 SL 058 a 22 u 16 1 2 2 2 v 70V 70 o gt LOGIC LO AT AUX_CUR_SENSE INDICATES CURRENT ENGINE MUST GO TO HIGH IDLE 12 o o 1 1008 14 0 V 01 106680 cic I rSv THERMAL SENSE CIRCUIT IN hs ARC FORCE SENSE CIRCUIT Aus 1KHZ OSCILLATOR BOTH 1 4W 1206 COMMON 3lZ
40. REASSEMBLY 1 COMMANDER 500 LINCOLN Using the long screw driver and needle nose pliers carefully assemble the retaining ring plain washer spacer washer and pivot pin to the to the linkage arm assembly See Figure F 26 Using the 7 16 wrench mount the shut down solenoid assembly to the engine with three nuts two bolts and three lock wash ers Attach the four spade connectors from the wiring harness leads 224 232M 265 and 4262 to the shutdown solenoid termi nals See Figure F 25 Replace the cable tie Close the engine access door Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 61 TROUBLESHOOTING amp REPAIR POWER MODULE OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual 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 trou blesho
41. Using the 1 2 wrench remove the flat strap to the negative output terminal Pull the strap through the power module top bracket With the 7 16 socket wrench remove the four nuts lock washers flat washers and carriage bolts that hold the power module bottom bracket to the machine base module output rectifier bridge assembly can now be removed and set to the side REPLACEMENT PROCEDURE 1 2 3 Place the assembly back into the machine Install the four carriage bolts flat washers lock washers and nuts that hold the bottom bracket to the machine base Pull the flat negative output strap through the top bracket and attach it 11 COMMANDER 500 LINCOLN Feed the stator W leads through the top bracket and attach them to the terminals on the glastic insulator bracket Pass choke lead W11 through the toroid and connect it to the shunt Connect plug assemblies P J50 and P J51 to the power module PC board both sides Connect the power module capacitor leads Torque the capacitor nuts to 50 60 inch pounds Replace any cable ties cut during removal Install the output panel Connect the ground wire to the output panel assembly if removed Attach the front left and right side panels and the front control panel F 66 F 66 TROUBLESHOOTING amp REPAIR POWER MODULE CHOPPER PC BOARD DIODE MODULE REMOVAL AND REPLACEMENT WARNING Service and repair shoul
42. Weld Control PC Board Sheet 2 G 15 Schematic Weld Control PC Board Sheet 3 G 16 Schematic Weld Control PC Board Sheet 4 G 17 Schematic Weld Control PC Board Sheet 5 G 18 PC Board Assembly Weld Control PC Board sse G 19 COMMANDER 500 LINCOLN 5 G 1 6 2 ELECTRICAL DIAGRAMS me WIRING DIAGRAM COMMANDER 500 EADS 3 amp PASS 6 0 0 COMMANDER 500 WIRING DIAGRAM IN OPPOSITE W2 amp w3 A wawe CORBESPQNOING SETTINGS 120V AUXILIARY POWER DIRECTIONS T AS VIEWED FROM THE FRONT BA INSULATED STUD STATOR AUXILIARY WINDINGS 2 2 ON BOTTOM LEFT WELD LEAD TO PASS y i PAN gt OF CONTROL BOX THRU TOROID ONCE D3 HEATSINK i AUXILIARY POWER pe 6 6 T LA NI GND SCREW ON POS i 5 5 CONTROL PANEL OLDER MACHINES MAY BE x WIRED AS SHOWN Return to Master TOC Return to Section TOC D1 DIODE MODULE Br SELECTOR SWITCH SELECTOR SWITCH MEWED FROM REAR 400 5 SOMV HEAT SINK CONN VIEWED FROM REAR WELD LEAD we LEFTSIDE 55 SILVER j Or gra J12 L1 CHOKE POS MODULE J C SS y 21 09 215 AUXILIARY NEUTRAL STUD 4 94 d STATOR p 10 BACK OF CONTROL O 2 0 213 BOX LEFT SIDE HOT GOLDS wa WINDINGS Aem ND
43. a Open the engine compartment door b Locate the two access holes on the upper mid dle region of the compartment wall just below the lift bale c Use the lifting strap to raise the lift bale to the full upright position This will align the mount ing holes on the lift bale with the access holes d Secure the lift bale with 2 thread forming screws The screws are provided in the loose parts bag shipped with the machine A WARNING WR FALLING EQUIPMENT cause injury Do not lift this machine using lift bale if it is equipped with a heavy accessory such as a trailer or gas cylinder Lift only with equipment of adequate lift ing capacity Be sure machine is stable when lifting HIGH ALTITUDE OPERATION At higher altitudes output derating may be necessary For maximum rating derate the welder output 596 for every 300 meters 984 ft above 1500 meters 4920 ft For output of 500A and below derate the welder output 596 for every 300 meters 984 ft above 2100 meters 6888 ft Contact a Deutz Service Representative for any engine adjustments that may be required HIGH TEMPERATURE OPERATION At temperatures above 30 C 86 F output voltage derating is necessary For maximum output current rat ings derate the welder voltage rating two volts for every 10 C 21 F above 30 C 86 F TOWING The recommended trailer for use with this equipment for road in plant and yard towing by
44. a 500 01wW MIN POT SENSE 22 8 02 m I R128 30740 5 5V_REF Y R369 10K mE s THK ow NA ent Em NA 1W 0715 8 RIT 01 SN Mes m 681K al 2 L03ARUL0 A F 4510 B na Bg m NA 3 HI DISPLAY MIN PRESET EI 9 21 8 3x 121 BOT d i SETBOINT MIN PRESET ENABLE fpga gt BW 14 SETPOINT WIPER SCALE 52 9 i wy m 4 t H fun 1 2 5 3 Me took E nm 5 TB low 4 3 lt NB Em 11 MIN_POT_END_PT 1V 1000 100V IX PAGE 5 OF 5 x5 1 2 1g403ARULO 256 ho 406680 2 m B BIT RES SHAD M MIN POT PRESET LEVEL NA 15V COM SV REF mm GENERAL INFORMATION o 0 m Se NA m NA T 15 dd gt ELECTRICAL SYMBOLS PER E1537 10 NA E NB 10 0K CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED 55 100 a 7 7 lt 01 2 01 45V gt s gt 1OV REF RESISTORS Ohms 0805 UNLESS OTHERWISE SPECIFIED LABELS ke ad PROGRAMMABLE Pa 54 1 COM COM gt DIODES 2A 200V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET LO 1 S TPUINT SCALE RESISTOR FOR 10 1 SETPOINT SCALE SETPOINT SCALING gt _ gt POWER SUPPLY SOURCE POINT 9 GND 5 COMMON CONNECTION pm o wy us FILENAME 5000749 G3660 2 63900 2C 7 FRAME CONNECTION THIS SHEET CONTAINS PROPRIET
45. 2 2 O O 42 o 9 c 2 9 19 PC BOARD ASSEMBLY WELD CONTROL BOARD ELECTRICAL DIAGRAMS E Jo w HQOOO R249 00000 god Hoo ood 7 05 039 064 Inn os NISI oss o6 on je cele HUI ero d e eye 2 5 D4 R380 x56 x24 RBS RB9 8766 051 Inr ge qur Ries L 1 RES 95 IRIS U L xy x7 on un tel x22 e e GEJ e imc R561 7 L l L L ohar RO ile eF 09 576 225 e 076 ss x40 1 x 04 eal me L C L V uau e xli Mr cuz I ejt xn 023 x35 x34
46. DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES DISCONNECT AND SERVICE 50AMP GROUND OVERCURRENT PROTECTION 240 VOLT DOUBLE POLE CIRCUIT BREAKER 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 240 VOLT 1 N 50 AMP 120 240 VOLT Pb a NN NOTE No 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS COMMANDER 500 LINCOLN 8 Retum to Master Retum to Master TOC Y 4 2 8 E 5 4 Retum to Master Section B 1 TABLE OF CONTENTS OPERATION SECTION jer mM Section B Operating Instt ctlohns dpa tita Pepe RE Fue EC RE ex brevia Pad B 2 6 NE alee 2 General Tegel 2 Recommended Applications 2 010100 a aN 3 Design Features and Advantages B 3 Welding Capability cota 4 Controls and Settings B 4 Engirie Controls uiui rui att 5 Welder Control S E B 6 Auxiliary Power Controls sisiring
47. terminals 6 Using the 7 16 wrench remove the nega tive jumper strap attaching the power capac itors to the Power Module PC board NOTE Make sure the bolts do not fall back against the heat sink COMMANDER 500 LINCOLN Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 48 F 48 TROUBLESHOOTING amp REPAIR POWER MODULE TEST CONTINUED FIGURE F 22 IGBT TEST Q HEAT SINK POSITIVE 4 CAPACITOR TERMINAL 5 5 Check IGBT For Shorts 7 Using the analog ohmmeter connect the 8 Reverse the meter probe leads The resis positive meter probe to the heat sink and the tance should be very high over 50 000 negative meter probe to the positive capaci ohms It the resistance is low in either Step tor terminal on the Power Module PC board 7 or 8 the IGBT may be shorted or leaky See Figure F 22 The resistance reading should be high over 20 000 ohms COMMANDER 500 LINCOLN F 49 F 49 TROUBLESHOOTING amp REPAIR POWER MODULE TEST CONTINUED FIGURE F 23 DIODE MODULE TEST Return to Section TOC Retum to Master TOC Q HEAT SINK DIODE MODULE TERMINALS C NS Return to Section TOC Retum to Master TOC Check Diode Module When all tests are complete 9 U
48. to Max 10 within each range Constant Voltage Output for MIG WIRE or CORED WIRE Welding 1 Range Setting 14 to 40 Volts Provides Fine Voltage Adjustment 1 If the WELD MODE switch is positioned between settings the pre vious setting is maintained until the switch is properly positioned on a setting OUTPUT also controls O C V while in the 5 sloped output ranges COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION 12 6 PINCONNECTOR 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 For positive polarity welding the electrode cable con nects to the terminal and the work cable connects to this terminal For negative polarity welding the work cable connects to the terminal and the elec trode cable connects to this terminal AUXILIARY POWER CONTROLS Items 14 through 18 14 120 240 RECEPTACLE This is a 120 240VAC 14 50R receptacle that provides 240VAC Or it can be split for 120VAC sin gle phase auxiliary power This receptacle has a 50 amp rating Refer to AUXILIARY P
49. x50 10V_REF 1 HI TG REF2 n e m RE25 T le fo X51 B FIXED MIN ENABLE 1 R163
50. EQUIPMENT TYPE COMMON ANALOG CONTROL 11400 or ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED 57 ONS PLAGE DEGAS 0 1 EET SUBECT WELD CONTROL PCB ASSEMBLY pee 5 DATE 1 27 2000 DRAWINGNo G 3660 2 Return to Section Return to Master TOC 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 This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine COMMANDER 500 LINCOLN amp ELECTRIC Return to Section Return to Section TOC Retum to Master TOC 5 8 9 8 Return to Section Retum to Master TOC Y 4 2 5 3 Retum to Master SVM ERROR REPORTING FORM We need to know if there are errors in our manuals We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you If you discover new or different Problems or Symptoms that are not covered in the three col umn troubleshooting chart please
51. MODE switch to the 150 MAX position and then adjust the OUTPUT for 140 amps When forceful digging arc is required use a higher setting and lower the open circuit voltage For example to obtain 140 amps and a forceful arc set the WELD MODE to the 250 MAX position and then adjust the OUTPUT to get 140 amps CONSTANT CURRENT CC WELDING In the CC STICK position of 30 to 575 the WELD MODE switch is designed for horizontal welds with all types of electrodes especially low hydrogen The OUTPUT adjusts the full range of 30 to 575 amps This setting provides a soft constant current arc If a more forceful arc is desired select the proper range from the slope controlled current ranges In the CC mode sticking can be prevented by adjust ing the ARC CONTROL Turning this control clockwise increases the short circuit current thus preventing sticking This is another way of increasing arc force TIG WELDING The furthest position clockwise of the WELD MODE switch is for TIG welding in the range of 20 amps to 250 amps with a Touch Start feature To initiate a weld the OUTPUT is first set to the desired current and the tungsten is touched to the work During the time the tungsten is touching the work there is very little voltage or current and in general no tungsten contamination Then the tungsten is gently lifted off the work in a rock ing motion which establishes the arc The Commander 500 can be used in a wide var
52. MODULATION is used to describe how much time is devoted to conduction in the cycle Changing the pulse width is known as MODU LATION 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 MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during a cycle The top drawing shows the minimum output sig nal possible over a 50 microsecond time period 50 usec Dwell or Off Ss The positive portion of the signal represents one IGBT group conducting for 2 microsecond The dwell time off time is 48 microseconds Since only 2 microseconds of the 50 microsecond time period is devoted to conduct ing the output power is minimized MAXIMUM OUTPUT By holding the gate signals on for 48 microseconds and allowing only 2 microseconds of dwell time off time during the 50 microsecond cycle the output is maxi mized The darkened area under the top curve can be compared to the area under the bottom curve The more darkened area under the curve the more power is present COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Return to Section TOC to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC THEORY OF OPERATION CHOPPER TECHNOLOGY FUNDAMENTALS The new era of welding machines such as the Co
53. ON 63900 2C4 VERSIONS AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO DESIGNED BY FC SS AM o gt NB COMPONENTS NOT INSERTED ON 83660 2 VERSIONS AND NOTES INSERTED ON G3660 2C4 VERSIONS UNLESS OTHERWISE SPECIFIED TOLERANCE Ch gesSht No THE LINCOLN ELECTRIC CO ANALOG WELD CONTROL EI 2C ON HOLES SIZES PER E 2056 NOT ASERTE nearer aoe VERSION ON 2 PLACE DECIMALS I5 02 XA CLEVELAND OHIO U S A POWER CONNECTIONS ECT 51 COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE ON PLACE DECIMALS IS 002 7 1 2000 03 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES IS 5 OF A DEGREE rot SCA NONE SHT amp NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE MATERIAL TOLERANCE t TO AGREE DR FC pate 10 12 2000 SUP S D G No G3661 2C4 3 5 NUMBER WITH PUBLISHED STANDARDS D NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 59 ELECTRIC COMMANDER 500 a ELECTRICAL DIAGRAMS did SCHEMATIC WELD CONTROL PC BOARD SHEET 4
54. POWER amp TRIGGER CURRENT 260A 0129 FROM LN25 TO 261A 12 10 ACTIVATE IDLER 232D 232T amp 232W MULTI LEAD mae 232W 112 14 2325 0 WHEN ON 996 42 15 IDLERAOLD COIL 56 J13 7 X7 omo g 25 23 012 1122 WELD CONTROL PC BOARD J4 1 THRU 10 J5 1 THRU 10 M1 THRU M10 M1 THRU M10 a gt v A 42 3 0124 013 3 405A 013 1 115A 15V 13 2 t01A COM 13 4 116A 19V 3 5 tt a 15 TO GND We e Fal 9 IDLER SWITCH uos ais TO AMPHENOL WELD TERMINALS SWITCH ov 2s 241 213 o cv 22246 59 90A PIPE 02 3 215 o 150 OUTPUT 24 21 o 250APIPE SELECTOR 25521 50 350A PIPE SWITCH 2 6 218 500A PIPE 02 7 220 o Ti 128 222 911 5 250 THERMOSTATS ON 249 CHOPPER MODULES NORMALLY CLOSED 11 4 254 we 9 J11 6 2532 012 12 404 lt gt NOTE This diagram is for reference only ENGINE ALTERNATOR p J 17 1423 18 428 15 42 1 16 42 6 42 2 115A 042 5 101A 42 7 116A 042 9 118 42 10 ANALOG POWER PC BOARD 510424 i3 441 1 14 412 M y 42VOLT AC WIRE FEEDER ROTOR FIELD POWER SLIP RINGS
55. SILVER BYPASS i 5 L FILTER HEAT SINK CONN HOT GOLD ASSEMBLY D2 DIODE MODULE PC BOARD TO 1 08 HEAT SINK CONN RIGHT SIDE 1 2008 gt 2 MODULE SX J 1199 201 200A 31 74 A emus 208A POWER MODULE 200 E 6D POWER SUPPLY E 200E J PCB2 300V 200C IOTE ON SOME MACHINES LEADS bm ROTOR pes Een amp 6F SH amp SP MAY BE CONNECT SWITCH SHOWN IN D POSITIVE POLARITY 201A D OUTSIDE THE SPS INLINE POSITION POSITIVE BRUSH CONNECTED TO SLIP RING NEAREST 241A TO THE LAMINATION 201B T 5H POLARITY mes ENGINE HARNESS SWITCH 21 226 200 097 232T 224A 234A 233A wuLTHLEAD s 239A 2320 Return to Section TOC Return to Master TOC 32W WELDING TERMINALS OUTPUT CONTROL SWITCH IDLER CONTROL VIEWED SHOWN IN CONTROL 4 IDLER SWITCH MAY NOT ccw gt FROM AWAYE ON POSTION EAR ON SOME MACHINES EAD 256 amp 257 WILL BE nsvac Ri BACK 2 4 i JONNECTED TOGETHER AND VIEWED IDLE WILL BE DISABLED ON 42VA
56. STATOR PULL COIL BOARD AND PERIPHERAL BOARD ENGINE PROTECTION COMMANDER 500 WORK THREE PHASE TERMINAL RECTIFIER TO WELD CONTROL BOARD ELECTRODE TERMINAL gt MECHANICAL ROTATION ENGINE STARTER CONTROL VOLTMETER AMMETER ALTERNATOR RUN STOP SWITCH AUXILIARY STATOR S THERMAL ARC OUTPUT PROCESS RANGE CONTROL CONTROL SELECTOR 42 VAC TO 14 AMPHENOL FOR WIRE FEEDER WINDINGS zzooJcro TO WELD CONTROL 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 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 240VAC RECEPTACLE 120VAC RECEPTACLES 2 battery voltage is fed through
57. TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TEST CONTINUED FIGURE F 16 OUTPUT RECTIFIER DIODE BRIDGE Return to Section TOC Retum to Master TOC W6 o W1 W2 o W3 W4 o W5 WELD WINDING LEAD CONNECTIONS Q Ji 510 2 8 8 AE E 74 4 Locate the weld winding leads connected to 8 If the tests Steps 6 and 7 OK and the the three phase output rectifier diode bridge stator voltages are low or missing the stator See Figure F 16 may be faulty 5 Check for approximately 68VAC from W1 to 9 Replace the lower front panel and output We Also check from W3 to W4 and from leads W5 to W6 10 Replace the upper control panel and 6 If any of these voltages are low or missing secure Tos 11 Replace the front left and right case sides 7 Also check leads 6F and 5P for loose or faulty connections to the field bridge See the Wiring Diagram Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN F 39 F 39 TROUBLESHOOTING amp REPAIR ANALOG POWER SUPPLY PC BOARD VOLTAGE TEST WARNING 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 For your safety
58. a vehicle is Lincoln s K953 1 If the user adapts non Lincoln trail er he must assume responsibility that the method of attachment and usage does not result in a safety haz ard nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of the trailer vs weight of the Lincoln equipment and likely additional attach ments 2 Proper support of and attachment to the base of the welding equipment so that there will be no undue stress to the trailer s framework 3 Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself 4 Typical conditions of use such as travel speed roughness of surface on which the trailer will be operated and environmental conditions Proper preventative maintenance of the trailer 6 Conformance with federal state and local laws Consult applicable federal state and local laws regarding specific requirements for use on public high Ways COMMANDER 500 LINCOLN 8 Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION PRE OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc tions supplied with this machine WARNING Keep hands away from the engine muf fler or HOT engine
59. anything to the 6 pin connector WELDING TERMINALS The Commander is equipped with a toggle switch for selecting hot welding terminals when in the WELD TERMINALS ON position or cold welding terminals when in the WELDING TERMINALS REMOTELY CONTROLLED position COMMANDER 500 LINCOLN 8 Return to Section Return to Section TOC 8 9 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION 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 Listed in Table A 1 are copper cable sizes recommend ed for the rated current and duty cycle Lengths stipu lated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop TABLE 1 COMBINED LENGTH ELECTRODE AND WORK CABLES Total Combined Length of Electrode and Work Cables Amps 100 Duty Cycle Up to 150 ft 150 200 ft 200 250 ft 500 3 0 AWG 3 0 AWG 4 0 AWG MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless
60. auxiliary power The engine operates nor mally Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check the brushes for wear and proper contact to the rotor slip rings Make sure the engine is operat ing at the correct high idle speed 1900RPM Check for loose or faulty con nections or leads on the auxil iary power studs in the control box See the Wiring Diagram RECOMMENDED COURSE OF ACTION 1 Perform the Rotor Resistance 2 Perform the If the flashing voltage is not present the Battery PC board or leads 201 or 200 be faulty See the Wiring Diagram Also make sure that lead 5P has continuity zero ohms to ground Check the field diode bridge and capacitor Replace if necessary 4 Perform the Stator Voltage 5 See the Start Up Diagnostic Chart and OCV No auxiliary power at the recepta cles The welding output is normal and the engine operates normally The circuit breakers may be tripped Reset if necessary Check for loose or faulty con nections at the auxiliary recep tacles Check the wiring between the auxiliary receptacles the con nection studs in the control box and the main stator See the Wiring Diagram 2 Perform the Stator Voltage CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely
61. avoid electrical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the shutdown solenoid is capable of functioning when it is ener gized with 12VDC MATERIALS NEEDED External 12VDC supply 30 amps required Wiring Diagram Volt Ohmmeter This procedure should take approximately 30 minutes to perform COMMANDER 500 LINCOLN F 23 Return to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 24 F 24 TROUBLESHOOTING amp REPAIR SHUTDOWN SOLENOID TEST CONTINUED FIGURE F 6 SHUTDOWN SOLENOID LEAD TERMINALS EACH SIDE SHUTDOWN SOLENOID TEST PROCEDURE Turn the engine off Unlatch lift and secure the right side engine service access door Locate and remove the four spade connec tors that attach the shutdown solenoid leads to the wiring harness leads 224 262 232M and 265 See Figure F 6 and the Wiring Diagram Remove any necessary wire wraps Check the pull in coil resistance larger ter
62. charged battery will have a specific gravity of 1 260 Charge the battery if the reading is below 1 215 NOTE Correct the specific gravity reading by adding four gravity points 0 004 for every five degrees the electrolyte temperature is above 80 degrees F 27 degrees C Subtract four gravity points 004 for every five degrees the electrolyte temperature is below 80 degrees F 27 degrees C CHECKING ELECTROLYTE LEVEL If battery cells are low fill them to the neck of the filler hole with dis tilled water and recharge If one cell is low check for leaks CHARGING THE BATTERY The Commander 500 is equipped with a wet charged battery The charging current is automatically regulated when the battery is low after starting the engine to a trickle current when the battery is fully charged When you charge jump replace or otherwise connect battery cables to the battery be sure the polarity is cor rect Improper polarity can damage the charging cir cuit The Commander 500 charging system is NEG ATIVE GROUND The positive battery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable before you attach the charger leads After the battery is charged reconnect the positive bat tery cable first and the negative cable last Failure to do so can result in damage to the internal charger com ponenis Follow the instructions
63. contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 COMMANDER 500 LINCOLN Retum to Section Return to Section TOC 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 6 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine has welding output but no control of output The auxil iary power is normal POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS If a remote control unit is con nected to the machine check the remote control and related cable Check the welding and work cables for loose or faulty con nections TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check the OUTPUT control potentiometer related leads See the Wiring Diagram Check the shunt and associated feedback leads See the Wiring Diagram Check the voltage feedback leads for loose or faulty connec tions See the Wiring Diagram 4 Perform the Power Module The Weld Control PC board may be faulty 5 See the Start Up and Diagnostic Chart The machine has low welding out put and low auxiliary output 1 Check the brushes for wear and proper contact to the slip rings 2 The engine RPM may be low I
64. duty industrial engine It is designed and built for rugged use It is very normal for any engine to use small quantities of oil until the break in is accom plished Check the oil level twice a day during the break in period about 200 running hours CAUTION During break in subject the Commander 500 to heavy loads Avoid long periods running at idle Before stop ping the engine remove all loads and allow the engine to cool several minutes The heavy loading of the engine during break in with in the rating of the machine is recommended to prop erly seat the piston rings and prevent wetstacking Wetstacking is an accumulation of unburned fuel and or lubricant in the form of a set black tar like sub stance in the exhaust pipe The rings are seated and the break in period is complete when there are no longer any signs of wetstacking which should occur within the first 50 to 100 hours of operation CAUTION Using your welder at low amperages with long idle run ning periods during the break in period may result in a glaze forming on the engine cylinder walls and the rings not seating properly No amount of loading will properly seat the pistons rings after they are glazed over TYPICAL FUEL CONSUMPTION Refer to Table B 2 for typical fuel consumption of the Commander 500 engine for various operating scenarios COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8
65. engine off before working inside the machine e Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete If covers or guards are missing from the machine get replacements from a Lincoln Distributor Read the Safety Precautions in the front of this manu al and in the instruction manual for the diesel engine used with your machine before working on the Commander 500 Keep all equipment safety guards covers and devices in position and in good repair Keep your hands hair clothing and tools away from the fans and all other moving parts when starting operating or repairing this machine ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE DAILY a Check the crankcase oil level b Refill the fuel tank to minimize moisture condensa tion in the tank Open the water drain valve located on the bottom of the water separator element one or two turns and allow to drain into a container suitable for diesel fuel for two to three seconds Repeat the above drainage procedure until diesel fuel is detected in the container WEEKLY Blow out the machine with low pressure air periodical ly In particularly dirty locations this may be required once a week A CAUTION To prevent the engine from accidentally starting dis connect the negative battery cable before servicing the engine See Table D 1 for a summary of maintenance intervals
66. for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD 8 8 5 5 TEST DESCRIPTION 9 g This test will determine if the engine alternator and associated circuitry are functioning 9 8 properly EJE E MATERIALS NEEDED 3 8 Wrench Volt Ohmmeter Wiring Diagram This procedure should take approximately 30 minutes to perform Retum to Master TOC 8 9 8 Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 51 239 F 51 TROUBLESHOOTING amp REPAIR CHARGING CIRCUIT TEST CONTINUED FIGURE F 24 ENGINE ALTERNATOR LOCATION Locate the engine alternator 238 TEST PROCEDURE Turn engine off Using the 3 8 wrench remove the left rear case cover See Figure 24 Start the engine and run it at high idle 1900 RPM Set the voltmeter for DC volts and measure the DC volts at lead 239 to engine ground See the Wiring Diagram Normal is 13 2 to 14 5VDC Set the voltmeter for DC volts and measure the DC volts at lead 238 to engine ground See the Wiring Diagram Normal is 13 2 to 14 5VDC 7 Set the voltmeter for DC volts and measure the DC volts at l
67. in damage to the machine COMMANDER 500 ELECTRICAL DIAGRAMS ov SCHEMATIC WELD CONTROL PC BOARD SHEET 1
68. ing your Commander 500 SAFETY INSTRUCTIONS A WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man uals supplied with your machine They include impor tant safety precautions detailed engine starting oper ating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing e Insulate yourself from the work and ground e Always wear dry insulating gloves FUMES AND GASES CAN BE 3 DANGEROUS 0 Keep your head out of fumes E Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS CAN SIS CAUSE FIRE OR EXPLOSION Keep flammable material away not weld on containers that have held combustibles ARC RAYS CAN BURN 4 Wear eye ear and body protection WM ENGINE EXHAUST can kill 3 a Use in open well ventilated areas or vent exhaust outside Do not stack anything near the engine MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts Only qualified personnel should operate this equipment ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and the side panels in place as these provide maxi mum protection from moving parts and insure prope
69. lt 4 T 120VAC AC AUX POWER 240 V AC ROTOR RESISTANCE 25 27 OHMS 120 VAC 120 VOLT AC POWER FOR ROTOR FIELD CIRCUIT 80V DC INPUT POWER 43 11 200 232D 2 20 amp 2 BW INSULATED MULTI 281A J43 3 043 14 271 43 8 270 232 43 5 12 INS STUD 2328 OIL PRES 2324 31 4 5T 31 9 PERIPHERAL PC BOARD 239A 32 8 032 12 732 10 229A 32 6 234A Ho SWI SENSOR TEMPERATURE 5 Erm SWITCH SENSOR FUELLVL SENSOR 32 9 229 SHUT DOWN HOLD COIL 031 5 2244 o D 3 403 J65 3 PULL COIL PC BOARD IDLE SOL 405 J65 5 PULL COIL 401 J65 1 227 B1 BATTERY PC BOARD BATT CHRG METER STUD LEAD RUN STOP SWITCH SHOWN IN RUN POS 2368 32A ENGINE STARTER SOLENOID ENGINE STARTER GROUND 402 65 2 55 B4 265 B3 404 65 4 232N B2 xeu DO NOT SCALE HS DRAWING X INFO It may not be accurate for all machines covered by this manual THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPA Chg Sheet No 031 6 2628 4 9 7 WES Wo 59 2 SHUT DOWN PULL COIL HOUR METER 232R 12 VOLTS FROM THE BATTERY VIA THE RUN STOP SWITCH 23 12 INS STUD C
70. panel output and 208 from their in line connectors panel to the case front assembly Then remove the front two screws holding the top of the panel These are accessed in the control box on the bottom at each side of the box Using the 7 16 wrench discon nect the green ground lead See Figure F 19 Carefully move the lower front panel to the right side Retum to Master TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 45 10 11 12 F 45 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE TEST CONTINUED FIGURE F 20 DIODE LEAD REMOVAL WELD WINDING LEAD CONNECTIONS Using the 7 16 wrench remove the stator leads and diode pigtail leads from the three studs Label the leads for reassembly Note leads and pigtail placement for reassembly See Figure F 20 Electrically isolate the six diode pigtail leads by carefully bending them out into free air With an ohmmeter or diode tester check each of the six diodes from their pigtails to their respective heat sinks Reverse the tester leads and check the diodes again Diodes should have a low resistance in one polarity and a very high resistance in the opposite polarity 13 14
71. share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 St Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below SD287 01 99 LINCOLN P
72. stored energy in the choke when the IGBTs are turned off See Technology in this section Output voltage and current feedback information is fed to the Weld Control PC board This information is sensed from the output terminal circuits and the shunt NOTE Unshaded areas of Block Logic Diagram are the subject of discussion COMMANDER 500 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC THEORY OF OPERATION FIGURE E 4 ANALOG CONTROL POWER SUPPLY BOARD AND WELD CONTROL BOARD COMMANDER 500 MECHANICAL ROTATION ENGINE STARTER WORK THREE PHASE TERMINAL RECTIFIER TO WELD uj CONTROL BOARD POWER MODULES 2 ELECTRODE TERMINAL pad gt CONTROL BOARD VOLTMETER AMMETER ALTERNATOR RUN STOP SWITCH zzoo4dcro PERIPHERAL BOARD ANALOG CONTROL POWER SUPPLY 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 It also supplies two regulated DC voltages to operate the IGBT driver circuitry on the two Power Modules The Weld Control PC board monitors the operator con trols arc control o
73. the 120 VAC or 240 VAC supply not both at the same time ARC GOUGING For optimal performance when arc gouging set the Commander 500 WELD MODE switch to the CC STICK position and the ARC CONTROL to 10 Set the OUTPUT knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table Electrode Current Range Diameter DC electrode positive 1 8 30 60 Amps 5 32 90 150 Amps 3 16 150 200 Amps 1 4 200 400 Amps 5 16 250 400 Amps 3 8 350 575 Amps Maximum current setting is limited to the Commander 500 maximum of 575 Amps PARALLELING When paralleling machines in order to combine their outputs all units must be operated in the CC STICK mode only To achieve this turn the WELD MODE switch to the CC STICK position Operation in other modes may produce erratic outputs and large output imbalances between the units COMMANDER 500 LINCOLN 8 OPERATION 8 8 E m TABLE B 4 COMMANDER 500 SIMULTANEOUS WELDING AND POWER LOADS ij 3 Permissible Permissible Auxiliary 818 Welding Power Watts Current in Amperes Output Range Unity Power Setting Welding Output Factor 9 120 V 10 240 V 10 cic 30 575 500A 40V 0 0 0 500 500A 40V 0 0 0 350 350A 30V 9500 80 40 250 250A 29V 12000 100 50 150 150A 27V 12000 100 50 90 90A 25V 12000 100 50 Each duplex receptacle is limited to 20 amps
74. the machine is connected to premises wiring home shop etc To prevent dangerous electric shock other equipment powered by this engine driven welder must a be grounded to the frame of the welder using a grounded type plug or b be double insulated When this welder is mounted on a truck or trailer its frame must be securely connected to the metal frame of the vehicle When this engine driven welder is con nected to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See further connection instructions in the sec tion entitled Standby Power Connections as well as the article on grounding in the latest U S National Electrical Code and the local code In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints or to the metal framework of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is provided on the front of the welder AUXILIARY POWER RECEPTACLES The auxiliary power capacity of the Commander 500 is 12 000 watts of 60 Hz single phase power The auxil iary power capacity rating in watts is equivalent to volt amperes at unity power factor The maxim
75. the top and bottom of the nuts lock washers and flat washers that 2 alternator shroud together hold the bottom of the shroud to the 6 i Return to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 78 F 78 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT CONTINUED FIGURE F 38 LIFT FRAME AND ASSOCIATED COMPONENT REMOVAL FUEL TANK SUPPORTS LIFT FRAME WELDMENT In steps 20 24 the lift frame weldment fuel tank supports and fan baffle are removed as a unit See Figure F 38 20 Using the 3 8 wrench remove the two 21 bolts at top that hold the center panel to the lift frame weldment Using the 1 2 wrench remove the two bolts at bottom that hold the center panel to the lift frame weldment 22 23 24 COMMANDER 500 LINCOLN CENTER PANEL With the 3 8 wrench remove the nuts lock washers and flat washers from the two studs that hold the fan baffle to the machine base Using the 3 4 wrench remove the four bolts lock washers and nuts from the bot tom of the lift frame weldment Carefully remove the lift frame weldment fuel tank supports and attached fan baffle You will need to lift the fan baffle off the two s
76. the welder NOTE Welding cable must be sized for current and duty cycle of application NOTE Figure 2 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the Commander 500 output terminals 3 Connect the K584 XX or K594 XX Input Cable Assembly to the LN 7 4 Connect the K584 XX or 594 XX input cable assembly to the 14 pin amphenol on the Commander 500 5 Place the IDLER switch in the HIGH position A CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control cir cuits may be damaged The engine governor setting is preset at the factory do not adjust above RPM speci fications listed in this manual 6 Set the VOLTMETER switch to or depend ing on the polarity chosen 7 Set the OUTPUT RANGE switch toWIRE WELD ING CV 7 Set the WELDING TERMINALS switch to WELD ING TERMINALS REMOTELY CONTROLLED 9 Adjust wire feed speed at the LN 7 10 Adjust the ARC CONTROL to the desired level soft or crisp NOTE For remote control a K857 or K857 1 remote control is required Connect it to the 6 pin amphenol FIGURE C 2 COMMANDER 500 LN 7 WITH K584 OR K594 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM OPTIONAL K857 REMOTE CONTROL TO L
77. volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 6 Setthe VOLTMETER switch to or depend ing on the polarity chosen 7 Setthe OUTPUT RANGE switch to WIRE WELD ING CV 8 Setthe WELDING TERMINALS switch to WELD ING TERMINALS REMOTELY CONTROLLED 9 Adjust wire feed speed and voltage at the LN 8 10 Adjust the ARC CONTROL to the desired level soft or crisp FIGURE C 3 COMMANDER 500 LN 8 WITH K867 ADAPTER CONNECTION DIAGRAM 82 LN 8 81 O WIRE FEEDER 14 PIN AMPHENOL ELECTRODE TO WORK f 2 O 2 4 4 21 21 4 K196 K867 UNIVERSAL M ADAPTER PLUG GND GND 4 INPUT CABLE TO WORK M 75 A 76 y ELECTRODE CABLE J TO WIRE FEED UNIT 7T 500 LINCOLN 8 Return to Section Retum to Section TOC 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC g 4 2 3 Retum to Master C 7 C 7 ACCESSORIES CONNECTION OF THE LN 8 TO THE COMMANDER 500 USING K595 INPUT CABLE ASSEMBLY SEE FIGURE C 4 1 Shut the welder off 2 Connect the electrode cable from the LN 8 to the terminal of the welder Connect the work cable to the terminal of the welder NOTE Welding ca
78. volts wire feeder control cir cuits may be damaged The engine governor setting is preset at the factory do not adjust above RPM speci fications listed in this manual 6 Set the VOLTMETER switch to or depend ing on the polarity chosen 7 Set the OUTPUT RANGE switch to WIRE WELD ING CV 8 Set the WELDING TERMINALS switch to WELD ING TERMINAL REMOTELY CONTROLLED 9 Adjust wire feed speed at the LN 7 10 Adjust the ARC CONTROL to the desired level soft or crisp FIGURE C 1 COMMANDER 500 LN 7 WITH K867 ADAPTER CONNECTION DIAGRAM 82 WIRE 42 0 FEEDER 41 _o 32 32 14 PIN 2 2 AMPHENOL 4 4 T 21 21 K867 UNIVERSAL 5 ati kagi OH K404 ADAPTER PLUG GND ABLE GREEN TO WORK M 75 75 76 76 4 O ELECTRODE CABLE C 77 WIRE FEED UNIT K775 OPTIONAL REMOTE CONTROL COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC ACCESSORIES CONNECTION OF THE LN 7 TO THE COMMANDER 500 USING K584 OR K594 INPUT CABLE ASSEMBLY SEE FIGURE C 2 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
79. wraps 10 Close and secure the right side engine ser vice access door COMMANDER 500 LINCOLN Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 25 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST A WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION If the machine output is low or high this test will determine whether the engine is operat ing at the correct speed RPM during both HIGH and LOW idle conditions Directions for adjusting the throttle to the correct RPM are given MATERIALS NEEDED Slot head screw driver 10mm Wrench White or red marking pencil Strobe tach frequency counter or oscilloscope This procedure should take approximately 35 minutes to perform
80. 0 3 8 Von GND TIG SWITCH Re MODE SELECTOR SWITCH AsV FPGA BOOT EEPROM 45V MACHINE SPECIFIC EEPROM PL_SWITCH 150K 010 24763 8 SOFTWARE 524762 5 SOFTWARE pga RS P2_SWITCH 150K 01W R6 P3 SWITCH 150 01W toga i P4_SWITCH 150K 01 DIN qm RB 1570 fuk X93 PS SWITCH 150 01W Bi x20 sm 120 5 pull 1 s 7 8 6 14 2 Ph TED WIRE SWITCH 15 01 O 3 GND l SC Tes RID Ps 2 DATA 4 B 15995 1 3 si vec T50K 01 STICK 1B 17 256 iw so J2 DEFAULT 5 5 2A 3 4 jd C9 ROL R78 7 p TS MEM fpga wW GND 924 275 WIRE CLK Foe 3155 1 50V o R90 RIS 25 O 25128 Fle 135 775 m Rub NC R89 2255 S TTK e 13 1 275 175 A DONE 4 15V 3 51 SIO REB REL 2 8 175 175 SNE sek o gt RET 8g 2 o 175 275 05 55 1 olo R66 R63 2 8 ind 2 5 176 175 gt AN J n NC cic RIS 1 m AN g SNC peser zoe 6 SN sERIAL DATA 5 5 dv R105 AS S SNC pata TZIK g E D a2 1 1 5_ Ge c7 010 10 gk 017 017 017 017 017 01 01 as n a sov sov sov sev sov sov sov mar d Shook scik S as g 50V zl fpga o1
81. 0 22105 R306 R307 RESISTOR SMD METAL FILM 1 10W 2210HMS 525001 15015MT R308 R309 R310 RESISTOR SMD 1 5K 1 4W 1206 1 1R 525000 15035 R316 R317 RESISTOR SMD METAL FILM 1 10W 1 82K 1 525000 10035 R318 R319 RESISTOR SMD METAL FILM 1 10W 10K 196 525001 10015 3238324 RESISTOR SMD 1K 1 4W 1206 1 TR S25000 39R28MT R325 RESISTOR SMD METAL FILM 1 10W 39 20HM 525000 47535 326 R370 RESISTOR SMD METAL FILM 1 10W 475K 1 525002 20005 R327 R328 R329 R330 R331 R332 R333 R334 RESISTOR SMD 2000HMS 1 3W MF 1 1210 S25000 10ROSMT R335 R336 337 R338 RESISTOR SMD METAL FILM 1 10W 10 00HM 525007 24315 R339 RESISTOR SMD PREC MF 1 10W 2 43K 0 1 525007 13015 R340 RESISTOR SMD PREC MF 1 10W 1 30K 0 196 525007 10235 R341 RESISTOR SMD PREC MF 1 10W 102K 0 195 525000 51115 R342 RESISTOR SMD METAL FILM 1 10W 5 11K 1 525001 23705 R343 R344 RESISTOR SMD 2370HMS 1 4W 1206 195 TR 525008 68125 R345 RESISTOR SMD PREC MF 1 10W 68 1K 0 5 525008 15035 R346 RESISTOR SMD PREC MF 1 10W 150K 0 5 525008 12125 R347 RESISTOR SMD PREC MF 1 10W 12 1K 0 5 525000 90915 R348 RESISTOR SMD METAL FILM 1 10W 9 09K 1 525007 68125 R349 R350 RESISTOR SMD P
82. 00 39225 R220 R221 R222 R223 R371 RESISTOR SMD METAL FILM 1 10W 39 2K 1 525000 33235 R224 R225 RESISTOR SMD METAL FILM 1 10W 332K 1 525000 68135 R226 RESISTOR SMD METAL FILM 1 10W 681K 1 525000 88125 R227 R228 IRESISTOR SMD METAL FILM 1 10W 68 1K 1 S25001 76818MT R229 R230 R231 RESISTOR SMD 7 68 1 4W 1206 1 TR 525000 51105 R232 R233 R234 R235 R236 R237 R379 RESISTOR SMD METAL FILM 1 10W 5110HMS 525000 22125 R238 R239 R240 R242 RESISTOR SMD METAL FILM 1 10W 22 1K 1 525020 25 C108 C109 C110 C111 112 113 114 115 116 ICAPACITOR SMD CERAMIIC 0 022MF 50V 10 S25020 5SMT C102 103 104 C 105 106 cto7 CAPACITOR SMD CERAMIC 2700pF 50V 5 X 525024 85 117 2118 CAPACITOR SMD TANTALUM 22MF 16V 109 5 525020 45 cna CAPACITOR SMD CERAMIC 820pF 50V 5 CO 525024 25 120 2121 0122 2123 0124 125 CAPACITOR SMD TANTALUM 1 0MF 35V 10 525020 85 C126 C127 CAPACITOR SMD CERAMIC 0 056MF 50V 10 825020 168MT C128 CAPACITOR SMD CERAMIC 0 018MF 50V 1 525024 15 129 CAPACITOR SMD TANTALUM 0 47MF 50V 10 525024 55 130 0131 132 CAPACITOR SMD TANTALUM 4 7MF 35V 10 525024 35 134 CAPACITOR SMD TANTALUM 2 ZMF 20V 109 525020 105 135 136
83. 01B and 5L J51 This turns the WE der TERM If in all modes and go i CHOPPER off If OCV e voltage goes away to LOW IDLE still exists then Chopper has some No LOW IDLE Check Idle P aig slight leakage Solenoid 3 ohms for PULL shorted or wired wrong C Continue COIL and 21 ohms for CORRECT that problem HOLD COIL and wires 232L amp 227 2328 amp 226A Also check mechanical linkage going to Idle Solenoid OK CORRECT that problem NOTE Under some circumstances the CONTROL PCB can become defective in such a way that it causes the ANALOG POWER SUPPLY APS to stop working and visa versa If you replace the APS it may be suggested to replace the Control PCB too Inspect BOTH boards If you notice any signs of over heated or burnt compo nents on either board replace BOTH boards together IF YOU CHANGE ANY CIR CUIT BOARDS START FROM THE BEGINNING OF THIS TEST ANALOG POWER SUPPLY MY BE BAD CORRECT that problem With the WELDING TER SW in WELD TERM did unit go to HI IDLE back to LO and is there OCV present at WELD TERMINALS No HIGH IDLE Check the WELD E 5 Blo olse 12 2 EJE s p o o CORRECT that problem OK wires 2 amp 4 No OCV Check CORRECT CORRECT ONTROL PCB MAY OK CHOPPER and wires that problem
84. 0G201ADY aL 0 Po 06680 e 406680 406680 e AE ta L din aV 330740 330740 330740 o X 0150 50V oj 8 7 7 E EM att 0425 7 2 cuj css S 0 0 9 v NA 50 NA 01 01 01 01 Van V gt 50 50 50 50 o 18 37 54 73 90 108128144 4 2 4 x1 XCS20 525070 55 GND I c V V V 1 17 27 35 4555 64 71 81 91 100110 116127137 i 5 GND V s D o 4 GND 5 A RANGE END POINT CIRCUIT TO 15V SUPPLY E 332K amp o1w T 01 5 TO 5V SUPPLY 328 Blagg LOVRE SERIAL DATA 018 fpga gt NA a 1215 eg 9 475K cix 15234 10 CLOCK sot 55 eU 17 T pga gt x57 SANH Olo xv x55 uls 023 us 9 Fi CS_END_PT 8L03ARULO TO SUPPLY GND 2 t R 604 0 25 5V_REF 15V_COM f 4 I c L qe X R379 1098 35v R363 En t Scia X S 287 NA g ot 6 iE 5560 is 8 TO 15V SUPPLY 4 4 R361 e TPA amp Ow 2 16 16 16 RESET Vee Sa S NA cuz l d ces e ce xas o gt R364 5 10 0K B sV ou ft T x3 E 2 3 qi Nr VoLT DISCHG s 30V l K amp loiw m 8403ARUL0 ADBGOOAR 8403ARU10 8403ARUL0 5 mE 556D 211175 9 211175 9 211175 9 xas GND o 9 R362 8 100 amp ow d 2K low R365 m 4 LAC N 8403ARULO A Veo Siz R366 V V 2K E GND NA 1215 G
85. 1 OIL DRAIN AND REFILL OIL FILTER DIPSTICK DRAIN PLUG CHANGE THE OIL FILTER 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 See Table D 1 for recommended maintenance intervals See Table D 2 for replacement oil filters Change the oil filter as follows 1 Remove the oil drain plug Drain the oil from the engine and allow the oil filter to drain See Figure D 1 2 Remove the old filter spin it off and discard it Wipe off the filter mounting surface and adapter See Figure D 1 3 Fill the new filter with fresh engine oil Apply a thin coat of new oil to the rubber gasket on the new oil filter 4 Spinthe new filter onto the mounting adapter finger tight until the gasket is evenly seated Then turn it down another 1 2 turn Do not overtighten the new filter m lt MIN OIL FILL CAP 5 Refill the engine with the proper amount and type of oil as described in the Change the Oil section above Start the engine and check for leaks around the filter element Correct any leaks usu ally by retightening the filter but only enough to stop leaks before placing the Commander 500 back in service 6 If there are no leaks stop the engine and rec
86. 1 ANALOG CONTROL POWER SUPPLY PC BOARD VOLTAGE TABLE Test Points Component Tested Voltage Reading 1J42 to 6J42 Chopper Power Supply 20 VDC 3J42 to 8J42 Chopper Power Supply 20 VDC 2J42 to 7J42 Weld Control PC Board Power Supply 5 VDC 5J42 to 7J42 Weld Control PC Board Power Supply 15 VDC 9J42 to 7J42 Weld Control PC Board Power Supply 15 VDC 10J42 to 4J42 Weld Control PC Board Power Supply 15 VDC COMMANDER 500 LINCOLN F 42 F 42 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE TEST WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum to Master TOC 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD Q JE 5 5 TEST DESCRIPTION 9 g This test will determine if there are faulty diodes in the output rectifier bridge HE E g MATERIALS NEEDED Volt Ohmmeter Diode Tester 3 8 Wrench 7 16 Wrench 3 4 Wrench Wiring Diagr
87. 11 0 15 0V at Min and 13 0 17 0V at Max There is no need to check the PIPE OCV Check for short on any STATOR TWO displays Is only ONE display N N y Mad Then NO displays winding Check Check the Amphenols illuminated illuminated are illuminated WELD BRIDGE for Check the CONTROL Insure nothing is shorts POT continuity and plugged into them Also The numbers DO CORRECT continuity of wires 75 check for excessive NOT change that problem 76 amp tracking or corrosion of the Amphenol Y The numbers Are J4 amp 5 Return to Section TOC Return to Master TOC CORRECT Hs iump as you turn Is WELD current D h AUX Did the dec smoothly with the Jump asy L_N Ae plugged gt you have that problem Control Pot rotation N the Control Pot flowing in properly voltage ROTOR flash Does it change The Pot may be bad CORRECT that problem Check BRUSHES Check wires 13 amp 14 BATTERY PCB aA OCV is higher 70V or OCV is between 9 20V With the and wires 200 more Check in all modes If so WELD TER SW in 200B 200C 200A CHOPPER for a short place a LIGHT load REM CONT and IDLER SW V No LOW IDLE Is 200E 201 201A by unplugging J50 amp about 1 4 amp across N in AUTO do you have 0 8V OCV 2 AUX current flowing gt 2
88. 115 VAC AUXILIARY 14 PIN AMPHENOL Ar TO ELECTRODE WORK 9 CONDUCTOR ADAPTER CABLE zc K350 1 LN 23P ADAPTER KIT FEEDER FEEDER Z m ER ELECTRODE WIRE FEEDER A ELECTRODE SANZA WAAL 77 WA UT U f WIRE FEEDER B COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC ACCESSORIES CONNECTION OF THE LN 25 TO THE COMMANDER 500 ACROSS THE ARC SEE FIGURE C 6 1 Shut the welder off 2 Connect the electrode cable from the LN 25 to the terminal of the welder Connect the work cable to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application NOTE Figure C 6 shows the electrode connected for negative polarity To change polarity shut the welder off and reverse the electrode and work cables at the Commander 500 output terminals Reverse the LN 25 polarity switch 3 Attach the single lead from the LN 25 to the work using the spring clip on the end of the lead This is only a sense lead it carries no welding current 4 Place the IDLER switch in the AUTO position CAUTION If you are using an LN 25 without an internal contactor the electrode will be HOT when the Commander 300 is started 5 Set the OUTPUT RANGE switc
89. 24764 3 1 pe SOFTWARE FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS 525020 35 15 C15 C17 C19 C20 C21 C22 SCAP 0 1uF 0805 50V X7R 10 TR NP 28 29 30 31 32 37 40 41 42 C2 C3 C36 C43 C44 C45 C46_ SCAP 0 022uF CER 0805 50V X 7R 10 TR C23 CAP 0 0047 3000V 2096 CERAMIC DISC 24 27 5 4 7 7343 35 10 34 SCAP 100uF TAN 7343 20V 20 TR NP C35 C38 SCAP 47uF TAN 7343 20V 10 c39 SCAP 22uF TAN 7343 25V 10 POLAR TR Di SDIO MURD620CT 6A 200V ULTRA FAST D6 D7 D10 D11 D12 D15 __ SDIO 1A 400V D0 214BA GLS NP D17 D18 D19 D20 D22 072 073 5 10 15 5929 3 3 1 15 5 074 SDIO 15MB5935BT3 3W 27V 5 TR NP DZ5 SDIO 15MB5943BT3 3W 56V 596 SDIO 15MB5932BT3 3W 20V 596 J30 CON MOLEX 39 28 1063 PCB 6 PIN TIN CON MOLEX 15 97 7162 MINI PCB 16 PIN TIN CON MOLEX 15 97 7122 MINI PCB 12 PIN TIN STRA IRF640S 200V D2 PAK STRA 2N4401 S0T 23 NPN TR STRA 2N4403L PNP SOT 23 NP R102 R156 R157 R158 SRES 511 TKF 0805 1 1 10W TR R159 R160 R103 SRES 47 5 0805 1 1 10W R127 SRES 475 TKF 0805 1 1 10W TR 129 8130 8144 SRES 1 21K 0805 196 1 10W TR NP 131 8132 8141 8142 8173 SRES 1 5K TKF 0805 196 1 10W TR R133 R150 SRES 47 5 TKF 1206 1 1 4W R134 SRES 4 32K 2512 1 1W R135 R143 5 5 3 92 2512 1 1 R136 SRES 750 TKF 0805 176 1 10W R145 R146 SRES 221 TKF 0805 1 1 10W TR R162 SRES 200 TKF 0805 1 1 10
90. 2W 1206 196 TR 525001 47505 R78 R79 R80 R81 R82 RBS R84 R85 R86 R87 R88 R89 R90 R91 RESISTOR SMD 4750HMS 1 4W 1206 1 TR 525000 20008MT R92 R93 R94 RZ10 RESISTOR SMD METAL FILM 1 10W 2000HMS 525000 88115 R95 R96 R97 R98 R99 R100 R101 R102 R103 R212 RESISTOR SMD METAL FILM 1 10W 6 81K 1 525000 12125 R105 R106 RESISTOR SMD METAL FILM 1 10W 12 1K 1 525000 10015 R07 RTOBRTOS RTIORTIT R112 R113 R114 R115 R116 R117 R118 R119 R120 R121 R122 R123 R124 R125 R126 R127 R128 R129 R130 R131 R132 R133 R134 R135 R136 R137 R138 R378 RESISTOR SMD METAL FILM 1 10W 10 0K 1 S25000 1001SMT R139 R140 R141 R142 R143 R144 R145 R146 R148 R149 R150 R151 R152 R153 R154 RESISTOR SMD METAL FILM 1 10W 1 00K 1 525000 47525 IR147 R301 R302 R303 R304 RESISTOR SMD METAL FILM 1 10W 47 5K 1 CAUTION this DEVICE 15 SUBJECT TO DAMAGE BY STATIC ELECTRICITY LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING PLACE CONNECTOR KEYING PLUG OVER HEADER PIN IN LOCATION SHOWN PLUG SHOULD BE INSERTED BELOW CONNECTOR TOP SURFACE 6 PLACES SECURE P C BOARD ASSEMBLY IN PLACE WITH ITEM 4 2 PLACES 5 3 5 IN LBS PLACE BARCODED ASSEMBLY NUMBER IDENTIFICATION AND BARCODED SERIAL NUMBER IDENTIFICATION IN AREA SHOWN 525000 43225 241 8320 8321 8322 RESISTOR SMD METAL FILM 1 10W 43 2K 1 S25003 47RSSMT IR245 R246 R2
91. 30 minutes to perform COMMANDER 500 LINCOLN F 21 Return to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 22 TROUBLESHOOTING amp REPAIR IDLER SOLENOID TEST CONTINUED FIGURE F 5 IDLER SOLENOID LEADS SHUTDOWN SOLENOID TEST PROCEDURE Turn the engine off Unlatch lift and secure the right side engine service access door Locate and remove the four spade connec tors that attach the idler solenoid leads to the wiring harness leads 226A 2325 227 and 4232L See Figure F 5 and the Wiring Diagram Remove and necessary wire wraps Check the pull in coil resistance larger ter minals 227 to 2321 The normal resis tance is approximately 0 4 ohms Check the hold in coil resistance smaller terminals 226A to 2325 Normal coil resistance is approximately 20 ohms If either coil resistance is not correct the solenoid may be faulty Replace Using the external 12VDC supply apply 12VDC to the larger idler solenoid terminals 227 to 232L The solenoid should acti vate IDLER SOLENOID PULL IN COIL LARGER TERMINALS TOP AND BOTTOM 227 AND 232L HOLD IN COIL SMALLER TERMINALS TOP AND BOTTOM 226A AND 2325 CAUTION When the solenoid activates remove the voltage supply immediatel
92. 4649 1 R36 RESISTOR WW 10W 4 7 OHM 5 SQ 19400 47R5 RESISTOR MF 1 4W 47 5 OHM 1 19400 24R9 RESISTOR MF 1 4W 24 9 OHM 1 19400 1000 R40 amp R46 R47 R48 R49 RESISTOR MF 1 4W 100 OHM 1 T14648 22 R45 RESISTOR WW 5W 50 OHM 5 SQ 15128 11 IC COMPARATOR QUAD 2901N olo o E E 5 8 FRE 0 12 2 e lt 5 3 o o UNLESS OTHERWISE SPECIFIED BUY PER E3867 CAPACITORS MFD VOLTS RESISTORS 1 4W OHMS TEST PER E3868 1 INDUCTANCE HENRYS SCHEMATIC REFERENCE L11309 BUY AS NOTES L11325 1C1 NA CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY IDENTIFICATION CODE STATIC ELECTRICITY LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING SECURE PC BOARD ASSEMBLY IN PLACE WITH ITEM 3 2 PLACES IDENTIFY COMPLETE ASSEMBLY WITH A PRINTED LABEL OR OTHER PERMANENT MARKING IN AREA SHOWN 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 U S A m Poer Ex Cho Sheet No X INFO DESIGNINFORMATION REFERENCE MANUFACTURING TOLERANCE PER E2056 F EQUIPMENT TYPE NO COMPONENTS ON BOTTOM SIDE OF PC BOARD ON 2 PLACE DECIMALS IS 02 3 31 2000 5000736 0 MISC ORAL ANGUS MAL S Opep xeur BATTERY PC BD ASSEMBLY WITH PUBLISHED STANDARDS E ae DONOT SCA
93. 47 R248 R240 RESISTOR SMD 1W 47 50HMS 1 525004 24305 R250 R251 R252 R253 R254 R255 R256 R257 R258 R259 RESISTOR SMD PREC MF 1 10W 10 0K 0 1 525008 43215 R260 R261 RESISTOR SMD PREC MF 1 10W 4 32K 0 5 525010 35 R262 R263 R264 RESISTOR SMD MF 1W 20 0K 1 SURGE 525001 12115 R265 RESISTOR SMD 1 21K 1 4W 1206 1 TR 525000 81915 266 8267 RESISTOR SMD METAL FILM 1 10W 6 19K 1 525008 10025 R269 R270 R271 R272 R273 R274 R275 R276 R277 R278 R279 R280 R281 R282 R283 R284 RESISTOR SMD PREC MF 1 10W 10 0K 0 5 S25000 4R70SMT R285 R286 R287 RESISTOR SMD METAL FILM 1 10W 4 700HM 525000 56215 R288 RESISTOR SMD METAL FILM 1 10W 5 62K 1 525008 90915 R289 R290 R297 RESISTOR SMD PREC MF 1 10W 9 09K 0 5 518380 14 R292 R293 R294 R295 THERMISTOR PTC 5000HMS 28mA 525008 47515 R296 RESISTOR SMD PREC MF 1 10W 4 75K 0 5 525007 21505 R297 IRESISTOR SMD PREC MF 1 10W 215OHMS 0 525007 80405 R298 IRESISTOR SMD PREC MF 1 10W 6040HMS 0 525001 47515 R299 RESISTOR SMD 4 75K 1 4W 1206 1 TR 525000 20015 R300 RESISTOR SMD METAL FILM 1 10W 2 00K 1 525000 20015 R300 RESISTOR SMD METAL FILM 1 10W 2 00K 1 525000 28015 R305 RESISTOR SMD METAL FILM 1 10W 2 60K 1 52500
94. 5000 5110SMT SI o 525000 47 55 525000 47505 525000 12115 525000 15015 1525001 47855 525010 45 525010 55 525000 75005 525000 22105 525000 20005 525000 51115 525000 20025 525056 35 525000 15025 a a 2 afro a ro cn co IS S i UNLESS OTHERWISE SPECIFIED RESISTANCE OHMS SCHEMATIC REFERENCE G3663 NOTES NAA CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING B PLACE CONNECTOR KEYING PLUG OVER HEADER PIN IN LOCATION SHOWN PLUG SHOULD BE INSERTED BELOW CONNECTOR TOP SURFACE SECURE PC BOARD ASSEMBLY IN PLACE WITHITEM 4 2 PLACES IDENTIFY COMPLETE ASSEMBLY WITH PRINTED LABEL OR OTHER PERMANENT MARKING IN AREA SHOWN BUY AS G NO COMPONENTS ON BOTTOM SIDE OF PC BOARD BUY PER E3867 G3662 1B1 TEST PER E3869 P WH PART NO IDENTIFICATION CODE PROGRAM ITEM 65 WITH ITEM THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PER
95. 7 1 to the heat sink mounting sur face 11 Connect the stator leads and diode pigtail leads as labeled at disassembly a Do not apply compound to the diode 12 Replace the output panel g Y stud or mounting threads E b Apply two drops of Loctite 271 to the 8 1 diode stud threads before tightening HIE 8 8 EIE DIODE STUD SIZE FOOT POUNDS INCH POUNDS 3 4 16 25 27 300 324 3 8 24 10 0 5 125 0 5 Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN F 73 F 73 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT A WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum to Master TOC 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD Q PP 5 5 DESCRIPTION 9 g The following procedure will aid the technician in removing and replacing the Commander 2 28 500 st
96. 75 ey PSU 885 ELECTRICAL SYMBOLS PER 1537 018 C20 iw 3 2r AVPHENGC LO ARC FORCE POT m CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED Lr E ax 20 2022 En S 6 RESISTORS Ohms 0805 UNLESS OTHERWISE SPECIFIED LABELS E gor 40V 400V 50 LOCAL is 010 DIODES 2 200V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE 9 169 REMOTE 3 gt 5 TO POT POWER SUPPLY SOURCE POINT c o AE g TN 01W 5 COMMON CONNECTION Olea asv V ont 10 3 tw s FILENAME 5000749 G3660 2 63900 20 1717 FROME CONNECTION 12V 3W THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN ELECTRIC CO THIS SCHEMATIC USED IN G3660 2C AND G3900 2C BOARDS i EARTH GROUND CONNECTION o 02254 NA COMPONENTS NOT INSERTED ON G3900 2C4 VERSIONS AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC DESIGNED BY IB FC SS AM y M NB COMPONENTS NOT INSERTED ON G3660 2 VERSIONS AND 15V GND INSERTED G3900 2C4 VERSIONS P Ch ge Sht No 9 9 Van NOTES NC ADDITIONAL COMPONENTS NOT INSERTED ON G3900 2C4 VERSION ME SEES XA THE LINCOLN ELECTRIC CO Tye ANALOG WELD CONTROL PCB N AA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE ON 3 PLAGE DECIMALS 19 2 22 TIAN CLEVELAND OHIO U S A sugsect STPNT PWM amp ARC CNTRL WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THI
97. 763 8 1 T 1 2 170 Ri 1 1 X33 SOFTWARE 525004 24305 R184 R185 R186 R187 RESISTOR SMD 1W 2430HMS 1 FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS 525020 35 1 2 03 4 27 58 09 10 11 12 13 014 15 C16 C17 C18 C19 20 C21 C22 C23 024 C25 C26 028 C29 30 31 32 33 34 35 36 37 38 39 40 41 2 43 44 45 46 47 49 50 51 52 53 54 55 56 57 58 59 C60 C61 C62 C63 64 C65 C66 C67 C68 69 C70 C71 1C72 C73 C74 C75 C76 C77 C78 C79 C80 C81 C82 C83 C84 C85 C86 C87 C88 C89 90 91 92 93 94 95 96 97 98 99 0100 101 133 141 142 ICAPACITOR SMD CERAMIC 0 1MF 50V 10 X 525000 20025 R188 RESISTOR SMD METAL FILM 1 10W 20 0K 1 525000 15005 R190 R197 R192 R193 R194 R195 R372 RESISTOR SMD METAL FILM 1 10W 1500HMS 525000 30115 R196 R197 R198 R199 R200 R201 R202 R203 R204 R205 R206 R207 RESISTOR SMD METAL FILM 1 10W 3 01K 1 525000 18225 R208 R208 RESISTOR SMD METAL FILM 1 10W 18 2K 1 525000 26705 R211 IRESISTOR SMD METAL FILM 1 10W 2670HMS 525000 33225 RZ13R214 RESISTOR SMD METAL FILM 1 10W 33 2K 1 525000 22135 RZ15 RZ16RZ17 RZ18 R369 RESISTOR SMD METAL FILM T T0W 221K 1 525000 15035 R219 RESISTOR SMD METAL FILM 1 10W 150K 1 5250
98. AL CODE WITH PRINTED LABELS PER E3876 N D NO COMPONENTS ON BOTTOM SIDE OF P C BOARD ELECTRICAL DIAGRAMS PULL COIL L11384 1 NA PC BOARD REFERENCE E TAPPING SCREW SEPON ENCAPSULATINGRESN 5 869 ELECTRICAL INSULATING COMPOUND FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS 1 B2 B3 B4 ONNECTOR TAB QC VERTICAL 1 4 REEL APACITOR TAEL 3 9 35V 10 APACITOR CEMO 0 1 50V 10 APACITOR CEMO 022 50V 20 IODE AXLDS 1A 400V FR 1N4936 IODE AXLDS 3A 200V 1N5402 13 12702 29 2 DIODE 1W 15V 5 1 4744 ONNECTOR MOLEX MINI PCB 6 PIN TIN JOSFET HEATSINK ASBLY 112704 82 amp S1810 T13157 14 7 513490 69 0 20 T ojojo 1 02 06 07 3 4 2 3 1 4 2 1 12705 14 12 12705 52 T ce eio e N N N e a c UNLESS OTHERWISE SPECIFIED CAPACITORS MFD VOLTS RESISTORS 1 4W OHMS INDUCTANCE HENRYS BUY AS 111384410
99. ALS NEEDED Ohmmeter 3 8 Wrench or socket wrench This procedure should take approximately 15 minutes to perform COMMANDER 500 LINCOLN F 29 Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 30 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE TEST CONTINUED FIGURE F 10 ROTOR BRUSH LEADS TEST PROCEDURE Conduct this test with the engine off Using the 3 8 wrench remove the right front case side Using the 3 8 wrench remove the brush holder access panel See Figure F 10 Using the 3 8 wrench remove the brush holder assembly See Figure F 10 Using the ohmmeter check the rotor winding resistance across the slip rings Normal resistance is approximately 27 0 ohms Measure the resistance to ground Place one meter probe on either of the slip rings Place the other probe on any good unpaint ed ground The resistance should be very high at least 500 000 ohms HOLDER ASSEMBLY COMMANDER 500 LINCOLN ACCESS PANEL If the test does not meet the resistance specifications then the rotor may be faulty Replace Position the brush holder assembly and attach it with two screws previously removed Make certain the brushes are centered and seated properly on the slip rings Adjust if ne
100. ALS SWITCH The toggle switch on the control panel labeled WELD TERMINALS ON and REMOTELY CONTROLLED is used to control the operation of the solid state contac tor The switch allows for the selection of Hot or Cold welding terminals With the switch in the WELD TERMINALS ON position the contactor is closed and the welding terminals are always Hot With the switch in the REMOTELY CONTROLLED position the contactor operation is controlled by an Amptrol Arc Start Switch or some other type of trig gering device through the use of a control cable con nected to the 14 pin amphenol When the triggering device is pressed the contactor is closed and the welding terminals are Hot When the triggering device is released the contactor is opened and the welding terminals are Cold NOTE The new Chopper Technology control circuitry automatically senses when a remote output control pot is plugged into either amphenol Therefore there is no need for a local remote switch TABLE 1 WELD MODE AND OUTPUT CONTROL FUNCTIONS M Application Weld Mode Output Sloped Output 5 Range for Pipe Settings Welding 90 150 200 Touch Start TIG Welding 350 500 max current on each setting 1 Range Setting 15 200 Amps Constant Current Output for Fabrication and General Purpose Welding 1 Range Setting 20 250 Amps Provides a Fine Adjustment of Welding Current from Min 1
101. ALTERNATOR ENGINE MUST S 5V_BATT CIRCUIT A O O 42 o 9 c 2 o ma 9 2 2 LOGIC HI AT FUEL LEVEL S ENGINE EARTH GROUND CONNECTION LINCOLN ELECTR EQUIP COMMON ANALOG CONTROL ELAND OHIO L c PERIPHERAL BOARD RCUITRY OF CONTROLS Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 3 COMMANDER 500 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 9 2 2 Return to Section Return to Master TOC O O 42 o 9 c 2 ELECTRICAL DIAGRAMS G 9 PC BOARD ASSEMBLY PERIPHERAL PC BOARD PC BOARD REFERENCE PART NO DESIGNATORS DESCRIPTION 53662 8 BLANK 524671 PLUG KEYING PLUG M19436 4 POTTING TRAY i N 58025 80 SELF TAPPING SCREW E2527 65g ENCAPSULATING RESIN E3539 5 REQ ELECTRICAL INSULATING COMPOUND 5
102. ARD THIS DIAGRAM MAY ON ALL ANGLES IS 5 OF A DEGF Po SCALE NONE SHT A cic NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY CONTROLS HAVING COMMON CODE MATERIAL TOLERANCE TO AGREE DR FE Date 10 12 2000 cy sies 3661 2 1 NUMBER WITH PUBLISHED STANDARDS 4 i 2 9 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 59 ELECTRIC COMMANDER 500 es ELECTRICAL DIAGRAMS alia SCHEMATIC WELD CONTROL PC BOARD SHEET 2 2 92 199 Asv A as olo MAIN WELDING CONTROL WITH MIN CURRENT AND ARC FORCE CONTROL CUR LIMIT 4 75K TEC AT t 5V_REF 15V AUTOMATIC REMOTE LOCAL SETPOINT CIRCUIT o i MIN CURRENT 2 25 9 A CUR_AMP N RU 3 gt Ri ans HOT SETPOINT 05
103. ARY INFORMATION OWNED BY LINCOLN ELECTRIC CO THIS SCHEMATIC USED IN G3660 2C AND G3900 2C BOARDS EARTH GROUND CONNECTION NA COMPONENTS NOT INSERTED ON G3660 2C4 VERSIONS ED 0150 08 s THE LINCOLN ELECTRIC CO FG SS 3 gt NAL COMPONENTS NOT INSERTED ON 63850 204 VERSION AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF DESIGNED BY IB FC SS AM INSERTED ON 03660 24 VERSIONS NOTES NC ADDITIONAL COMPONENTS NOT INSERTED ON G3660 2C4 VERSION Ihies OTHERWISE SPECIFIED TOLERANCE Chasse THE LINCOLN ELECTRIC CO TYPE ANALOG WELD CONTROL 9 ON 2 PLACE DECIMALS 18 s 02 CLEVELAND OHIO U S A DISPLAY AND IDLER N A A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE ON 3 PLACE DECIMALS IS 002 727 2000 05 NONE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES IS 5 OF A DEGREE PG SCALE SHT c NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE MATERIAL TOLERANCE TO AGREE DR FC pate 10 12 2000 cu AM sup sio c G3661 204 5 NUMBER WITH PUBLISHED STANDARDS 25 9 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 59 ELECTRIC COMMANDER 500 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 9
104. AX PRESE 3 D 9 TW 2 tesa NA MAX_POT_QUT 1 2j 30740 gt 62A fpga m vi NA 5 xm MAX POT SENSE Liia fe Shox R119 SV NA AN B 3 NA NA 2 4 SENSE CIRCUIT sv 2 019 PD GNO T iz v 07 o E n R377 NA D gt i oj REMOTE WELDING CONTACTOR CONTROL CIRCUIT m Eli O 5 00 00K R281 13 30740 NA AAN ali 2 amp 4 CLOSURE FROM AMPHENOL amp TERMINALS CONTROL E 12 oiw rir 01W 01W TOOK A 051 00680 R283 NA 7 Er c ES 16mv E 17 R274 30V Av SETPOINT 31 wA GND TOOK v NEG ROTATE GLAVA olg 172 2 N f N e NA i PRESET 5 09k DISPLAY SETPOINT NEG COMP PRESET Olea NA m 100 Ade 2 USE WSC 1 glow E R295 8403ARUL0 C sU Tuus o gt 1 2 NA 5 NA 243 Fu olo NA NA BRE Sy NA NA NA 1W 500 2 10 r NA 221 i E R276 2279 lease c 014 1 01 252 PROGRAMMABLE _ 7 6 30740 10 0K NA X46 C 7 oT o1w Cle 1 RESISTOR FOR 01W 9 NA 100K s SE A Q2A fpga gt TWO FOUR E BU R290 Ow VEL NA oR an USE WSC 1 R294 NA 1 POS_ROTATE LO POT IS AT MIN 2 LO_SETPOINT NA 290200 70K VA tose 408 Dag ae 9 120 NA 76 i72 71821 ae NA MIN POT OUT 243 v 1905 ne HI DISPLAY SETPOINT POS COMP PRESET
105. BOARD REFERENCE NEM DESIGNATORS PART NO QTY DESCRIPTION PLUG KEYING PLUG POTTING TRAY SELF TAPPING SCREW Return to Section TOC Return to Master TOC EPOXY ENCAPSULATING RESIN ELECTRICAL INSULATING COMPOUND FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS 513490 66 C1 C3 C4 C5 C6 513490 25 C2 CAPACITOR TAEL 47 35V 10 CAPACITOR TAEL 4 7 35V 10 16 21 14 S13490 97 18 19 23 CAPACITOR TAEL 100 20V 10 516668 9 22 CAPACITOR CEMO 150P 100V 5 T12705 47 DIODE AXLDS 4A 200V UFR 3 1 1 D1 7 i 6 1 2 10 11 12 13 Return to Section TOC Return to Master TOC LI LI LI z D4 D5 D7 D8 D9 D10 0 1 N N ninj Ex o o 24020 4 14 m JCONNECTOR MOLEX MINI PCB 4 PIN 1 J41 524020 10 1 J42 CONNECTOR MOLEX MINI PCB 10 PIN 1 OCI 1 OPTOCOUPLER PHOTO Q 70V 1 Q1 TRANSISTOR NMF T247 38A 250V SS 4 515000 10 T12704 89 19400 47R5 3 R7 R8 R26 RESISTOR MF 1 4W 47 5 1 T12300 86 1 R9 RESISTOR WW 3W 0 05 1 19400 1500 1 R10 RESISTOR MF 1 4W 150 196 519400 1211 3 13 14 15 RESISTOR MF 1 4W 1 21K 196 519400 2211 2 R16 R17 RESISTOR MF 1 4W 2 21K 196 N 55 N A N Oyo C5 ho Nh No ho ojoj UNLESS OTHERWISE SPECIFIED CAPACITORS MFD VOLTS RESISTORS 1 4W OHMS INDUCTANCE HENRYS 4 BUY AS 55 N NOTES CAUTION THIS DEVICE IS S
106. C 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master C 8 C 8 ACCESSORIES CONNECTION OF THE LN 23P TO THE COMMANDER 500 USING K350 1 ADAPTER SEE FIGURE C 5 1 Shutthe welder off 2 Connect the electrode cable from the LN 23P to the terminal of the welder Connect the work cable to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application NOTE Figure C 5 shows the electrode connected for negative polarity 3 Connect the K350 1 adapter to the amphenol on the LN 23P and the 14 pin amphenol of the Commander 500 as indicated in Figure C 5 4 Placethe IDLER switch in the HIGH position CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 5 Set the VOLTMETER switch to negative 6 Set the OUTPUT RANGE switch to WIRE WELD ING CV 7 Set the WELDING TERMINALS switch to WELD ING TERMINALS REMOTELY CONTROLLED 8 Adjust wire feed speed and voltage at the LN 23P FIGURE C 5 COMMANDER 500 LN 23P CONNECTION DIAGRAM COMMANDER 500 WITH
107. C FROM BACK 77 10K 2A 2 M5 5 55 M5 P 76 L obi 738A 236A CBS 6 gt 6 gt 6 262 SHOWN IN HIGH POSITION 257 WORK 232L 4 9 capes REMOTE IDLE CONTROL LM 00 Ms 262B M10 90 M10 232M 17 0 285 Mt D5 Mt SHUTDOWN SOL ON STANDARD MODELS 9 DENOTES ITEMS po 1 enm INCLUDED ON DELUXE 22 m 0 L es MODELS ONLY 280 J REMOTE CONTROL 2 9 108 wee mo PRESS TEMP uf x LL 758 METER KIT OPTIONAL M00 M0 12 o 11 CONTACTOR a ON STANDARD MODEL 218 240 INS ED Run POS 55 STUD gt sensor 929 GROUND F i EE gt gt 228A 242C 4 J FTT 2420 amp 229 4 CN P d TO BE TAPED snum 3 TURNS V siver DS OPTIONAL ON enon x STANDARD MODEL 2420 0 4 mE Af 36 n ERI 236C GROUND STUD ON 231 OUTPUT PANEL EVA NOTE LEADS 229 AND 229A MAY e 5R SPLICED TOGETHER ON SOME MACHINES LOW FUEL SHUTDOWN GND STARTER ILL BE DISABLED ON THESE ACHINES SOLENOID PERIPHERAL BD BATTERY po 12V BATTERY 5 1 m ae BOARD T STUD ON ENGINE a CONTACTOR 2 M3 M4 M5 M6 M9 y GROUND B e4 AMPHENOL 1 Hmi 254 M3 5 on
108. C Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS A WARNING 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 e ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring e Insulate yourself from the work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 5 Use in open well ventilated areas or vent exhaust outside Do not stack anything near the engine MOVING PARTS can injure x Do not operate with doors open or AN guards off Stop engine before servicing Keep away from moving parts Only qualified personnel should install use or ser vice this equipment LOCATION VENTILATION The welder should be located to provide an unrestrict ed flow of clean cool air to the cooling air inlets and to avoid restricting the cooling air outlets Also locate the welder so that the engine exhaust fumes are properly vented to an outside area STORING 1 Store the machine in a cool dry place when it is not in use Protect it from dust and dirt Keep it where it can t be accidentally damage
109. CONTROLLED position This will keep the solid state contactor open and provide a cold electrode until the triggering device Amptrol or Arc Start Switch is pressed COMMANDER 500 LINCOLN 8 Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 E Retum to Master TOC OPERATION WIRE FEED CONSTANT VOLTAGE WELDING Connect a wire feeder to the Commander 500 and set welder controls according to the instructions listed ear lier in this section The Commander 500 in the CV WIRE position can be used with a broad range of flux cored wire Innershield and Outershield electrodes and solid wires for MIG welding gas metal arc welding Welding can be finely tuned using the ARC CONTROL Some recommended Innershield electrodes are NR 311 NS 3M NR 207 NR 203 Ni 1 NR 204 H Recommended Outershield electrodes 05 70 0S 71M Some recommended solid wires for MIG welding are 035 0 9 mm 045 1 1 mm and 052 1 3 mm L 50 and L 56 035 0 9 mm and 045 1 1 mm Blue Max MIG 308 LS For any electrodes including the above recommenda tions the procedures should be kept within the rating of the machine For additional electrode information see Lincoln publications N 675 GS 100 and GS 210 AUXILIARY POWER OPERATION Start the engine and set the IDLER control switch to the desired operat
110. Change oil filter Change fuel filter Check fan belt Every 50 Hours Check fuel lines and clamps Every 100 Hours Check battery electrolyte level and connections Clean air filter Refer to your Deutz engine operation manual for periodic maintenance at 100 hours and beyond 1125 Hours for severe conditions ITEM MANUFACTURER PART NUMBER Air Cleaner Element Donaldson P181052 AC A302C Cooling Blower Belt Lincoln T13536 3 Gates 7585 Oil Filter Element Deutz 1174418 Purolator PER2168 Napa 1820 Fram PH3776 Fuel Filter Element Deutz 1174423 Purolator PC42 Napa 3358 Fram P4102 Water Separator Element Lincoln 16890 Stanadyne 31572 Fuel Pre Filter Screen Lincoln M16890 B Stanadyne 29575 Battery Group 34 TABLE D 2 ENGINE MAINTENANCE PARTS COMMANDER 500 LINCOLN 8 Retum to Section Retum to Section TOC 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC MAINTENANCE BATTERY MAINTENANCE WARNING Th GASES FROM BATTERY can explode 4 Keep sparks flame and cigarettes away from battery BATTERY ACID can burn eyes and skin 5 Wear gloves and eye protection and be careful when working near a battery Follow the instructions printed on the battery To prevent EXPLOSION when INSTALLING A NEW BATTERY Disconnect the negative cable from the old battery
111. D LO ENABLED I lo m n Im ho kn le o 2 4 SLOPE 128 tpga tc 4777 R289 PRE_SETPOINT SLOPE 64 509K 01W SLOPE 32 fpga 12 13010 ml d p SLOPE 16 fpga amp otv 5007 RL SELECT S SE Sow SLOPE 8 fpga DB 1 2 3 SLOPE L XA Cu XE my LOCAL REF ge 76 SLOPE 2 T 4 3 qu E52 qe o SLOPE 1 fpoa 406660 5 01 ww iw 1023V REF septal DATA Te p LOCAL PRE SETPOINT A Li pga 075 10 T 50V CS_LOWSETPT f LOCAL WIPER 2 Aran 10 0K sur cock xs 8 B403ARULO D 01W 3 p lt 12 US fpgal gt 255V ADBLOOAR JA ESI x55 p gt xs 811 SETPOINT R132 4 5 5 10 0K SERIAL_DATA xL R266 131 ux 4 um 7 O 1O Y 5 078 V x 3 51K 7 a 8 Em TOK o 11 4 a m CHANT vaj i ml m 5 C18 fpga leuk x53 SHIRE 1 4 01 SII 34 LO SETPOINT Uo 061 01 01 bat 01w 01 R271 05A 15V gt 15V 50V 50V T 01 11 13 ES 5 1 T c T 1 on 50V cs stTPONTS 155 guo3anuLo 00 Pilguo3ARUL0 GV d nde gt TOK 30V 2 lt 12 2530740 7 Lr 12 Tp e cao Chi 13 4 REMOTE 5 45V DL 01 p a 7 E 02254 U alza me E look S GND 50 50 2o 08 aw vt R262 41052 QI 13 2 101 V Y 1 10 TO x 30740 5 5 gt D GND 15
112. DC open circuit volt age at the output terminals If the correct is present at the welding output terminals check the welding cables clamps and electrode holder for loose or faulty connections Check for loose or faulty con nections on the heavy current carrying leads between the out put bridge the power modules the choke and the output termi nals Check the Welding Terminals Switch and associated leads See the Wiring Diagram Check gate leads 23 23A 25 and 25A for loose or faulty connections See the Wiring Diagram Perform the Stator Voltage Perform the Output Rectifier Bridge Test Perform the Power Module Perform the Analog Power Supply PC Board Test The Weld Control PC Board may be faulty See the Start Up Diagnostic Chart and OCV 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 Call 1 800 833 9353 COMMANDER 500 LINCOLN 8 geri Retum to Section Retum to Section TOC 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS No welding output in neither Stick or CV modes Also no
113. ELECT pone 7 DONE GIW MACH SEL 3 341 032 1 060 99 AMMETER ON 1240124 4 REMOTE_DETECT seca al m fal fas us tul P MACH SEL 4 E 105989 METER PSET MODE 125 1 0125 1 0140 140 CS_LOWSETPT mTP3 INIT amp sov sov sov ARC_FORCE_SENSE 441 942 1 1 058 58 MIN PRESET ENABLE 1261 0126 x3 F 1 0139 139 CS SETPOINTS T 475 ans 75 178 AUX CUR SENSE 431 043 1 057 PE MAX PRESET ENABLE 15 gue yega 1 0138 138 E TIG LIMIT piw HLIDLE SENSE 481 046 10056 B 55 1 SCALE 30013 1 0136 1136 alaz GTS 05282 Me TER_WELD_SIGNAL ioa 1 0135 235 OIW GAVA MIN POT our 481 048 10051 Bi POS ROTATE 1321170132 170134 138 13 went 1 049 1 050 9 1 NEG ROTATE 3311 0133 NA 25070 5SMT 525070 55 1255 m E REMOTE SENSE 009292 E O NA wa PULL UP RESISTOR 1 089 amp Yens ke Um pn CAPABLE OF lima 1 088 SHOT_START_ENABLE c a que Ka 5 18V 1 087 BL gt FIXED_HOT_START OIW NA W xai p 1 086 86 ARC FORCE_ENABLE to A R25 Vose AF_POT ENABLE Ole NA S UN mo Iv INPUT FROM 15V 1 08 8 FX_ARC_FRC_ENABLE m SOURCE CAPABLE OF 108383 MIN POT ENABLE o gt 01W LOGI 0 70 BE 70V 1 082 82 FIXED MIN ENABLE u NA MIN CUR DISABLE olo NA 976 6 hae 10 525070 55 naL G5 Wate R58 591 15 10
114. FLASHING AND ROTOR VOLTAGE TEST CONTINUED FIGURE F 12 FIELD DIODE RECTIFIER BRIDGE AND FILTER CAPACITOR FILTER CAPACITOR 7 If the voltage reading is low or not present the generator field is not functioning proper ly Perform the Also check the field diode rectifier bridge fil ter capacitor and associated leads and con nections See Figure F 12 for location See the Wiring Diagram NOTE The normal flashing voltage is approxi mately 9VDC This is battery voltage which is processed through the Battery board This volt age must be present during start up to flash the rotor field 8 COMMANDER 500 LINCOLN DIODE RECTIFIER BRIDGE If the rotor voltage readings are normal the field circuit is functioning properly Replace any cable ties cut during the test Install the right case side 34 F 34 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TEST A WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the L
115. IC 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 NOTE Gas shielded welding requires a Magnum Gun Gasless welding requires an Innershield Gun OTHER WIRE FEEDERS FOR THE COMMANDER 300 NA 3 Automatic Wire Feeder LN 742 Semiautomatic Wire Feeder Spool gun and K488 Module HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi Freq Unit and the K930 ALL TIG Modules are suitable for use with the Commander 500 The Commander 500 is equipped with the required RF bypass circuitry for the connection of high frequency generating equipment The high frequency bypass net work supplied with the K799 Hi Freq Unit does NOT need to be installed into the Commander 500 The Commander 500 and any high frequency generat ing equipment must be properly grounded See the K799 Hi Freq Unit and the K930 All TIG Module oper ating manuals for complete instructions on installation operation and maintenance CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS A WARNING ELECTRIC SHOCK can kill Do not operate with panels open Disconnect NEGATIVE BATTERY LEAD before servicing 0 Do not touch electrically live parts MOVING PARTS can in
116. LE THIS DRAUING APPROVED DATE 5 26 99 pDRAWNGNo L 11325 1 Return to Section TOC Return to Master TOC 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 This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN amp i TETI machine COMMANDER 500 Return to Section Return to Section TOC Return to Master TOC o 9 2 3 Return to Section Return to Master TOC Return to Master TOC o 5 9 6 SCHEMATIC CHOPPER BOARD c9v6l N ELECTRICAL DIAGRAMS Ci C2 C4 C5 G1 16100 39 E1 E2 E4 6 to heatsink MIC4451BN GND GND to Ci C2 C4 C5 G1 A2 M16100 39 15 to 32 Vac AND Ri 9 uU 24
117. MANDER 500 LINCOLN 8 Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE A WARNING 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 and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunc tions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into four main categories Output Problems Function Problems Engine Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con du
118. MISSION OF THE LINCOLN ELECTRIC COMPANY CLEVELAND EOE TED To MANUFACTURING TOLERANCE PER E2056 abi DESIGN INFORMATION EQUIPMENT TYPE COMMON ANALOG CONTROL ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 s Eas wu _ PERIPHERAL CONTROL PCB ASSEMBLY OLERAN AGREE ENGINEER APM IG eme J 504 15 DATE 2 10 99 DRWNGN G 3662 1 MA WITH PUBLISHED 57 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 This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN amp i LINCOLN machine COMMANDER 500 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo O10 FIle amp 9 218 AE x 1 Return to Section TOC Return to Master TOC G 10 SCHEMATIC POWER SUPPLY ANALOG PC BOARD LINCOLN B 227610 ELECTRICAL DIAGRAMS 40 100 VDC Operation
119. N 7 INPUT BEN UN CABLE PLUG AMPHENOL K584 OR K594 CONTROL CABLE 14 PIN 4 _ AMPHENOL WORK ELECTRODE CABLE TO WIRE FEED UNIT COMMANDER 500 LINCOLN 8 Retum to Section Return to Section TOC 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master C 6 C 6 ACCESSORIES CONNECTION OF THE LN 8 TO THE COMMANDER 500 USING K867 UNIVERSAL ADAPTER SEE FIGURE C 3 1 Shut the welder off 2 Connect the electrode cable from the LN 8 to the terminal of the welder Connect the work cable to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application NOTE Figure C 3 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the Commander 500 output terminals 3 Connect the K867 Universal Adapter to the K 196 input cable and the 14 pin amphenol of the Commander 300 as indicated in Figure C 3 Make the proper connections for local or remote control according to Figure C 3 4 Connectthe K196 input cable to the LN 8 5 Place the IDLER switch in the HIGH position A CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140
120. N4401 T12704 69 Q7 TRANSISTOR PNP TO226 0 5A 40V 2N4403 T12704 49 Q8 TRANSISTOR P T220 8A 150V MJE15031 T12704 41 Q9 TRANSISTOR N T220 8A 150V MJE15030 519400 4750 R1 RESISTOR 1 4W 475 OHM 1 519400 1001 R2 R4 RESISTOR MF 1 4W 1K OHM 1 519400 2211 R3 R25 RESISTOR MF 1 4W 2 21 OHM 1 519400 4751 R6 RESISTOR MF 1 4W 4 75K OHM 1 19400 1002 R7 R8 R9 R10 RESISTOR MF 1 4W 10K OHM 1 519400 1211 R11 R12 R13 R14 amp R16 R17 RESISTOR MF 1 4W 1 21K OHM 1 519400 6812 R15 RESISTOR MF 1 4W 68 1K OHM 1 19400 3321 R18 R19 RESISTOR MF 1 4W 3 32K OHM 1 M M Return to Section TOC Return to Master TOC 19400 8251 R20 R21 RESISTOR MF 1 4W 8 25K OHM 1 519400 9091 R26 RESISTOR MF 1 4W 9 09K OHM 1 19400 3322 R5 R27 RESISTOR MF 1 4W 33 2K OHM 1 519400 5110 R28 RESISTOR MF 1 4W 511 OHM 1 519400 1003 R29 RESISTOR MF 1 4W 100K OHM 1 518380 3 THERMISTOR 08 0 19 OHMS 1 85A 519400 3921 R33 R34 RESISTOR MF 1 4W 3 92K OHM 1 T1
121. ND R367 SP E NA x Vss a 4 8403ARULO R383 NA x E me ALL B RESISTORS ARE 1 4W DALE 1206 30740 E M B4034RUL0 B M lt P NA um 15V 15V MAX POT END PT gt gt 13 15V_COM 15V_COM GND lt 6 lt gt 1 023V_REF lt 1 1 023V_REF qM BL03ARUL0 C 7 6 1 5V Ji 16 PIN W MINI MOLEX PROGRAMMING lt Vss X Vss 2 3 0 2 m 32 8 PIN B MINI MOLEX MODE SELECT Sg J3 8 PIN W MINI MOLEX MACHINE SEL c lt se KEY x56 D gt MIN POT END PT red PAGE 3 OF 5 COM a 13 7 m 39 NB 15V 15V 733070 075 5 rtf E GENERAL INFORMATION LASTNO USED 380 561 BIA 619 amp 766 ELECTRICAL SYMBOLS PER 1537 maa O 5V_REF gt aun gt 90 MI ERMAL CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED ke 2 16 PIN B MINI MOLEX MISC CNTRL amp EXP RESISTORS Ohms 0805 UNLESS OTHERWISE SPECIFIED LABELS 0 6 JI3 8 PIN B MINI MOLEX POWER DIODES 2A 200V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET 5 GND POWER SUPPLY SOURCE POINT aam 57 COMMON CONNECTION o NOTES FILENAME 5000749 G3660 2 G3900 2C 1747 FRAME CONNECTION THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO THIS SCHEMATIC USED IN G3660 2C AND G3900 2C BOARDS EARTH GROUND CONNECTION NA COMPONENTS NOT INSERTED
122. ND FEEDBACK COMMANDER 500 WORK THREE PHASE TERMINAL RECTIFIER TO WELD CONTROL BOARD MECHANICAL ROTATION ENGINE STARTER RUN STOP STATOR 8 AUXILIARY gt CONTROL BOARD VOLTMETER AMMETER ARC OUTPUT PROCESS RANGE CONTROL CONTROL SELECTOR THERMAL 42 VAC TO 14 PIN AMPHENOL FOR WIRE FEEDER WINDINGS zzooocro PERIPHERAL BOARD 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 There are two capacitors in each module These capacitors func tion as filters and also as power supplies for the IGBTs See IGBT Operation in this section The IGBTs act as high speed switches operating at 20KHZ These devices are switched on and off by the Weld Control PC board through pulse width modulation circuitry See Pulse Width Modulation this section This 240VAC RECEPTACLE 120VAC RECEPTACLES 2 chopped DC output is applied through choke coils and a shunt to the welding output terminals The choke functions as a current filter and it helps to balance the outputs of the two power modules Free wheeling diodes are incorporated in the power modules to pro vide a current path for the
123. NT AMP CIRCUIT 5 TURN 019 lt 16 R619 8 400A 200K CW T sd od SHUNT INPUT 4 2 POSITIVE Lean 1 u X14 IDLE SWITCH SENSE CIRCUIT im inie HOT START CIRCUIT Somv 400 AMPS E CIRCUIT SELECTS TYPE OF HOT START FIXED OR ADJ 0206 1 4 Y a bosean FPGA SELECTS APPROPRIATE TIME AFTER TIME OUT R77 1V 100AMPS TIG SWITCH i LOGIC LO AT HLIDLE SENSE HOT START IS SHORTED AND BECOMES SETPOINT BUFFER TK 9 ENGINE MUST GO TO HI IDLE 2 PIN MINI MOLEX GND 5 15K SES xis Cie 4 ue TIG SETPOINT 8 s 4 9010 A Es HLLIDLE SENSE 51475 5 35v SHUNT CIRCUIT 7 Bw 06680 7 280 pog 50V 829 1 243V NOMINAL 1 Um 4 ER E T 3 m SETPOINT TPP O w 12 HOT SETPOINT gt F304 NEG TIG_WELD 5 0 d g j o 2 RIO R341 R300 S 100 TO IDLE SWITCH BR L E TTSK xe gt TIK 10K P9 a 50 70 13 TOOK 511 107 530740 ke O1W 01W 01W o1w 1 1 212 T olo i Gn CUR e 01W 052 o 1 2100 Van 1 C126 05A oO _ E 0 056 30V 9 LO FIXED HOT START 50v o gt OF 175 OF SETPOINT A 5V REF HI VARIABLE HOT START 5 5 5 SENS Xi 9 AVERAGE AND ABSOLUTE CURRENT LIMIT CIRCUITS WELDING CURRENT SENSE CIRCUIT TOROID SENSE AUX CIRCUIT Av UD ALSCESE TEUINT WHEN _ _ _ IS of R230 GNO 76 406680 9 5 3 ABSOLUTE CURRENT LIMIT he
124. OLN 53 53 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM STICK MAX TAP MAX CONTROL POT HIGH IDLE NO LOAD Retum to Section TOC Retum to Master TOC es HH EEE EH 0 volts 50V 5ms Retum to Master TOC 9 u 8 a This is the typical DC open circuit out put voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division rep 5 8 resents 5 milliseconds in time F il A SCOPE SETTINGS 8 E Volts Div 50V Div F Horizontal Sweep 5 ms Div cic Coupling DC Trigger Internal gio PE 512 2 2 8 ili cc COMMANDER 500 LINCOLN Retum to Section Return to Section TOC 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 54 F 54 TROUBLESHOOTING amp REPAIR NORMAL WELD VOLTAGE WAVEFORM STICK CC MACHINE LOADED TO 500 AMPS AT 40 VOLTS 20V 0 1ms This is the typical DC output voltage generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal division represents 0 1 milliseconds i
125. OT DIGITAL SMD 10K QUAD TSSOP 24 S25069 28MT 90 IC SMD CMOS EEPROM SERIAL SPI 64Kx8 S 525070 55 91 IC SMD FPGA XCS20 TOFP T44PIN 525069 55 pas IC SMD EEPROM CMOS CONFIGURATION 256K 515128 105 paa IC SMD VOLTAGE REF ADJ PECISION 431I 525067 18MT pas IC BIPOLAR TIMER SOIC 14 S15018 118MT 60 IC SMD CMOS SWITCH ANALOG QUAD 201 S S25057 28MT 64 POT SMD DIGITAL 10K 1 CHNL SOIC 8 825001 18218MT RESISTOR SMD 1 82K 1 4W 1206 1 TR 825001 15028MT RESISTOR SMD 15K 1 4W 1206 1 TR NOTE G3990 2 MUST BE REVIEWED WHEN MODIFYING THIS BOARD PART NO BUY AS 3660 2C c UNLESS OTHERWISE SPECIFIED RESISTANCE OHMS SCHEMATIC REFERENCE G3661 2C3 BUY PER E3867 TEST PER E3869 C FOR PARTS ORDERS SEND IDENTIFICATION CODE 1 G3660 2 WELD CONTROL PC BOARD ASSEMBLY 1 518250 743 PLUG amp LEAD ADAPTER 1 S25110PRINT PARTS ORDER INSTRUCTION SHEET PROGRAM ITEM 140 WITH ITEM 7 PROGRAM ITEM 142 WITH ITEM 8 J PARTS SHOWN MUST BE COMPLETELY COVERED 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 i WITH ENCAPSULATION D MANUFACTURING TOLERANCE E2085 C19 Sheet No
126. OTE SCHEMATIC BATTERY PC BOARD G 4 NOL Je1Se A 0 uunjeH DOL uonoes 0 DOL DOL uonoeg oj DOL Je1se N 0 uunjeH DOL uonoeg 0 uunjeg L 11309 NOL Je1se N 01 uunjeH DOL uonoeg 0 uunjeg COMMANDER 500 LINCOLN E ELECTRICAL DIAGRAMS G 5 PC BOARD ASSEMBLY BATTERY PC BOARD PC BOARD REFERENCE Ww ITEM PART NO DESIGNATORS DESCRIPTION 1 L11325 C 1 BATTERY PC BOARD BLANK 2 M19436 3 1 POTTING TRAY 8025 80 2 SELF TAPPING SCREW E2527 112g EPOXY ENCAPSULATION RESIN E3539 AS REQ D ELECTRICAL INSULATING COMPOUND Return to Section TOC Return to Master TOC FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS T11577 26 CAPACITOR PEF 0 1 100V 1096 516668 8 CAPACITOR 330pf 100V 5 513490 121 CAPACITOR ALEL 1000 35V 30 20 513490 15 C5 CAPACITOR ALEL 100 16V 75 10 T11577 58 C6 CAPACITOR CD 0 0047 3000V 2096 516668 11 C7 THRU C12 CAPACITOR CEMO 1 50V 10 T12705 37 D1 D2 D3 DIODE AXLDS 3A 40V SCHOTTKY T12199 1 D4 D5 D6 D7 D8 D13 D14 D15 D16 DIODE AXLDS 1A 400V 1N4004 T12705 29 D9 D10 D12 D17 DIODE AXLDS 3A 600V 1N5406 524020 16 J43 CONNECTOR MOLEX MINI PCB 16 PIN TIN T13640 26 MOV1 MOV 14VRMS 100J 20MM T12704 68 Q1 THRU Q6 TRANSISTOR NPN TO226 0 5A 40V 2
127. OWER RECEP TACLES section in the Installation section for further information about this receptacle Also refer to the AUXILIARY POWER OPERATIONI later in this section 15 50 AMP CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 120V circuit at the 240V receptacle 16 120VAC RECEPTACLES These two 120VAC 5 20R receptacles provide 120VAC for auxiliary power Each receptacle has a 20 amp total rating Refer to RECEPTACLES in the Installation section for further information about these receptacles Also refer to the AUXILIARY POWER OPERATIONIlater in this section 17 20 AMP CIRCUIT BREAKERS o These circuit breakers provide separate overload cur rent protection for each 120V receptacle 18 Provides connection point for connecting the machine case to earth ground for the safest grounding procedure Refer to MACHINE GROUNDING the Installation section for proper machine grounding infor mation 19 20 AMP CIRCUIT BREAKER This circuit breaker provides overload protection for the 120 VAC circuit in the 14 pin amphenol 20 VOLTMETER SWITCH Changes the polarity display on the wire feeder 21 10 AMP CIRCUIT BREAKER This circuit breaker provides overload protection for the 42 VAC circuit in the 14 pin amphenol 22 14 CONNECTOR AMPHENOL For quick connection of interfacing equipment 23 ARC CONTROL The A
128. PART NO IDENTIFICATION CODE BUY PER E3867 TEST PER E3883 SCHEMATIC REFERENCE L11383 EXPERIMENTAL DRAWING NOT TO BE USED FOR PRODUCTION EE TITLE BLOCK FOR REVISION LEVEL 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 UN OTHERWISE oP DTOLERAN MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS LO NOT SCALE DRAWING Chg Sheet No X INFO 5000762 DESIGN INFORMA TION REFERENCE EQUIPMENT TYPE ENGINE WELDERS 5000751 DRAWN BY MAP XC ENGINEER PULL COIL P C BOARD ASSEMBLY APPROVED SCAENONE DATE8 26 99 DRAWNGNo 11384 1 G 13 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 This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result
129. PC BOARD TROUBLESHOOTING PROCEDURES A WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn 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 To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect board using standard practices to avoid static elec trical damage and electrical shock Read the warn ing inside the static resistant bag and perform the following procedures Do Not Destroy PC Board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist IWAN ATTENTION strap For safety use a 1 Meg Static Sensitive ohm resistive cord connected to a Devices grounded part of the equipment Handle only at frame Static Safe e f you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent sta tic build up Be sure not to touch any electr
130. PER SPACERS DIODE MODULE ALLEN HEAD SCREWS 4 POWER MODULE PC BOARD Retum to Section TOC Retum to Master TOC POWER MODULE PC BOARD REMOVAL Refer to Figure F 30 to the Power Module PC board Right 1 Turn the engine off side W7 W8 and D3 Left side W9 W10 and D4 See the Wiring Diagram 2 Remove the front right or left case side depending on which Power Module PC board you are removing 7 With the 7 16 wrench remove the nuts lock washers and flat washers holding the posi tive capacitor straps to the Power Module 3 Perform the Output Panel Removal proce PC board Loosen the nuts at the capacitor dure section of the Case Cover Removal terminals and swing the straps out of the Retum to Master TOC 8 9 8 procedure way 4 Perform the Power Module Capacitor 8 With the 3 8 allen wrench remove the top Discharge procedure and bottom cap screws from the Power Module PC board 5 With the phillips screw driver remove plug and lead assembly for P J 50 right side or NOTE Each top cap screw has a copper stand P J51 left side Cut any necessary cable on the opposite side of the board Be sure ties to place this standoff between the heat sink and 6 With the 7 16 wrench remove the nuts the PC board at reassembly lock washers and flat washers holding the 9 Remove the power module board two heavy leads and the small diode leads Retu
131. R TERMINALS Using the resistor and jumper leads CARE FULLY discharge the capacitor terminals NEVER USE A SHORTING STRAP FOR THIS PURPOSE DO NOT TOUCH THE TERMINALS WITH YOUR BARE HANDS Repeat procedure on the other side Check the voltage across the capacitor ter minals It should be zero volts Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 21 TROUBLESHOOTING amp REPAIR IDLER SOLENOID TEST A WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the idler solenoid is capable of functioning when it is energized with 12VDC MATERIALS NEEDED External 12VDC supply 30 amps required Wiring Diagram Volt Ohmmeter This procedure should take approximately
132. RAME CONNECTION v THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN ELECTRIC CO THIS SCHEMATIC USED IN G3660 2C AND G3900 2C BOARDS EARTH GROUND CONNECTION gt NA COMPONENTS NOT INSERTED ON G3660 2C4 VERSIONS AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO DESIGNED BY IB FC SS NB COMPONENTS NOT INSERTED ON G3660 2 VERSIONS AND o INSERTED ON G3660 2C4 VERSIONS ene eH E NERA Ch ge Sht No EQUIP ANALOG WELD CONTROL PCB NOTES NC ADDITIONAL COMPONENTS NOT INSERTED ON G3660 2C4 VERSION SMCS SEs PORE d THE LINCOLN ELECTRIC CO TYPE p Giza ON 2 PLACE DECIMALS 1S 02 CLEVELAND OHIO U S A sue ecr CUR LIM FEEDBACK ETC COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE ON 3 PLACE DECIMALS IS 002 7 7 2000 04 WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES 16 5 5 OF A DEGREE PG SCALE NONE SHT t HoT Si THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE MATERIAL TOLERANCE tan AGREE DR FC pate 10 12 2000 chk SUP S D G NO C3661 2C4 4 5 amp D m NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 59 ELECTRIC COMMANDER 500 ae ELECTRICAL DIAGRAMS SCHEMATIC WELD CONTROL PC BOARD SHEET 5
133. RC CONTROL potentiometer is active in two modes CC STICK and CV WIRE with different pur poses in each mode CC STICK mode In this mode the ARC CONTROL knob sets the short circuit current during stick welding Increasing the number from 1 to 10 increases the short circuit current This prevents sticking of the electrode to the plate at low welding current settings This also increases spatter It is recommended that the control be set to the minimum number without electrode stick ing CV WIRE mode In this mode increasing the number from 1 to 10 changes the arc from soft and washed in to crisp and narrow It acts as an inductance control The proper setting depends on the application and operator preference In general MIG welding performs best in the SOFT range and Innershield in the CRISP range COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y 4 2 8 5 Retum to Master TOC OPERATION ENGINE OPERATION STARTING 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 Close engine compartment door 3 Remove all plugs connected to the AC power recep tacles 4 Set IDLER sw
134. RD NCE t ENGINEER MATERIAL TOLERANCE t XC UF TK WITH PUBLISHED 57 SCALE THISDRAWNG B XD UF APPROVED SOLID ED GE Return to Section TOC Return to Master TOC 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 This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine COMMANDER 500 LINCOLN ore ELECTRICAL DIAGRAMS G 12 SCHEMATIC PULL COIL PC BOARD SCHEMATIC 111383 X SH AST NO USED NO Return to Section TOC Return to Master TOC TO 232N BATT ENGINE WELDERS PULL COIL PCB 25V REF IDLE 25V REF a PULL COIL CHK 227 100K z 6 sv Y SHUTODWN PULL COIL xi 2 D 259018 10 265 e Q6 5A 6 Bis U S A 03 07 00 L11383_1B 022 50V ILENAME ENERAL INFORMATION CLEVELAND OHIO 01 b THE LINCOLN ELECTRIC CO
135. REC MF 1 10W 68 1K 0 1 525007 90915 R351 RESISTOR SMD PREC MF 1 10W 9 09K 0 1 525000 13305 R352 RESISTOR SMD METAL FILM 1 10W 1330HMS 525008 15025 R353 RESISTOR SMD PREC MF 1 10W 15 0K 0 5 525007 90925 3548355 RESISTOR SMD PREC MF 1 10W 90 9K 0 1 525000 22815 R356 RESISTOR SMD METAL FILM 1 10W 22 10HM S25010 T8MT R357 RESISTOR SMD MF 2 Z1K 1 4W 1 6 SURGE 525000 33205 R358 RESISTOR SMD METAL FILM 1 10W 3320HMS 525003 0R155MT R359 RESISTOR SMD 1W 0 1SOHMS 1 525001 20015 R360 R361 R362 R363 R364 R365 R366 R367 R383 RESISTOR SMD 2K 1 4W 1206 1 TR 525007 33215 R368 RESISTOR SMD PREC MF 1 10W 3 32K 0 1 525056 25 R380 R561 R619 R766 TRIMMER SMD MT 1 4W 2K 10 LINEAR 515128 275 x TC OP AMP SINGLE PRECISION LT 109758 515128 45 DOG X39 X40 X41X42 X51 55 5 0 GEN PURPOSE 224D 515128 185 4 6 6 7 16 22 46 52 56 IC OP AMP SMT QUAD HIGH PERF 33074D 15458 65 pa IC SMD PWM CONTROL 515018 65 DG XIOXTI X14 X17 X24 X34 35 X36 IC SMD CMOS SWITCH ANALOG QUAD 4066B S15128 118MT 15 43 IC SMT COMPARATOR QUAD 2901D 525065 15 20 IC SMD MULTIPLEXER TO 1 LINE DATAH 525057 35 27 X53 X57 P
136. Retum to Master TOC 5 Using the 3 8 wrench remove the four 7 Remove the fuel tank cap gasket and the screws from the top front of the roof assem lift bail cover seal bly and the two screws from the sides of the control box Carefully lower the front con trol panel See Figure F 2 8 With the help of an assistant carefully remove the roof The door assembly remains attached to the roof Replace the 6 sWith the 9 16 wrench remove the fuel cap exhaust pipe rain cap 1r SB 8 8 E cic 9 With 3 8 wrench remove the left rear panel and the right and left front panels See Return to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN 18 18 TROUBLESHOOTING amp REPAIR CASE FRONT KNOBS REMOVAL AND REPLACEMENT PROCEDURE Fue SB Removal 318 7 Side View 9 9 Pull 88 c Knob Nameplate x gt Push Removal 1 Rotate the handle portion of the knob to an approximate vertical orientation switch detent may position handle a few degrees off vertical This orientation should be noted and repeated at replacement for proper D shaft orientation 2 With one hand grasp the very bottom of vertical handle and push towards the machine nameplate and pull down At the same time and with the other hand grasp the very top of the handle and pull the top edge of the knob away from the machine nameplate Th
137. S DIAGRAM MAY ON ALL ANGLES IS 5 OF DEGREE PG SCALE NONE sur NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE MATERIAL TOLERANCE TO AGREE DR FURS pate 10 12 2000 chk ANY 63661 2472 5 NUMBER WITH PUBLISHED STANDARDS eis 5 o NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 59 ELECTRIC COMMANDER 500 da ELECTRICAL DIAGRAMS SCHEMATIC WELD CONTROL BOARD SHEET 3
138. S ae PC BOARD ASSEMBLY CHOPPER PC BOARD COMPONENT SIDE CIRCUITRY OPPOSITE G8MPONENT SIDE GIRGUITRY 11815 1 300 CHOPPER 516668 11 1 50 513490 8 5D 25 Cl CX CB U7 L 11315 1 REQ D PART NO IDENTIFICATION 51 CAPACI MPF 1 0 UF B3VDC T11577 49 5DO 5D nam T127D5 23 1N58 1 474504 DPTOCDUPLER TIL OUT T12704 41 USE H S 520530 5183BD 5 THERM STOR 1 1 17 UHMS J ZIK 1 4 519400 5 20 562 1 4 5194DO 1001 1 4 519400 LDRO JD 1 4 5194DD 4751 4 75K 519 00 4750 475 174W 515D 18 21 LC DRI VER LOw 5 MOSFET D 02 03 04 D5 R u SHT NO Return to Section TOC Return to Master TOC ENGINE WELDERS 300 CHOPPER P C BOARD AS BLY SUP S D G ain oio SEES NS mis SSD X d 2 S m amp 8 3 e m _ SE SUBJECT a a 0 20 0 0 0 SCALE FULL CAPACITORS MFD VOLTS i INCLUDE 1 L11167 PRINT RESISTORS OHMS AND 1 T12837 1 THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A MAKE FROM 519399 MAKES 6 BOARDS REQ D PART IDENTIFICATION NOTE FOR BLANK SHEARING TOLERANCE SEE P C BOARD ASSEMBLY 1 111315 C BOARD BLANK M16100 39 LECTRONIC MODULE A1 421 BLANK PART NO L11315 B 19147 15 YELETS MALE B4 BS B9 79147 11 YELETS FEMALE 2 Return to Section TOC R
139. SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuen
140. SVM153 A Commander 500 For use with machines having Code Numbers 10837 Standard 10838 Deluxe September 2002 Return to Master TOC View Safety Info Safety Depends on You 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 and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info 9 gt 2 o gt E SERVICE MANUAL is 7 P o 9 c 3 View Safety Info LINCOLN Copyright 2002 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC SAFETY WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains 2 are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproduct
141. UBJECT DAMAGE BY STATIC ELECTRICITY LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING olo O10 FIle amp 9 218 AE x 1 PLACE CONNECTOR KEYING PLUG OVER HEADER PIN IN LOCATION SHOWN PLUG SHOULD BE INSERTED BELOW CONNECTOR TOP SURFACE PART NO M19423 1 IDENTIFICATION CODE 9 1 2 519400 15 0 1 R23 RESISTOR MF 1 4W 15 0 1 519400 2490 1 24 RESISTOR MF 1 4W 249 196 520375 7 1 T1 TRANSFORMER PCB PWM FLYBACK T13640 9 1 TP 1 MOV 75VRMS 22J 14MM M15458 4 IC PWM CONTROLLER IMODE 2842A 151280 280 1 REF ADJ 4311 2 PLACES 867 oie TEST PER E3861 SCHEMATIC REFERENCE M19422 THS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TOBE REPRODUCED DISCLOSED CR USED WTHOUT THE EXPRESSWRITTEN PERMISSION CF THE LINCOLN ELECTRIC COMPANY CLEVELAND OHO USA UNLESS OTHERWISE SPECIFED TOLERANCE DESIGNINFORMATION REFERENCE MANUFACTURING TOLERANCE PER E2056 EQUIPMENT TYPE COMMON ANALOG CONTROL mE SUBJECT ANALOG POWER SUPPLY PCB ASSEMBLY ONS PLACE DECIMLS Ss D BEES EXE E l SCALE I1 DATE 2 23 99 DRAWNGN 19423 1 A IDENTIFY COMPLETE ASSEMBLY WITH A PRINTED LABEL OR OTHER PERMANENT MARKING IN AREA SHOWN LI C SECURE PC BOARD ASSEMBLY IN PLACE WITH ITEM 4 NO COMPONENTS BOTTOM SIDE PC BOA
142. Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or death Always use enou
143. W R163 SRES 5 11K TKF 0805 1 1 10W R168 SRES 20K TKF 0805 1 1 10W 1 R169 SRES 50K 5 TURN 1 4 10 i R170 5 15 0805 1 1710 i j 525000 68115 R171 R172 SRES 6 81K TKF 0805 1 1 10W 6 525000 47518MT R20 R21 R23 R25 R27 R30 _ SRES 4 75K 0805 1 TR NP R32 R33 R34 R109 R113 R114 R115 R116 R138 R151 R152 R153 R154 R166 525000 68125 R35 R111 SRES 68 1K 0805 196 1 10W NP 525000 33215 R37 R118 R119 R139 R140 _ SRES 3 32K 0805 1 1 10W NP B80Q42M71 R155 525000 10015 R40 R46 R167 SRES 1K 0805 1 1 10W TRNP 525056 45 RAT SRES 5K 5 TURN POT 1 4W 10 525000 22125 R51 SRES 22 1K TKF 0805 196 1 10W 525000 10005 R55 R124 R125 R126 100 TKF 0805 1 1 10W 525001 26705 R57 R58 R59 R60 R62 R63 _ SRES 267 1206 1 1 4W TR NP R64 R65 525000 10025 7 110 8164 8165 SRES 10K 0805 1 1 10W TRNP 515128 115 Xue SICS 2901 NP 15102 45 SICS MC1413BD ARRAY DRIVER SOT6 525068 15 SICS 5V 0 5 2 525070 35 SICS XC9536 44 PIN VO44 517900 85 51 5 74 14 525020 25 111577 58 525024 55 525024 95 525024 75 525024 85 525040 35 525040 25 OOOOOCO 525044 45 525044 65 OOOOONM 525044 75 525044 85 518248 6 524020 16 524020 12 525051 25 525050 15 525050 25 S2
144. ace the O ring onto the angled seal surface of the filter header and re install the plastic cap Make sure its flange rests on the O ring 9 Screw on the cap ring and tighten hand tight 10 Remember to open the fuel shutoff valve Lever in line with the hose before starting the engine Water Separator Element The water separator ele ment is a two stage filter with a special filtration water separating media An expanded water reservoir pro vides maximum protection against water in the fuel The recommended change interval for the water sepa rator element is 1 000 hours See Figure D 2 and follow this procedure 1 Close the fuel shutoff valve located on the side of the Fuel Pre Filter Water Separator Assembly The lever should be perpendicular to the hose 2 Rotate the quick change ring located just below fil ter header clockwise approximately 1 2 turn and slide it down and off the element 3 Grasp the element and pull down with a slight rock ing motion to remove the element from the grommet post on the bottom of the filter header FIGURE D 2 FUEL PRE FILTER WATER SEPARATOR ASSEMBLY FUEL FILTER QUICK CAP SHUTOFF HEADER CHANGE RING VALVE RING COMMANDER 500 LINCOLN 8 Return to Section Retum to Master TOC MAINTENANCE Slide the new element onto the grommet post on the bottom of the filter header until the element no longer easily
145. act the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 COMMANDER 500 LINCOLN 8 geri Retum to Section Return to Section TOC 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 11 F 11 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The engine will not go to high idle when using the auxiliary power Auxiliary power is normal when the IDLER switch is in the HIGH posi tion Automatic idle function works properly when the welding termi nals are loaded Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS Make sure the auxiliary power leads are tight The automatic idler may not function if the auxiliary power is loaded to less than 150 watts RECOMMENDED COURSE OF ACTION 1 Check the current sensing toroid for loose or faulty connec tions See the Wiring Diagram Make sure leads 3 and 6A pass through the toroid twice in opposite directions The current sensing toroid may be faulty The Weld Control PC board may be faulty The engine will not go to high idle when attempting to weld or when the auxiliary power is loaded Welding output and auxiliary power outputs are normal when IDLER switch is in the HIGH positi
146. aid the technician in the removal and replacement of the case sheet 2 28 metal covers AE 74 MATERIALS NEEDED 3 8 wrench 7 16 wrench 1 2 wrench 3 4 wrench This procedure should take approximately 30 minutes to perform Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 16 F 16 TROUBLESHOOTING amp REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 1 COVER REMOVAL ROUND HEAD SCREW LOCATION LEFT FRONT PANEL PROCEDURE 1 Turn the engine off 4 Support the door assembly Using the 3 8 wrench remove the 10 24 round head screw lock washer flat washer and nut from the top corner of the door hinge assembly where it attaches to the roof Remove the 3 Unlatch and open the engine service access support rod door See Figure F 1 2 Using the 3 8 wrench remove the battery cover Slide the battery out and disconnect the negative battery cable COMMANDER 500 LINCOLN 17 17 TROUBLESHOOTING amp REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 2 FRONT PANEL ROOF DETAILS Return to Section TOC Retum to Master TOC Return to Section TOC
147. al Solid State contactor allows for the selection of hot or cold output terminals with a toggle switch on the control panel Arc Control potentiometer in Wire and Stick modes for precise adjustment of arc characteristics Advanced circuitry to prevent pop outs in the five slope modes FOR AUXILIARY POWER 12 000 watts of 120 240 VAC 60Hz auxiliary power Power for tools 120 240 VAC lights electric pumps and for standby emergency power Drive a 5 HP motor provided it is started under no load Two 20 amp 120 VAC duplex receptacles for up to 40 amps of 120 VAC power One 50 amp 120 240 VAC dual voltage receptacle for up to 50 amps of 240 VAC and up to 50 amps per side to separate branch circuits not in parallel of 120 VAC single phase auxiliary power Allows easy connection to premises wiring Weld and AC auxiliary power at the same time with in machine total capacity OTHER FEATURES Deutz 3 cylinder air oil cooled diesel engine Designed for long life easy maintenance and excel lent fuel economy Engine protection system shuts the engine down for low oil pressure high oil temperature or a broken fan engine alternator belt Gauges for oil pressure oil temperature engine alternator output and fuel level Indicator lights for low oil pressure high oil tempera ture engine alternator low output broken belt and low fuel level on K1639 2 only Automatic low fuel shutdown befo
148. am This procedure should take approximately 40 minutes to perform Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN F 43 F 43 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE TEST CONTINUED FIGURE F 18 FRONT CONTROL PANEL REMOVAL Retum to Section TOC Retum to Master TOC Retum to Master TOC g 0 9 u 8 E a TEST PROCEDURE 0 2 1 Turn the engine off 5 Perform the Power Module Capacitor 8 z 2 Using the 3 8 wrench remove the screws 9 5 holding the front control panel to the case 6 Using the 3 4 wrench remove the internal 8 8 top and sides See Figure F 18 There leads from the output terminals Insulate the two screws on the top and screw leads F F each side cic 3 Carefully lower the front control panel 4 Using the 3 8 wrench remove the front left and right side panels Retum to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN 44 F 44 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE TEST CONTINUED FIGURE F 19 OUTPUT PANEL REMOVAL Return to Section TOC Retum to Master TOC OUTPUT LEADS BEHIND PANEL OUTPUT PANEL Retum to Section TOC Retum to Master TOC 7 Using the 3 8 wrench remove the three 8 Disconnect Bypass PC board leads 206B screws holding the lower front
149. ances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c SAFETY LINCOLN 8 CYLINDER may explode 22584 i if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintain
150. and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum to Master TOC 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the Analog Power Supply PC board is receiving and passing the proper signal voltages Retum to Section TOC Retum to Master TOC MATERIALS NEEDED Analog Volt Ohmmeter Wiring Diagram This procedure should take approximately 30 minutes to perform Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN Return to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 40 F 40 TROUBLESHOOTING amp REPAIR ANALOG POWER SUPPLY PC BOARD VOLTAGE TEST CONTINUED FIGURE F 17 ANALOG POWER SUPPLY PC BOARD CONTROL CIRCUIT INPUT POWER 13 1J41 to POS TERMINAL 14 2 41 to NEG TERMINA N C2 85V SUPPLY TEST PROCEDURE Turn the engine off Perform the Case Cover Removal proce dure Locate plugs J41 and J42 from the Analog Power Supply PC board See Figur
151. anual PROBLEMS SYMPTOMS The engine shuts down shortly after starting POSSIBLE AREAS MISADJUSTMENT S ENGINE PROBLEMS Check for adequate fuel supply If any indicator light is lit when the engine shuts down that par ticular system has faulted Check system Check the battery cables for loose or faulty connections TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check the RUN STOP switch and associated leads for loose or faulty connections 2 Perform the Shutdown Solenoid Test The Peripheral PC board may be faulty With the RUN STOP switch in the RUN position the Peripheral PC board should nor mally supply 10VDC to the shut down solenoid via leads 224 and 262 See the Wiring Diagram See the Engine Starting Diag nostic art The engine will not idle down to low speed The machine has normal weld output and auxiliary power Make sure the IDLER switch is in the AUTO position Make sure there is NOT an external load on the weld termi nals nor the auxiliary power receptacles Check for mechanical restric tions in the solenoid linkage 1 Perform the dler Solenoid Check leads 227 232L 232M and 226A for loose or faulty connections See the Wiring Diagram The Pull Coil PC board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely cont
152. ar the engine This is the FUEL SOLENOID engaging It should stay engaged You should also see all 5 ENGINE WARNING LIGHTS come on for about 5 seconds and then go off Then operate the START button ENGINE WARNING LIGHTS WILL COME BACK on then off again All gauges should be in the NORMAL operating ranges About 30 seconds after starting the engine the inihibit circuit which prevents ENGINE SHUTDOWN will turn off Engine should remain running Are the BATTERY CABLES properly connected Does the PULL COIL read 3 ohms Did you hear the FUEL SOLENOID engage Is the SOLENOID INKAGE bound up Is the BATTERY charged CORRECT that problem Look at wires 224 262 405 270 5T 402 232 236a amp 236 Also 403 232M or 265 PERIPHERAL PCB TRUM OK MAY BE BAD PERIPHERAL PCB or BATTERY PCB MAY BE FUEL SOLENOID engage and REMAIN Does the HOLD COIL read 21 ohms CORRECT that problem Look at wires 243 PERIPHERAL PCB Check the WARNING 247 248 245 MAY BAD LIGHTS 232f 232g 232 Look at wires 224 262 BAD ALSO THE PULL COIL PCB Did all 5 ENGINE WARNING LIGHTS come on 232p 252 amp 253 CORRECT that problem PERIPHERAL PCB MAY BE BAD Did all 5 ENGINE WARNING LIGHTS go OFF F 13 s the BATTER charged ENOUGH to tart the ENGINE
153. areful when working near battery Follow instructions printed on battery COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION IMPORTANT To 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 Before you operate the machine make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the neg ative battery terminal Remove the insulating cap from the negative battery terminal Replace and tighten the negative battery cable terminal NOTE This machine is furnished with a wet charged battery if unused for several months the battery may require a booster charge Be sure to use the correct polarity when charging the battery MUFFLER OUTLET PIPE Remove the plastic plug covering the muffler outlet tube Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned to direct the exhaust in the desired direction SPARK ARRESTER Some federal state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain loca tions where unarrested sparks may present a fire haz a
154. aster TOC COMMANDER 500 LINCOLN Return to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC g 4 2 3 Retum to Master F 28 F 28 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST CONTINUED 6 If either of the readings is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 10mm wrench to loosen the locking nut See Figure 8 for location of the adjusting screw and lock ing nut Turn the threaded screw counter clockwise to increase the HIGH IDLE speed Adjust the speed until the tach reads between 1890 and 1910 RPM Retighten the locking nut Adjust LOW IDLE First make sure there is no load on the machine Set the IDLE switch to AUTO and wait for the engine to change to low idle speed Use the 10mm wrench to loosen the solenoid lever arm locking nut See Figure 9 Adjust the col lar to change the amount of throw in the lever arm until the tach reads between 1450 and 1500 RPM Retighten the locking nut Frequency Counter Method 1 Plug the frequency counter into one of the 115 VAC auxiliary receptacles Start the engine and check the frequency counter At HIGH IDLE 1900 RPM the counter should read 63 Hz At LOW IDLE 1475 RPM the counter should read 49 Hz Note that these are median measure ments hertz readings may vary slightly above or
155. ate at full speed for approximately 12 seconds and then go to low idle speed b When the electrode touches the work or power is drawn for lights or tools approximately 100 Watts minimum the engine accelerates and operates at full speed c When welding ceases or the AC power load is turned off a fixed time delay of approximately 12 seconds starts d Ifthe welding or AC power load is not restarted before the end of the time delay the idler reduces the engine speed to low idle speed e The engine will automatically return to high idle speed when the welding load or AC power load is reapplied COMMANDER 500 LINCOLN 8 Return to Section Return to Section TOC 8 9 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION Idler Operational Exceptions When the WELDING TERMINALS switch is in the Welding Terminals Remotely Controlled position the idler will operate as follows a When the triggering device Amptrol Arc Start Switch etc is pressed the engine will accelerate and operate at full speed provided a welding load is applied within approximately 15 seconds f the triggering device remains pressed but no welding load is applied within approximately 15 seconds the engine will return to low idle speed f the triggering device is released or welding ceases the engine will return to low idle speed afte
156. ator and rotor AE 3 MATERIALS NEEDED 5 16 Wrench 3 8 Wrench Slot head screw driver 7 16 Wrench Phillips head screw driver 1 2 Wrench Gear puller small 3 4 Wrench Hoist 1 Open end wrench Feeler gauge for air gap check 1 1 8 Wrench 9 16 Deep socket wrench 17mm Wrench This procedure should take approximately 5 1 2 hours to perform Retum to Master TOC 8 9 8 Retum to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN Return to Section Retum to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 74 F 74 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT CONTINUED FIGURE F 33 FUEL TANK REMOVAL DETAILS LEADS 229 OQ AND 242D PREPARATION AND LEAD REMOVAL PROCEDURE Refer to Figure F 33 1 2 Turn the engine off Perform the Case Cover Removal dure including removing the output panel Perform the Power Module Output Rectifier Bridge Assembly Removal Perform the Power Module Capacitor Discharge Procedure Using the 3 8 wrench remove leads 229 white and 242D from the fuel level sensor Label the leads for reassembly COMMANDER 500 LINCOLN PLUG FUEL LINES U BOLTS 2 Turn the fuel off at the shutoff valve Remove and plug the fuel return line Remove and plug the lowe
157. below If either of the readings is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 10mm wrench to loosen the locking nut See Figure 8 for location of the adjusting screw and lock ing nut Turn the threaded screw counter clockwise to increase the HIGH IDLE speed Adjust the speed until the frequen cy reads 63 Hz Retighten the locking nut Adjust LOW IDLE First make sure there is no load on the machine Set the IDLE switch to AUTO and wait for the engine to change to low idle speed Use the 10mm wrench to loosen the solenoid lever arm locking nut See Figure F9 Adjust the col lar to change the amount of throw in the lever arm until the frequency reads 49 Hz Retighten the locking nut Oscilloscope Method 1 COMMANDER 500 LINCOLN Connect the oscilloscope to the 115 VAC receptacle according to the manufacturer s instructions At HIGH IDLE 1900 RPM the waveform should exhibit a period of 15 8 milliseconds At LOW IDLE 1475 RPM the waveform should exhibit a period of 20 3 milliseconds Refer to the NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115 VAC SUPPLY HIGH IDLE NO LOAD in this section of the manual If either of these waveform periods is incor rect adjust the throttle as follows Adjust HIGH IDLE Use the 10mm wrench to loosen the locking nut See for location of the adjusting screw and lock ing nut Turn the threaded screw counter clockwise to increase the HIGH IDLE spee
158. ble must be sized for current and duty cycle of application NOTE Figure C 4 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the Commander 500 output terminals 3 Connect the K595 XX Input Cable Assembly to the LN 8 4 Connect the K595 XX to the 14 pin amphenol on the Commander 500 5 Place the IDLER switch in the HIGH position CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 6 Setthe VOLTMETER switch to or depend ing on the polarity chosen 7 Setthe OUTPUT RANGE switch to WIRE WELD ING CV 8 Setthe WELDING TERMINALS switch to WELD ING TERMINALS REMOTELY CONTROLLED 9 Adjust wire feed speed and voltage at the LN 8 10 Adjust the ARC CONTROL to the desired level soft or crisp FIGURE C 4 COMMANDER 500 LN 8 WITH K595 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM 14 PIN AMPHENOL a TO LN 8 INPUT Ww CABLE PLUG K595 INPUT CABLE ASSEMBLY Co o TO WORK ELECTRODE CABLE TO WIRE FEED UNIT COMMANDER 500 LINCOLN 8 Return to Section Return to Section TO
159. cable tie and pull lead W11 through the toroid Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 64 F 64 TROUBLESHOOTING amp REPAIR POWER MODULE OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT CONTINUED FIGURE F 29 POWER MODULE OUTPUT RECTIFIER BRIDGE ASSEMBLY DETAILS POWER MODULE PC BOARD CHOPPER PC BOARD DIODE amp c W LEAD c s TERMINAL lt GLASTIC INSULATOR BRACKET CONTROL 21 NX o nm Mu 555 5 BOTTOM BRACKET E y n lt amp 5 4 ce rd E LD CAPACITOR B d COMMANDER 500 LINCOLN Return to Section Retum to Section TOC 5 8 9 8 Return to Section TOC to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 65 F 65 TROUBLESHOOTING amp REPAIR POWER MODULE OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT CONTINUED Refer to Figure F 29 for Steps 13 15 13 14 15 The power Using the 7 16 wrench remove the stator W leads from the three terminals on the plastic insulator bracket of the rectifier bridge Label the leads for reassembly Pull the leads out through the power mod ule top bracket
160. ceptacle K857 25 ft 8 5 m or K857 1 100 ft 30 4 m REMOTE CONTROL Portable control provides same dial range as the output control on the welder from a location up to the specified length from the welder Has convenient plug for easy connection to the welder The Commander 500 is equipped with a 6 pin connector for connecting the remote control K704 ACCESSORY SET Includes 35 feet 10 m of electrode cable and 30 feet 9 m of work cable head shield work clamp and electrode holder Cable is rated at 500 amps 60 duty cycle K953 1 TWO WHEEL TRAILER For road in plant and yard towing Road towing with optional fender and light kit For highway use consult applicable federal state and local laws regarding possible additional requirements K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender and Light Kit K965 1 Cable Storage Rack K825 1 ETHER START KIT Provides maximum cold weather starting assistance for frequent starting below 10 F 12 2 C Required Ether tank is not provided with kit K949 1 OIL DRAIN KIT Includes ball valve hose and clamp K1690 1 1 DUPLEX GFCI Klt Includes a UL approved 115 volt ground fault circuit interrupter recep tacle duplex type with cover and installation instruc tions Each half of the receptacle is rated 15 amps but the maximum total current from the GFCI duplex is lim ited to 20 amps The GFCI receptacle replaces the fac tory in
161. cess panel 14 Using the 3 8 wrench remove the brush holder assembly 15 Cut the cable tie and then label and remove brush leads 201 and piggy backed leads 200A and 200B from the brush holder assembly The piggy backed leads connect closest to the stator laminations Return to Section TOC Retum to Master TOC FIGURE F 36 CONTROL BOX CONNECTIONS PULL COIL PC BOARD LEADS 265 AND 227 CONTROL BOX 12 VDC STUD LEADS 232L AND 232M 1r SB HE 8 8 E cic 16 See Figure F 36 Disconnect leads 265 and 4227 17 With the 3 8 wrench remove the two screws from from the Pull Coil PC board With the 7 16 the bottom of the control box Swing the control wrench remove the nut lock washer and flat box aside and lay it down washer from the 12 VDC insulated stud Remove leads 2321 and 232M from the stud Cut any necessary cable ties Pull all leads freed in this step through the control box panel Return to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN 77 77 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT CONTINUED FIGURE F 37 ALTERNATOR SHROUD REMOVAL Return to Section TOC Retum to Master TOC 6 SCREWS SHROUD Retum to Master TOC B 5 9 u 8 a machine base Remove the shroud gig FE 8 18 With the 5 16 wrench remove the six 19 With the 7 16 wrench remove the two g screws that hold
162. cessary Replace the brush holder access panel Replace the right front case cover Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 31 TROUBLESHOOTING amp REPAIR FLASHING AND ROTOR VOLTAGE TEST WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct DC voltage is being applied to the rotor at the maxi mum engine speed 1900 RPM This information will aid the technician in determining if the generator field is operating properly MATERIALS NEEDED Volt Ohmmeter 3 8 Wrench Wiring Diagram This procedure should take approximately 35 minutes to perform COMMANDER 500 LINCOLN F 31 Return to Section Return to Section TOC 5
163. cted without removing the case cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this section Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points Components terminal strips etc can be found on the referenced elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram 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 Call 1 800 833 9353 COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC TROUBLESHOOTING amp REPAIR
164. ctions The welding cables may be too long or coiled causing an excessive voltage drop Make sure the electrode wire gas voltage current etc is cor rect for the process being used TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check for the correct OCV at the welding output terminals If the correct voltage is present at the output terminals check for loose connection on the heavy current carrying leads inside the Commander 500 See the Wiring Diagram If the OCV is low at the welder output terminals perform the Engine Throttle Adjustment Test 3 Perform the Output Rectifier Bridge Test Perform the Stator Voltage Perform the Power Module st The Weld Control PC board may be faulty 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 Call 1 800 833 9353 COMMANDER 500 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Ojo ojo E 56 t olse wn 12 81 8 E E s p Bie o o Return to Section TOC Return to Master TOC F 13 TROUBLESHOOTING amp REPAIR ENGINE STARTING DIAGNOSTIC CHART Starting ENGINE Upon placing the RUN STOP switch in the RUN position you should hear a click ne
165. cur rent DC welding output for stick SMAW and TIG weld ing The Commander 500 also provides excellent con stant voltage DC welding output for MIG GMAW and Innershield FCAW welding GENERATOR The Commander 500 provides smooth 120 240 VAC output for auxiliary power and emergency standby power DESIGN FEATURES AND ADVANTAGES K1639 2 COMMANDER 500 DELUXE MODEL FEATURES FOR WELDING Excellent DC multi purpose welding for stick MIG TIG cored wire and arc gouging applications 30 to 500 amps output in five slope controlled ranges for out of position and pipe electrodes one constant current output range for general purpose welding one constant voltage range for MIG wire and cored wire welding and one 20 250 amp range for Touch Start TIG welding 100 duty cycle at 500 amps output and 50 duty cycle at 575 amps output Dual 3 digit output meters are provided optional on K1639 1 for presetting the weld amperage or volt age and displaying the actual amperage and voltage during welding The meters use superbrite L E D s for improved readability in full sunlight LOOK BACK FEATURE After welding has stopped both displays will remain on for 7 seconds with the last current and voltage value displayed During this time the left most decimal point in each display will be FLASHING Standard remote control capability with 14 pin and 6 pin connectors for easy connection of Lincoln remote control accessories An intern
166. d Adjust the speed until the period is 15 8 milliseconds Retighten the locking nut Adjust LOW IDLE First make sure there is no load on the machine Set the IDLE switch to AUTO and wait for the engine to change to low idle speed Use the 10mm wrench to loosen the solenoid lever arm locking nut See Figure F 9 Adjust the col lar to change the amount of throw in the lever arm until the period is 20 3 millisec onds Retighten the locking nut Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 29 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE TEST WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if there is a shorted winding in the rotor or if the rotor is grounded MATERI
167. d Amps Voltage Load Volts Load Amps 245 254 225 240 50 118 132 112 128 15 COMMANDER 500 LINCOLN Retum to Master Retum to Master Y 4 2 8 5 4 Retum to Master ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams G 1 Wirmg Diagram SR G 2 Schematic Complete G 3 Schematic Battery PC G 4 PC Board Assembly Battery PC Board G 5 Schematic Chopper PC nennen nennen trn enne enne G 6 PC Board Assembly Chopper PC G 7 Schematic Peripheral PC Board sess nnne nnns G 8 PC Board Assembly Peripheral PC Board sess G 9 Schematic Power Supply Analog PC 2 G 10 PC Board Assembly Power Supply Analog PC G 11 Schematic Pull Coil PC Board sssssssssssssssseeeeen enne enne nter nnne ns G 12 PC Board Assembly Pull Coil PC Board ssssssssssssseeeeeeeeenneee eene G 13 Schematic Weld Control PC Board Sheet 1 G 14 Schematic
168. d 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum to Master TOC 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will aid the technician in the removal and replacement of the Power Module chopper PC board and the board diode module Retum to Section TOC Retum to Master TOC MATERIALS NEEDED 7 16 Wrench 3 8 Allen head wrench 9 64 Allen head socket Phillips head screw driver Penetrox A13 thermal joint compound T12837 1 2 gm tube This procedure should take approximately 60 minutes to perform Retum to Master TOC 8 9 8 Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN F 67 F 67 TROUBLESHOOTING amp REPAIR E POWER MODULE CHOPPER BOARD DIODE 5 z MODULE REMOVAL AND REPLACEMENT CONTINUED 2 2 8 FIGURE F 30 POWER MODULE BOARD EJE i TEMPERATURE SWITCH HEAT SINK COP
169. d from construction activities moving vehicles and other hazards 2 Drain the engine oil and refill with fresh 10W30 oil Run the engine for about five minutes to circulate oil to all the parts See the MAINTENANCE section of this manual for details on changing oil 3 Remove the battery recharge it and adjust the electrolyte level Store the battery in a dry dark place STACKING Commander 500 machines cannot be stacked ANGLE OF OPERATION To achieve optimum engine performance the Commander 500 should be run in a level position The maximum angle of operation for the Deutz engine is 30 degrees fore and aft 40 degrees right and 45 degrees left If the engine is to be operated at an angle provi sions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the specified 25 gallons 94 6 liters COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC g 4 2 3 Retum to Master INSTALLATION 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
170. date your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will insure that the large capacitors in the power modules have been dis charged This procedure should be performed whenever work is to be attempted on or near the power modules MATERIALS NEEDED 3 8 Wrench Volt Ohmmeter Resistor 25 1000 ohms and 25 watts minimum Jumper leads This procedure should take approximately 15 minutes to perform COMMANDER 500 LINCOLN F 19 Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 20 F 20 TROUBLESHOOTING amp REPAIR POWER MODULE CAPACITOR DISCHARGE PROCEDURE CONTINUED FIGURE F 4 POWER MODULE CAPACITOR TERMINAL DISCHARGE PROCEDURE 1 This procedure must be performed with the 4 engine off 2 Using the 3 8 wrench remove the front left and right side panels 3 Locate the four capacitors two on each side See Figure F 4 COMMANDER 500 LINCOLN CAPACITO
171. du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POU R partie du corps LE S MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillaant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront ef
172. e lt 5 3 o o Return to Section Return to Master TOC G 3 SCHEMATIC COMPLETE MACHINE COMMANDER 500 _ _ REMOTE CONTROL ROUND AMPHENOL A B D E F POSITIVE OUTPUT Lt NOTE COMMANDER 500 USES 2 300 AMP CHOPPER MODULES amp COMMANDER 300 USES 2 200 CHOPPER MODULES SHUNT 50MV 400 AMPS SN ELECTRICAL DIAGRAMS IGBT MODULE EMMITTER IS COMMON TO HEATSINK PC BOARD 050 3 18 50 1 17 IGBT MODULE EMMITTER 15 COMMON TO HEATSINK X wi 90 2045 CURRENT LEVEL 2068 206A 2065 FEED BACK SIGNAL BY PASS PC BOARD WIREFEEDER VOLTMETER 777 NEGATIVE __ OUTPUT TERMINAL TO sisvac _ Foo wo 4 EP 3 POLARITY SWITCH 208A 2400uf 100vdc THREE PHASE RECTIFIER N A Wi we STATOR WELD FOUR POLE 1800 RPM ALTERNATOR 37 9 omia gN 2065 6 2 2048 J6 1 2088 J12 16 ARC VOLTAGE FEEDBACK TI Q7 OUTPUT CONTROL 10K P 76 27 2 ov 75 J7 3 30V rra 10 1 REMOTE 15V WIOPOT PHENOL CONTROL 10K lt ov 75a 10 3 279 9 3 278 92 277 9 1 ARC CONTROL 10K TOROID SENSES AC
173. e F 17 Start the engine and run it at high idle 1900 RPM with no load Check for the correct input voltage a Set the volt ohmmeter to the Volts DC position b Place the negative probe on J41 pin 2 and the positive probe on J41 pin 1 c The reading should be between 75 and 85 VDC ON C2 85V SUPPLY o J41 p nina o0000 7 500 LINCOLN J42 If the reading is not correct the stator out put may be incorrect the rectifier output may be incorrect the power capacitors may be faulty or the Power Module PC board may be faulty Perform the Sito Vonage the and the The capacitors C1 C2 C3 or C4 may be faulty Test and replace if necessary Check for the correct output voltage read ings per Table F 1 If any of the readings are not correct the Analog Power Supply PC board may be faulty When finished testing perform the Cover Heplacement procedure Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 5 Retum to Master TOC F 41 TROUBLESHOOTING amp REPAIR F 41 ANALOG CONTROL POWER SUPPLY PC BOARD TEST CONTINUED TABLE F
174. e X9 A 400V 200K a 3 ano o 27 406880 cuore 19 ape REMOTE BINCH POT R275 R279 o 50V sov amp 10 0K 10 0K em 3 2 FX ARC FRC ENABLE E BW gt 15 olo 10 V Mee Pert X10 R 4 75 5 01 10V_REF 10V_REF MIN_POT_ENABLE g X42 9 06680 1 2 6 poH 240 Aviv e ps 4 50 0 LO PINCH POT IN CV 5 m gt 3 14 15 E70 5V_REF 45V REF E A RIBl r1 i um 33K g al E Em 167 Atv H E 8 362 FIXED arc FORCE 8 622 L 330748 7 TU P L ae 1 023V_REF lt p 1 023V_REF lesik D Ww Veo He als 5 0 lt SETPOINT AMP FOR Ausv REMOTE_DETECT 0 28 3 B ARC FORCE INCREASE 51 70v 3 R59 v R62 30740 100 825K asv V o E 01 EMT 28 OIW B S noi Vasv oa ARC FORCE POT E C 3 177 e az ARC FORCE CONTROL 15v Lt 0056 XII U XJT 29 WIPER 50 1 a p 8 9 E 2 ia vo 190 8 T 5 eios 01 B A Rr D 406680 12 406680 01 90228 75K S 150 100 5 Cw fI 50V ARC FORCE ENABLE 8 50 2 01 amp oiw 6 2 1 Vow mis T 2 LO ARC FORCE POT OR FIXED g vw 7 mn bsa ia PAGE 2 OF 5 S 6 50740 ZZIK dv USE WSC 1 30V 01 GND 01 400V R293 406680 m R186 REMOTE 1 AF POT LE x2 0 GENERAL INFORMATION O So 213
175. e air cleaner hose clamp and detach the hose Remove the engine end panel with air box and air cleaner attached for access to the engine See Figure D 4 Loosen the alternator mounting bolts 1 2 3 and rotate the alternator toward the engine Remove the old cooling blower belt and install a new one Push outward on the alternator 4 and adjust the cold belt tension to 63 73 165 10 15 mm mum deflection midway between any two pulleys Tighten bolts 1 2 3 Reinstall the air cleaner hose engine case side and engine end panel Reattach the negative bat tery cable Slide in and refasten the battery holder Check the cooling blower belt tension after 100 hours of operation Follow seps 1 6 9 and 10 FIGURE D 4 COOLING BLOWER BELT REPLACEMENT AND ADJUSTING COMMANDER 500 LINCOLN 8 Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC MAINTENANCE TABLE D 1 DEUTZ ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Starting Engine Fill fuel tank Check oil level Check air cleaner for dirty loose or damaged parts Replace if necessary Check air intake and cooling areas clean as necessary First 50 Hours and Every 250 Hours Thereafter Change engine oil
176. e bolts and lock washers Install the fan blade making sure that it faces the proper direction with the fan nut and four cap screws Check the air gap for 010 minimum Install the brush holder assembly Be sure the brushes are centered and properly seated on the slip rings Install the flywheel splash plate COMMANDER 500 LINCOLN Return to Section Retum to Section TOC 5 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 81 TROUBLESHOOTING F 81 amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT CONTINUED LEAD RECONNECTION CHECKLIST ENGINE OUTPUT PANEL AND CONTROL BOX Leads 242D and 229 to fuel level sensor Plug J52 Brush leads 201 and 200A and 200B Leads 5P 201 and 201A 200D and 6F to the field bridge rectifier COMMANDER 500 LINCOLN Leads 265 and 227 to Pull Coil PC board Leads 232L and 232M to 12 VDC insu lated stud Leads 200C 200E and 200B to the field capacitor F 82 F 82 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine If itis rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics OR f you repair or replace any electrical components Retum to Section TOC Retum to Mast
177. e knob should peel away from the nameplate and the white nylon holding fingers of the knob base from top to bottom Return to Section TOC Return to Master TOC Replacement O10 Fle 5 5 zelo 218 5 a Replacement 1 If the white nylon cam of the detent mechanism is removed from it s spring loaded base by the above procedure or intentionally it should be returned before the knob replacement is attempted Press the cam into it s spring loaded holder so it sets flat and flush Selector Switch Only 2 Orientate the knob handle to the vertical as noted above and position the knob over the base centered and parallel 3 Press the knob onto the D shaft and white nylon holding fingers maintaining the parallel position The knob should click into place and should not pull off with normal operation Return to Section TOC Return to Master TOC COMMANDER 500 LINCOLN Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 19 TROUBLESHOOTING amp REPAIR POWER MODULE CAPACITOR DISCHARGE PROCEDURE WARNING 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 invali
178. ead 281 to engine ground See the Wiring Diagram Normal is 13 2 to 14 5 VDC NOTE Lead 281 carries the flashing voltage for the engine alternator Battery voltage should be present whenever the engine is running See the Wiring Diagram 8 10 COMMANDER 500 LINCOLN If the correct flashing voltage is present and the charging output voltage is low or missing the engine alternator may be faulty Stop the engine and check the alternator V belt for proper tension See the engine operation manual Replace the left rear case cover 52 52 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY HIGH IDLE NO LOAD 15 8 ms Retum to Section TOC Retum to Master TOC TEETH Ht 0 volts Retum to Master TOC g 0 9 u 8 E a 50V 5ms This is the typical auxiliary output voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division rep resents 5 milliseconds in time P P dr 4 Note Scope probes connected at 9 5 machine 115VAC receptacle 818 SCOPE SETTINGS g Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal 91 P P 5 8 2 2 8 ali a COMMANDER 500 LINC
179. ed in good condition Always keep cylinders an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Retum to Master Retum to Master Y 4 2 3 Retum to Master
180. element changing procedures FIGURE D 3 SECONDARY FUEL FILTER SECONDARY FUEL FILTER OIL FILTER COMMANDER 500 LINCOLN 8 Return to Section Retum to Master TOC Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC D 6 D 6 MAINTENANCE 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 FILTER CAUTION Excessive air filter restriction will engine life result in reduced The air filter element is a dry cartridge type It can be cleaned and reused However damaged elements should not be reused Stop engine after 100 hours of running time and clean filter element Replace the fil ter if necessary Service the air cleaner regularly according to your engine operation manual 1 Locate the air filter canister located behind the engine door on the top of the engine 2 Remove the air filter element Remove loose dirt from the element with com pressed air or a water hose directed from inside out Compressed Air 100 psi maximum with nozzles at least one inch away from the element Water Hose 40 psi maximum without nozzle Soak the element in a mild detergent solution for 15 minutes Do not soak more than 24 hours Swish the element around
181. ent flow The drain terminal of the IGBT may be connected to a voltage supply but since there is no conduction the circuit will not supply current to components connected to the source The circuit is turned off like a light switch in the OFF position POSITIVE VOLTAGE GATE SOURCE BODY REGION DRAIN DRIFT REGION lt BUFFER LAYER lt INJECTING LAYER DRAIN B ACTIVE Drawing B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply con nected to the drain terminal will allow the IGBT to con duct and supply current to circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the posi tive gate signal is present This is similar to turning ON a light switch COMMANDER 500 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o E 5 B Return to Section Return to Master TOC Q 52 x 2 THEORY OPERATION FIGURE E 6 TYPICAL IGBT OUTPUTS MINIMUM OUTPUT 2 usec 48 u sec 50 sec Dwell or Time MAXIMUM OUTPUT 48 u sec PULSE WIDTH MODULATION The term PULSE WIDTH
182. er Belt 2 e nne bes nib Er dnd ee Rx D 7 f Engine Maintenance D 8 Engine Maintenance Parts t snae Ree Erbe dudes D 8 Battery Maintenariece iie are ed ae Pau Ro rep aa eg D 9 Cleaning the 2 4024 040000000 D 9 Checking Specific D 9 Checking Electrolyte Level D 9 Charging the Battery sssssssssssssssesseee D 9 Welder Generator Maintenance D 10 5 Ses D 10 g GIG ANIING D 10 8 D 10 E Brush Removal and D 10 ec aries D 10 M D 10 Cable CONMOCHONS DE D 10 Major Component D 11 Y 4 2 8 5 A COMMANDER 500 LINCOLN 8 Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC g 4 2 8 3 Retum to Master MAINTENANCE SAFETY PRECAUTIONS WARNING Have qualified personnel do all maintenance and troubleshooting work Turn the
183. er TOC ENGINE RPM Mode No Load RPM Load RPM Low Idle 1400 1450 NA High Idle 1890 1910 1750 1890 WELDER DC STICK OUTPUT Mode Selector Open Circuit Switch Fine Control Voltage Load Volts Load Amps 30 575 Setting Maximum 75 80 39 5 42 0 575 585 Return to Section TOC Retum to Master TOC PIPE MODES SHORT CIRCUIT CURRENT FINE CONTROL AT MAXIMUM Selector Position Short Circuit Current Amps 90 127 140 150 215 230 200 310 330 350 545 575 500 640 660 Retum to Master TOC 9 8 9 8 WELDER CV WIRE OUTPUT Mode Selector Open Circuit Switch Fine Control Voltage Load Volts Load Amps CV Wire Maximum 75 78 39 42 520 535 CV Wire Maximum NA 48 49 20 CV Wire Minimum 23 25 13 14 20 Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN Retum to Section Return to Section TOC 9 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 83 F 83 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR CONTINUED TOUCH START TIG MODE OUTPUT Mode Selector Open Circuit Short Circuit Switch Fine Control Voltage Current 20 250A Maximum 14 0 15 8 25 27 TIG 20 250A Minimum 12 0 13 8 21 24 AUXILIARY POWER OUTPUT 230 Volt Receptacle 115 Volt Receptacles Open Circuit Open Circuit Voltage Load Volts Loa
184. eturn to Master TOC m 1 2 0 07 2861 SEALANT 2 820590 1 HEAT SINK 490 005 518250 542 LUG amp LEAD ASSEMBLY RESTRAINED 79 NOTES CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 BEFORE HANDLING N C THESE AREAS TO BE COVERED ON BOTH SIDES OF BOARD WITH ig I SEALANT PRIOR TO ENCAPSULATION 105 N D INJECT SEALANT ITE 5 THROUGH THE PC BOARD HOLES CRIMP HEIGHT 10 HOLES TO SEAL MODULE LEADS CAVITY BETWEEN BOARD AND MODULE TO BE COMPLETELY FILLED WITH TEM 5 SEALANT MATERIAL AS PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS COVER ALL MODULE LEADS THAT PROTRUDE FROM THE NON MODULE EYELET DETAIL SIDE OF THE BOARD WITH 5 SEALANT N E FEMALE EYELET TO BE AGAINST THE OPPOSITE COMPONENT SIDE AS SHOWN EYELET MUST NOT SPIN AFTER CLINCHING N F SOLDER THAT SOLDER COVERS ENTIRE EYELET AND ALL AROU ON OPPOSITE COMPONENT SIDE ONLY NO ICICLES OR SOLDER BLOBS MITTED MANUFACTURED AS N G DO NOT COVER OVER COMPONENT C5 WITH SEALANT 1315 180 PLACE SEALANT ALONG SIDE AND UNDER COMPONENTS ELECTRONIC MODULES ON A COMMON BOARD ASSEMBLY TO HAVE IDENTIFICATION CODE VGE TH WITHIN 5 SORT CODES 0 5VSPAN FOR THE SAME VCE SAT CODE AND MANUFACTURING CODE N J THIS DIMENSION APPLIES TO TWO OF THE FOUR EYELETS ELECTRONIC MODULES TO BE ASSEMBLED AND ENCAPSULATD PER E3875 ON HOLE SIZES PER E2056 WITH PUBLISHED STANDARDS
185. f the electrode cable is on your right Do not put your hands near the engine fan Do not attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance d 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropriate Retum to Master TOC LINCOLN 8 Retum to Master Retum to Master TOC Y 4 2 8 5 3 Retum to Master SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there i
186. f the engine high idle speed is low perform the Throttle Ad justment Test 2 Perform the Rotor Resistance Perform the Flashing and Rotor Voltage Test f the rotor voltage is low the field capacitor or field bridge may be faulty Test and replace if necessary See the Wiring Diagram If the engine high idle RPM is OK then the engine may have lost horsepower and be in need of major repair 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 Call 1 800 833 9353 COMMANDER 500 LINCOLN 8 geri 7 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS The machine control is still active This is normal in TIG mode 1 Check Plug J10 on the Weld when the remote control unit is Control PC board for loose or The remote control unit may be attached faulty connections defective 2 The Weld Control PC board may be faulty Retum to Section TOC Retum to Master TOC Check the Amphenol connec tions and associated wiring The machine seems locked into the 1 Check the position of the MODE 1 Check the MODE SELECTOR CC mode of operatio
187. fectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 MASTER TABLE CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page SANE ERE i iv DEICUCUT Section A RTT Section B Accessories Section 222000 Section D Theory of Operation 2 2 20 2124 441222 Section E Troubleshooting and Repair ette Section F Electrical Diagrams seetetnen entren Section G Parts WAN AM ea ttti meii rau PO COMMANDER 500 LINCOLN 8 V Section 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION 8 i Metalai oN epo cee cate cel ae Section A g TECHNICAL Specifications eet a a 2 8 Safety PPE CAUN 6 MH A 3 E LOCAtION Enn 3 4 x M A 3 3 Angle of Operation tists ai A 3 Niro A 4 High Altitude Operation 1 000 enne nennen 4 High Temperature Operation
188. first and connect to the new battery last e THE CORRECT POLARITY 15 NEGATIVE GROUND Damage to the engine alternator and the printed circuit board can result from incorrect con nection SB CONNECTING A BATTERY CHARGER Remove the battery from the welder by disconnecting the negative cable first then the positive cable and battery clamp When reinstalling connect the negative cable last Keep the area well ventilated USING A BOOSTER Connect the positive lead to the battery first then connect the negative lead to the engine foot To prevent BATTERY BUCKLING tighten the nuts on the battery clamp until snug CLEANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty If the termi nals appear corroded disconnect the battery cables and wash the terminals with an ammonia solution or a solution of 1 4 pound 0 113 kg of baking soda and 1 quart 0 946 of water Be sure the battery vent plugs if equipped are tight so that none of the solution enters the cells After cleaning flush the outside of the battery the bat tery compartment and surrounding areas with clear water Coat the battery terminals lightly with petroleum jelly or a non conductive grease to retard corrosion Keep the battery clean and dry Moisture accumulation on the battery can lead to more rapid discharge and early battery failure CHECKING SPECIFIC GRAVITY Check each battery cell with a hydrometer A fully
189. flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician Keep all equipment safety guards covers before welding and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known Y 4 2 8 All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 6 In some cases it may be necessary to remove safety 2 d 1 Route the electrode and work cables together Secure guards to perform required maintenance Remove them with tape when possible guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 2 Never coil the electrode lead around your body Always use the greatest care when working near moving parts 2 d 3 Do not place your body between the electrode and work cables I
190. form the Output Panel the Case Cover Replacement Procedures COMMANDER 500 LINCOLN Return to Section Retum to Section TOC 5 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y 4 2 8 3 Retum to Master F 69 F 69 TROUBLESHOOTING amp REPAIR POWER MODULE CHOPPER PC BOARD DIODE MODULE REMOVAL AND REPLACEMENT CONTINUED FIGURE F 31 DIODE MODULE MOUNTING DETAILS AND TIGHTENING SEQUENCE 12 18 IN LBS SPRING WASHER PLAIN WASHER lt lt 5 0 10 IN LBS 30 40 IN LBS FINGER TIGHT 5 0 10 IN LBS OLO 9 JO DIODE MODULE REMOVAL Refer to Figure F 31 1 Remove the Power Module PC board as described above Using the 7 16 wrench remove the two outer screws spring washers and large flat washers from the diode module Using the 9 64 allen wrench remove the set screw from the center of the diode module Remove the diode module from the heat sink DIODE MODULE REPLACEMENT Refer to Figure F 31 A CAUTION The proper tightening sequence is required to mount the diode module to the heat sink in order to avoid warping the base plate Apply the proper torque to all fasteners COMMANDER 500 LINCOLN Be sure the heat sink mounting surface is clean dry and free of grease Apply a thi
191. gh ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Mar 95 Retum to Master Retum to Master TOC Retum to Master TOC Retum to Master TOC RUS WELDING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard 249 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from subst
192. h to WIRE WELD ING CV 6 Set the WELDING TERMINALS switch to WELD ING TERMINALS ALWAYS ON 7 Set the VOLTMETER switch to or depend ing on the polarity chosen 8 Adjust wire feed speed at the LN 25 9 Adjust the ARC CONTROL to the desired level soft or crisp FIGURE C 6 COMMANDER 500 LN 25 ACROSS THE ARC CONNECTION DIAGRAM 14 PIN AMPHENOL 6 PIN AMPHENOL TO WORK OPTIONAL K444 1 REMOTE CONTROL LN 25 WIRE FEEDER WORK CLIP LEAD TO WORK NN ELECTRODE CABLE COMMANDER 500 LINCOLN 8 Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE SECTION 8 i Maintenance eee ee nS EE sn ep a Pe oD PEERS ae Section D g Safety Precautionis uae foster t a ea aaa a D 2 Routine and Periodic D 2 E eer ee ee eT ee ene D 2 ec WV GCI se HR D 2 m D 2 Change the m cM D 2 Change the Oil Filter 6505 D 3 I D 3 D 4 5 Bleeding the Fuel D 6 5 0 6 g Cooling eri dete et deaas D 7 8 Cooling Blow
193. heck the oil level If necessary add oil to bring the level up to the MAX mark but do not overfill See Figure D 1 FUEL At the end of each day s use refill the fuel tank to minimize moisture condensation and dirt contamina tion in the fuel line Do not overfill leave room for the fuel to expand Refer to your engine operation manual for recom mended grade of fuel COMMANDER 500 LINCOLN 8 Return to Section Return to Section TOC 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC MAINTENANCE FUEL FILTERS A WARNING A When working the fuel system Keep naked lights away do not smoke Do not spill fuel The Commander 500 is equipped with a Fuel Pre Filter Water Separator Assembly located before the lift pump and al amp econdary Fuel Filterllocated after the lift pump and before the fuel injectors The Fuel Pre Filter Water Separator is mounted to the engine block just below the lift pump Figure D 2 The Secondary Fuel Filter is mounted directly to the engine just above the oil filter Figure D 3 Fuel Pre Filter Water Separator Assembly The pre filter is a 150 micron screen designed to protect against gross fuel contamination of the water separator ele ment and the Secondary Fuel Filter If the pre filter becomes plugged it may be removed inspected cleaned and reinstalled In ge
194. hnology Controlling the switch in such a way as to produce superior welding COMMANDER 500 LINCOLN 8 Section F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION E 5 Troubleshooting amp Repair Section F E How to Use Troubleshooting Guide ssssssssneeeeenneeene nennen nnne F 2 9 Board Troubleshooting PIODSOHEBS au sassie cirea ad viande aic adiri F 3 Troubleshooting Gulde 4 2 Engine Starting Diagnostic Chart ssssssssssssssssssseesee enne F 13 Start Up and Diagnostic Chart ennt nnns F 14 Test Procedures RT F 15 Case Cover Removal and Replacement F 15 Case Front Knobs Removal and Replacement Procedure F 18 Power Module Capacitor Discharge Procedure F 19 Idler Solenoid E ttes F 21 Shutdown Solenoid MI c Nea acces state ate F 23 E Engine Throttle Adj ustment Test nennen nennen enne F 25 9 Rotor Resistance Test iiiter n Eiern ie enel F 29 E Flashing and Rotor Voltage Test F 31 c Stator Voltage Mr 34 Analog Power Supp
195. ically live parts at the same time Workstations Reusable Container Tools which come in contact with the PC Board must be either conductive anti static or static dissipative Remove the PC Board from the static shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag e If the PC Board uses protective shorting jumpers don t remove them until installation is complete e If you return a PC Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all electri cal components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a f the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replaceme
196. iety of DC Tungsten Inert Gas TIG welding applications In general the Touch Start feature allows contamination free starting without the use of a Hi Freq unit But the K930 1 or 2 TIG module or K799 Hi Freq unit can be used with the Commander 500 The settings for these follow the tungsten current range table Table B 3 COMMANDER 500 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC B 10 B 10 OPERATION TABLE TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES Approximate Argon Gas Flow Rate DCEN DCEP Tungsten Electrode 1 2 1 2 TIG TORCH Diameter Thoriated Thoriated Nozzle in mm Tungsten Tunsten Aluminum Stainless Steel Size 0 010 25 2 15 2 4 2 4 4 5 6 0 020 50 5 20 3 5 10 3 5 5 10 3 5 0 40 1 0 15 80 3 5 10 3 5 116 1 6 70 150 10 20 5 10 3 5 9 13 4 6 5 6 3 32 2 4 150 250 15 30 13 17 6 8 11 15 5 7 6 7 8 1 8 3 2 250 400 25 40 15 23 7 11 11 15 5 7 5 32 4 0 400 500 40 55 21 25 10 12 13 17 6 8 8 10 3 16 4 8 500 750 55 80 23 27 11 13 18 22 8 10 1 4 6 4 750 1000 80 125 28 32 13 15 23 27 11 13 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shielding gases Tu
197. in the solution to help remove dirt Rinse elements from inside out with a gentle stream of water less than 40 psi to remove all suds and dirt Dry the element before reuse with warm air at less than 160 F 71 C Do not use a light bulb to dry the element Inspect for holes and tears by looking through the element toward a bright light Check for damaged gaskets or dented metal parts Do not reuse dam aged elements Protect the element from dust and damage during drying and storage Reinstall the air filter element After six cleanings replace the air filter A cleaned filter will have approximately 70 of the life of a new filter element A restricted filter element may not appear excessively dirty COMMANDER 500 LINCOLN 8 Return to Section Return to Section TOC 5 8 9 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master MAINTENANCE 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 BELT The following procedure should be followed to replace the cooling blower belt 1 2 Allow the machine to cool Unfasten and slide the battery holder out from the welder 3 Disconnect the negative battery cable 4 Remove the engine case side 5 Loosen th
198. incoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD Q JE 5 5 TEST DESCRIPTION 9 g This test will determine if the correct AC voltages are being generated from the stator 9 8 windings AE MATERIALS NEEDED Volt Ohmmeter 3 8 wrench 3 4 Wrench This procedure should take approximately 40 minutes to perform Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN 35 35 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TEST CONTINUED FIGURE F 13 FRONT CONTROL PANEL REMOVAL Return to Section TOC Retum to Master TOC Retum to Master TOC B 5 9 u 8 a gig FE 8 RE 2 818 TE TEST PROCEDURE 1 Turn the engine off 4 Using the 3 8 wrench remove the front left 2 Using the 3 8 wrench remove the four and right side panels screws holding the front control panel to the 5 Using the 3 4 wrench remove the internal case top and sides See Figure F 13 leads from the output terminals Insulate the There are two screws on the top and one leads Screw on each side 3 Carefully lower the front control panel Return to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN 36 36 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TEST CONTINUED FIGURE F 14 OUTPUT PANEL REMOVAL Retum to Secti
199. ing mode Full power is available regardless of the welding control settings if no welding current is being drawn The auxiliary power of the Commander consists of two 20 Amp 120VAC 5 20R duplex receptacles and one 50 Amp 120 240 VAC 14 50R receptacle The 120 240VAC receptacle can be split for single phase 120 VAC operation The auxiliary power capacity is 12 000 watts of 60 Hz single phase power The auxiliary power capacity rating in watts is equivalent to volt amperes at unity power factor The maximum permissible current of the 240 VAC output is 50 A The 240 VAC output can be split to provide two separate 120 VAC outputs with a maxi mum permissible current of 50 A per output to two sep arate 120 VAC branch circuits Output voltage is within 10 at all loads up to rated capacity NOTE The 120 240V receptacle has two 120V out puts of different phases and cannot be paralleled The auxiliary power receptacles should only be used with three wire grounded type plugs or approved dou ble insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS It must be noted that the above auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in Table 4 The permissi ble currents shown assume that current is being drawn from either
200. itch to AUTO 5 Set the RUN STOP switch to RUN Observe that all engine protection lights momentarily turn on Some lights may turn off before starting Check the fuel gauge K1639 2 only to make sure that there is an adequate fuel level 6 Press and hold the engine START button for a min imum of two seconds 7 Release the engine START button when the engine starts 8 Check that the indicator lights are off If the LOW FUEL light is on K1639 2 only the engine will shut down 30 minutes after starting If any other indica tor light is on after starting the engine will shut down in a few seconds Investigate any indicated problem 9 Allow the engine to warm up at low idle speed for several minutes before applying a load and or switching to high idle Allow a longer warm up time in cold weather COLD WEATHER STARTING With a fully charged battery and the proper weight oil the engine should start satisfactorily even down to about O F If the engine must be frequently started below 10 F it may be desirable to install the optional ether starter kit K825 1 Installation and operating instructions are included in the kit STOPPING THE ENGINE 1 Switch the RUN STOP switch to STOP This turns off the voltage supplied to the shutdown solenoid A backup shutdown can be accomplished by shutting off the fuel valve located on the fuel line BREAK IN PERIOD The engine used to supply power for your welder is a heavy
201. ive harm 8 The Above For Diesel Engines The Above For Gasoline Engines 4 ARC WELDING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS 99 2 1 avoid scalding do not remove the radiator pressure cap when the engine is powered equipment AW 8 n 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running cm 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Retum to Master TOC ELECTRIC AND 3 MAGNETIC FIELDS E may be dangerous Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current
202. jure Keep guards in place Keep away from moving parts Only qualified personnel should install use or service this equipment AX COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC ACCESSORIES CONNECTION OF THE LN 7 TO THE COMMANDER 500 USING K867 UNIVERSAL ADAPTER SEE FIGURE 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 NOTE Welding cable must be sized for current and duty cycle of application NOTE Figure C 1 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the Commander 500 output terminals 3 Connect the K867 Universal Adapter to the K291 or K404 input cable and the 14 pin amphenol of the Commander 500 as indicated in Figure C 1 Make the proper connections for local or remote control according to Figure C 1 4 Connect the K291 or K404 input cable to the LN 7 5 Place the IDLER switch in the HIGH position CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage If this voltage goes over 140
203. ly PC Board Voltage F 39 Output Rectifier Bridge F 42 Power Module 5 222 220 ederet Lied tete Hanis ERE Pe HE De Vea deere F 46 Charging 50 Oscilloscope Waveforms 2 2 2004440 0 52 Normal Open Circuit Voltage Waveform F 53 t Normal Weld Voltage Waveform Stick 54 E Normal Weld Voltage Waveform Wire nennen nennen F 55 9 Normal TIG Mode Voltage 56 E Normal Open Circuit Voltage Waveform Wire CV F 57 2 Replacement Procedures ces ae csi tele eter E PNE ERR Ure auis F 58 Shutdown Solenoid Removal and Replacement sss F 58 Power Module Output Rectifier Bridge Assembly Removal and Replacement F 61 Power Module Chopper PC Board Diode Module Removal and Replacement F 66 Output Rectifier Bridge Diode Removal and F 70 Stator Rotor Removal and nennen F 73 Retest After eiue dpi riti e ie e aod dtd ee a Ae eL d ea OR dte Le rud dme F 82 Return to Master TOC COM
204. m a properly operating machine Note that each vertical division represents 10 volts and that each horizontal division rep resents 50 microseconds in time The machine was loaded with a resis tance grid bank to 200 amps at 16 VDC Retum to Master TOC 8 9 8 SCOPE SETTINGS Volts Div 10V Div Horizontal Sweep 50 ms Div Coupling DC gio Trigger Internal PP 512 2 8 8 x COMMANDER 500 LINCOLN 57 57 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM WIRE CV TAP MAX CONTROL POT HIGH IDLE NO LOAD Retum to Section TOC Retum to Master TOC BEER EH 0 volts 50V 5MS Retum to Master TOC 9 u 8 a This is the typical DC open circuit output voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal 5 8 division represents 5 milliseconds time 8 5 8 SCOPE SETTINGS 818 Volts Div 50V Div F E Horizontal Sweep 5 ms Div Coupling DC gc Trigger Internal 91 5 8 E 2 8 8 IE a COMMANDER 500 LINCOLN Retum to Section Retum to Section TOC 5
205. m to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN Return to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 68 F 68 TROUBLESHOOTING amp REPAIR POWER MODULE CHOPPER PC BOARD DIODE MODULE REMOVAL AND REPLACEMENT CONTINUED POWER MODULE PC BOARD REPLACEMENT 1 Apply Penetrox A 13 joint compound T12837 1 to the surface of the heat sink where the Power Module PC board mounts 2 Install the top and bottom allen head cap screws Insert the bolts into the board before mounting it Torque the screws to 50 60 inch pounds IMPORTANT Each top cap screw has a copper standoff on the opposite side of the board Be sure to place this standoff between the heat sink and the PC board 3 Install the positive capacitor straps flat washers lock washers and nuts Torque the nuts to 50 60 inch pounds at the Power Module PC board and at the capacitor termi nals 4 Install the small diode leads and the heavy leads flat washers lock washers and nuts to the Power Module PC board Torque the nuts to 50 60 inch pounds 5 Install plug and lead assembly P J50 right side or P J51 left side 6 Replace any cable ties cut at disassembly See the procedures below for removal and replacement of the Power Module PC board diode module When procedures are complete per
206. minals 232M to 265 The normal resis tance is approximately 0 4 ohms Check the hold in coil resistance smaller terminals 224 to 262 Normal coil resis tance is approximately 20 ohms If either coil resistance is not correct the solenoid may be faulty Replace Using the external 12VDC supply apply 12VDC to the larger shutdown solenoid ter minals 232M to 265 The solenoid should activate PULL IN COIL LARGER TERMINALS 232M AND 265 HAND IN COIL SMALLER TERMINALS IDLER EACH SIDE SOLENOID 224 AND 262 CAUTION When the solenoid activates remove the voltage supply immediately Do not leave the external supply connected to terminals 232M and 265 for longer than three seconds Component dam age could result The solenoid should deactivate when the 12VDC is removed 6 If the solenoid does not operate properly check for a mechanical restriction in the link age 7 Using the external 12VDC supply apply 12VDC to the smaller idler solenoid terminals for the hold in coil 262 to 224 Push in the solenoid plunger With 12 VDC applied to the hold in coil the plunger should stay in until the 12 VDC is removed 8 If the linkage is intact and the solenoid does not operate correctly when the 12VDC is applied the solenoid may be faulty Replace 9 Replace harness leads to the correct termi nals See Figure F 6 and the Wiring Diagram Replace any previously removed wire
207. mmander 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 The biggest advantage of chopper technology is the high speed control of the arc similar to the inverter machines A block diagram for this is as follows INDUCTOR ARC EXTERNAL DC SOLID STATE SOURCE SWITCH ARC CONTROL In this system the engine drives a three phase alter nator which generates power that is rectified and filtered to produce about 85VDC The current is applied through a solid state switch to an inductor By AND DIODE turning the switch on and off current in the inductor and the arc can be controlled The following diagram depicts the current flow in the system when the switch is open and closed s 70 80VDC DIODE B CURRENT WITH SWITCH OPEN 221 CURRENT WITH SWITCH CLOSED When the switch is closed current is applied through the inductor to the arc When the switch opens current stored in the inductor sustains flow in the arc and through the diode The repetition rate of switch closure is 20Khz which allows ultra fast control of the arc By varying the ratio of on time versus off time of the switch Duty Cycle the current applied to the arc is con trolled This is the basis for Chopper Tec
208. 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 With the prop er orientation now established apply additional pressure to seat the element in the filter header You should feel the element pop into place when properly seated 5 Slide the quick change ring up over the element and rotate counter clockwise until an audible click or pop is heard If you do not hear the click you have not rotated the ring far enough and the element is not in the locked position Another indication that the ring is in the locked position is that one set it doesn t matter which one of arrows located on the outside of the ring should be located directly under the air vent valve 6 Open the fuel shutoff valve lever in line with the NOTE The element will only go on one way Never use hose excessive force when mounting the element to the header 7 Open the air vent valve on the front of the filter Retum to Section TOC 8 9 8 Return to Section Retum to Master TOC Y 4 2 3 Retum to Master header until fuel emerges free of air bubbles Then close the air vent valve Secondary Fuel Filter The Secondary Fuel Filter is a spin on cartridge type mounted directly to the engine Consult your engine Operator s Manual for complete information on service intervals and
209. n Figure A 2 COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC A 8 1 A 8 INSTALLATION 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 2 Take necessary steps to assure load is limited to the capacity of the Commander by installing a 50 amp 240 VAC double pole circuit breaker Maximum rated load for each leg of the 240 VAC auxiliary is 50 amperes Loading above the rated able 10 of rated voltage which may damage appliances or other motor driven equipment and may result in overheating of the Commander 500 engine Install a 50 amp 120 240 VAC plug NEMA Type 14 50 to the double pole circuit breaker using No 6 four conductor cable of the desired length The 50 amp 120 240 VAC plug is available in the optional K802R plug kit Plug this cable into the 50 amp 120 240 volt recep tacle on the Commander 500 case front output will reduce output voltage below the allow FIGURE A 2 CONNECTION OF THE COMMANDER 500 TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR 240 Volt POWER 120 VOLT a 60 Hz 3 Wire COMPANY METER LOAD
210. n Stick SELECTOR switch It must be switch and associated leads mode in the correct position for the See the Wiring Diagram process being used 2 The Weld Control PC board Return to Section TOC Retum to Master TOC Check that the jumper plug J3 is may be faulty properly installed in the Weld Control PC board J3 has a jumper wire from pin 1 to pin 5 Retum to Master TOC 5 8 9 8 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 Call 1 800 833 9353 Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN F 8 F 8 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION Retum to Section TOC Retum to Master TOC The wire feeder does not work when connected to the welder amphenol FUNCTION PROBLEMS Check the appropriate circuit breaker CB1 or CB6 Reset if tripped The wire feeder control cable may be faulty 1 Check for the presence of appropriate source voltage at the 14 pin amphenol If the appropriate voltage 42 VAC or 115 VAC is NOT pre sent at the 14 pin amphenol check for loose or fault
211. n even coat 1 to 25mm or 004 to 010 in of Penetrox A13 thermal joint compound T12837 1 to the diode module base plate only under the plastic body of the module Do not apply compound to the area under the mounting holes Press the module firmly against the heat sink aligning the mounting holes Place a spring washer then a flat washer over each outer mounting screw and insert them into the holes Insert the allen head screw into the center hole Tighten all three screws 2 3 turns each finger tight only 1 Using the torque wrench and 7 16 socket tighten each outer screw between 5 0 and 10 in Ibs 2 Using the torque wrench and 9 64 allen head socket tighten the center screw between 12 and 18 in lbs 3 Now tighten the two outer screws between 30 and 40 in lbs 4 Replace the Power Module PC board as described above F 70 F 70 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE DIODE REMOVAL AND REPLACEMENT WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum to Master TOC If for any reason you do not understand the tes
212. n time The machine was loaded with a resistance grid bank to 500 amps at 40 volts SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 0 1 ms Div Coupling DC COMMANDER 500 LINCOLN 0 volts Retum to Section Return to Section TOC 9 8 9 8 Retum to Section to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 55 F 55 TROUBLESHOOTING amp REPAIR NORMAL WELD VOLTAGE WAVEFORM WIRE CV MACHINE LOADED TO 500 AMPS AT 40 VOLTS 20V 0 1ms This is the typical DC output voltage generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time The machine was loaded with a resistance grid bank to 500 amps at 40 volts SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 0 1 ms Div Coupling DC COMMANDER 500 LINCOLN 0 volts 56 F 56 TROUBLESHOOTING amp REPAIR NORMAL TIG MODE VOLTAGE WAVEFORM LOADED TO 200A 16 VOLTS Retum to Section TOC Retum to Master TOC 0 volts Return to Section TOC Retum to Master TOC 10V 50ms This is the typical TIG MODE output voltage generated fro
213. neral this only needs to be done with each water separator element change about every 1 000 hrs However if at any time exces sive fuel contamination is suspected or a sudden fall off in engine performance is detected the pre filter screen should be inspected and cleaned See Figure D 2 and follow this procedure 1 Close the fuel shutoff valve located on the side of the Fuel Pre Filter Water Separator Assembly The lever should be perpendicular to the hose 2 Unscrew the cap ring located on the top of the filter header and remove the plastic center cap and O ring 3 Remove the large white volume plug located direct ly under the center cap in the upper cavity of the fil ter header Use a small screwdriver or similar device to lift the plug part way out of the cavity to assist with its removal NOTE Be careful not to damage the pre filter screen with the tool used to remove the plug 4 Using a pair of pliers gently tug on the pull tabs of the pre filter screen in an alternating pattern to gradually remove the pre filter screen 5 Brush off any debris and rinse in diesel fuel 6 Re install the pre filter screen into the upper cavity of the filter header making sure the four pull tabs are pointing up Putting your fingers on the pull tabs push down evenly until the lower body of the pre fil ter screen contacts the floor of the upper cavity 7 Re insert the large white volume plug into the upper cavity 8 Pl
214. ngsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 1 Thoriated EWTh 1 2 Thoriated EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications 3DCEP is not commonly used in these sizes torch nozzle sizes in multiples of 1 16ths of an inch 4 1 4 in 6 mm 5 5 16in 8mm 6 3 8 in 10 mm 7 7 16 in 11 mm 8 1 2 in 12 5 mm 10 5 8 in 16 mm STIG torch nozzles are typically made from alumina ceramic Special applications may require lava nozzles which are less prone to break age but cannot withstand high temperatures and high duty cycles 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 NOTE This is necessary because the K799 circuitry with respect to the 2 and 4 leads does not provide the proper signal to open and close the solid state con tactor in the Commander 500 COMMANDER 500 SETTINGS WHEN USING THE K930 1 TIG MODULE Set the WELD MODE switch to the 20 250 setting TIG Set the IDLER switch to the AUTO position Set the WELDING TERMINALS switch to the REMOTELY
215. nsufficient greasing When greasing the bearings keep all dirt out of the area Wipe the fittings completely clean and use clean equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease RECEPTACLES Keep the electrical receptacles in good condition Remove any dirt oil or other debris from their surfaces and holes CABLE CONNECTIONS Check the welding cable connections at the weld output terminals often Be sure that the connections are always tight COMMANDER 500 LINCOLN 8 Retum to Section Return to Section TOC 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC DNAN MAINTENANCE FIGURE D 5 MAJOR COMPONENT LOCATIONS CASE DOOR ASSEMBLY ENGINE SHUT DOWN SOLENOID IDLER SOLENOID REAR PANEL ASSEMBLY BASE FRONT PANEL ASSEMBLY WITH OUTPUT PANEL CONTROL PANEL OUTPUT RECTIFIER BRIDGE ASSEMBLY 10 FUEL TANK 11 ROTOR STATOR 12 CASE TOP AND SIDES ooN COMMANDER 500 LINCOLN 8 Section E 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION 8 i General Description LL 2 g Battery Starter Engine Rotor Stator Pull Coil Board and Peripheral 8 Board Engine ProtectOn E 2 Weld Windings Rectifier Power Mod
216. nt PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims COMMANDER 500 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 4 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident POSSIBLE AREAS MISADJUSTMENT S OUTPUT PROBLEMS Contact your Authorized Facility Lincoln Service local Field TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department at 1 800 833 9353 WELD No welding output in neither Stick or CV modes The engine operates normally The auxiliary output is normal Place the Welding Terminals Switch in the ALWAYS ON position If the problem is solved the fault may be in the external control cable if used leads 2 and 4 See the Wiring Diagram With the engine at high idle 1900RPM the machine in the Stick mode and the OUTPUT CONTROL at maximum check for the presence of approxi mately 87V
217. o Master TOC All welder and engine controls are located on the case front panel Refer to Figure B 1 and the explanations that follow Q PP HE 3 g FIGURE B 1 CASE FRONT PANEL CONTROLS 8 8 JE 8 3 o Y s 9 b 3 z4 CY GY j J OL 7 WY 1r SB HE 8 8 E cic Return to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN 8 Return to Section Return to Section TOC 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION 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 NOTE If the switch is left in the RUN position and the engine is not running the fuel solenoid will be engaged for 15 seconds and then shut down This is to protect the battery from discharge After 15 seconds the RUN STOP switch must be toggled off then on before starting 2 START PUSHBUTTON C Energizes the starter motor to crank the engine With the engine RUN STOP switch in the RUN position push and hold the Start button to crank the engine release as the engine starts The S
218. of the battery charger manufac turer for proper charger settings and charging time COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC MAINTENANCE WELDER GENERATOR MAINTENANCE STORAGE Store the Commander 500 in clean dry protected areas CLEANING Blow out the generator and controls peri odically with low pressure air Do this at least once a week in particularly dirty areas NAMEPLATES Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are no longer clear Refer to the parts list for the replacement item number BRUSH REMOVAL AND REPLACEMENT It is normal for the brushes and slip rings to wear and darken slight ly Inspect the brushes when a generator overhaul is necessary WARNING Do not attempt to polish slip rings while the engine is running BEARINGS The Commander 500 is equipped with double shielded ball bearings having sufficient grease to last indefinitely under normal service Where the welder is used constantly or in excessively dirty loca tions it may be necessary to add one half ounce of grease per year A pad of grease one inch wide one inch long and one inch high weighs approximately one half ounce Over greasing is far worse than i
219. on Make sure the welding cables and auxiliary power lead con nections are tight The Weld Control PC board may be faulty The current sensing toroid may be faulty The machine goes to low idle but does not stay at low idle Make sure there is NOT an external load auxiliary or weld connected to the Commander 500 The idler solenoid linkage may be misadjusted or damaged The idler solenoid lead connec tions may be loose or damaged See the Wiring Diagram Perform the dler Solenoid The Weld Control PC board may be faulty 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 Call 1 800 833 9353 COMMANDER 500 LINCOLN Retum to Section Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 12 F 12 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The welding arc is cold The engine runs normally The auxiliary power is normal POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Check for loose or faulty con nections at the weld output ter minals and welding cable con ne
220. on TOC Retum to Master TOC OUTPUT LEADS BEHIND PANEL OUTPUT PANEL Retum to Master TOC B 0 9 u 8 E a 8 il 2 6 Using the 3 8 wrench remove the three control box on the bottom at each side of g 8 screws holding the lower front panel output the box See Figure F 14 Carefully move panel to the case front assembly Then the lower front panel to the right side Note remove the front two screws holding the top the green ground lead will still be attached X of the panel These are accessed in the Retum to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN 37 37 TROUBLESHOOTING amp REPAIR STATOR VOLTAGE TEST CONTINUED FIGURE F 15 AUXILIARY LEAD TEST LOCATION Return to Section TOC Retum to Master TOC AUXILIARY LEADS 5B 5E 8 9 11 12 BEHIND PANEL s 3 Iw Retum to Master TOC B 0 9 u 8 E a gig 8 5 5 AUXILIARY POWER AND WELD y g WINDINGS TEST 818 1 Start the engine and run at high idle 1900 3 Check for 230 to 264VAC at leads 11 to E RPM not load welding or auxiliary 312 See Figure F 15 and the Wiring F cic 2 Check for 115 132VAC at leads 9 to 5B Also check for 115 132VAC from leads 8 to 5E See Figure F 15 and the Wiring Diagram Retum to Section Retum to Master TOC COMMANDER 500 LINCOLN F 38 F 38
221. oting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will aid the technician in the removal and replacement of the power mod ule output rectifier bridge assembly Once the assembly is removed the power module PC boards and output rectifier bridge diodes can be accessed for removal and replace ment MATERIALS NEEDED 3 8 Wrench 7 16 Wrench or socket wrench 1 2 Wrench Phillips head screw driver This procedure should take approximately 80 minutes to perform COMMANDER 500 LINCOLN F 61 Return to Section Return to Section TOC 5 8 9 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 62 TROUBLESHOOTING amp REPAIR POWER MODULE OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT CONTINUED F 27 CONTROL PANEL REMOVAL PROCEDURE Turn the engine off Using the 3 8 wrench remove the screws holding the front control panel to the case top and sides See Figure F 27 There are two screws on the top and one screw on each side 3 Carefully lower the front control panel 4 Using the 3 8 wrench remove the front left and right side panels 6 COMMANDER 500 LINCOLN Perform the Output Panel Removal section of the Case Cover Removal procedure Perform the Power Module Capacitor Discharge Procedure Optional Wi
222. parts e Stop engine and allow to cool before fueling Do not smoke when fueling Fill fuel tank at a moderate rate and do not overfill Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank OIL The Commander is shipped with the engine crankcase filled with high quality SAE 10W 30 oil API class CD or better Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Check the oil level every four hours of running time during the first 35 running hours Refer to the engine Operator s Manual for specific oil recommendations and break in information The oil change interval is dependent on the quality of the oil and the operating environment Refer to the engine Operator s Manual for the proper service and mainte nance intervals FUEL NOTE USE DIESEL FUEL ONLY Fill the fuel tank with clean fresh diesel fuel The capacity of the fuel tank is 25 gallons 94 6 liters See the engine Operator s Manual for specific fuel recom mendations The Commander 500 Deluxe is protected by a low fuel shutdown to prevent the engine from run ning out of fuel The machine will indicate a low fuel condition by turning on the low fuel light A time of 30 minutes will elapse once the low fuel light illuminates before the machine will shutdown restart of the machine will restart the timer to allow the operator to over
223. r cooling air flow GENERAL DESCRIPTION The Commander 500 is a diesel engine driven welding power source The machine uses a brush type alter nating current generator for DC multi purpose welding and for 120 240 VAC auxiliary standby power The welding control system uses state of the art Technology The generator has a single sealed bearing for mainte nance free service The rotor is a copper wound design with two slip rings and brushes The stator is wound entirely with heavy gauge copper wire and insulated with NEMA class F insulation material The stator is then impregnated with three layers of high quality var nish After the stator is assembled using tie bars the entire assembly is covered with an environmentally protective coating These measures insure trouble free operation in the harshest environments The fuel tank is made from high density polyethylene and holds 25 gallons 94 6 liters of diesel fuel This will provide enough fuel to run for more than 12 hours at full load The Deutz F3L 912 engine is equipped with a stan dard heavy duty combination fuel filter water separa tor element COMMANDER 500 LINCOLN 8 Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master TOC OPERATION RECOMMENDED APPLICATIONS WELDER The Commander 500 provides excellent constant
224. r approximately 15 seconds 8 HOUR METER The hour meter displays the total time that the engine has been running This meter is a useful indicator for scheduling preventive maintenance WELDER CONTROLS Items 9 through 13 9 WELD MODE amp OUTPUT CONTROL These two controls allow you to select between various welding output slopes and adjust the desired welding output Refer to Table B 1 for a description of how these two controls work 10 DIGITAL OUTPUT METERS The digital output meters are located in the center of the control panel between the two large control knobs The meters allow the output current level to be set prior to welding in stick mode and voltage level to be set prior to welding in the wire modes During the welding process the meters display the actual output current and voltage within 5 accuracy The digital meters allow the output voltage CV WIRE mode or current CC STICK PIPE and TIG modes to be set prior to welding using the OUTPUT control dial During welding the meters display the actual output voltage VOLTS and current AMPS A memory fea ture holds the display of both meters on for seven sec onds after the welding is stopped This allows the oper ator to read the actual current and voltage just prior to when welding was ceased While the display is being held the left most decimal point in each display will be flashing The accuracy of the meters is 3 11 WELDING TERMIN
225. r fuel line Pull it through the firewall Using the 9 16 deep socket wrench remove the four lock nuts washers and rub ber washers from the fuel tank mounting U bolts Carefully remove the U bolts and lift the fuel tank from the machine Return to Section Return to Section TOC 5 8 9 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master 75 75 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT CONTINUED FIGURE F 34 PLUG J52 FILTER CAPACITOR FIELD RECTIFIER BRIDGE DISCONNECTION PLUG P J52 E F 2000 Swe IR gt ESS 2222 27 c 5P e 201 6F 201A FILTER FIELD DIODE CAPACITOR RECTIFIER BRIDGE Refer to Figure F 34 for Steps 10 12 10 Disconnect plug J52 at the right front side See Figure F 34 11 Using the slot head screw driver discon nect leads 200C 200E and 201D from the filter capacitor 12 Label and remove leads 5P 201 and 201A 200D and 6F from the field diode rectifier bridge COMMANDER 500 LINCOLN F 76 F 76 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT CONTINUED FIGURE F 35 BRUSH HOLDER AND LEAD REMOVAL Return to Section TOC Retum to Master TOC Refer to Figure F 35 for Steps 13 15 13 Using the 3 8 wrench remove the brush holder ac
226. rd The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations a suitable spark arrester must be installed and properly maintained A CAUTION An incorrect arrester may lead to damage to the engine or adversely affect performance HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi Freq Unit and the K930 1 or 2 TIG Module are suitable for use with the Commander 500 The Commander 500 is equipped with the required R F bypass circuitry for the connection of high fre quency generating equipment The high frequency bypass network supplied with the K799 Hi Freq Unit does NOT need to be installed into the Commander 500 The Commander 500 and any high frequency generat ing equipment must be properly grounded See the K799 Hi Freq Unit and the K930 1 or 2 TIG Module operating manuals for complete instructions on instal lation operation and maintenance ELECTRICAL CONNECTIONS REMOTE CONTROL The Commander 500 is equipped with a 6 pin and a 14 pin connector The 6 pin connector is for connecting the K857 or K857 1 Remote Control optional or in the case of TIG welding applications with the foot or hand Amptrol K870 or K963 1 respectively The 14 pin connector is used to directly connect a wire feeder or TIG Module K930 1 or 2 control cable NOTE When using the 14 pin connector if the wire feeder has a built in power source output control do not connect
227. re running out of fuel K1639 2 only Engine hour meter standard on all models Extended range 25 gallon 94 6 1 fuel tank Automatic idler reduces engine speed when not welding or drawing auxiliary power This feature reduces fuel consumption and extends engine life Compact size fits crosswise in full size pickup truck Single side engine service Copper alternator windings and high temperature insulation for dependability and long life New paint system on case and base for outstanding corrosion protection COMMANDER 500 LINCOLN 8 1639 1 COMMANDER 500 STANDARD MODEL WELDING CAPABILITY K1639 1 is the standard version of the Commander 500 is rated at 500 amps 40 VDC at Commander 500 and has all the features of the 100 duty cycle and 575 amps 36 VDC at 50 duty K1639 2 Deluxe version except that there are no cycle The maximum open circuit voltage at 1900 RPM gauges low fuel light nor dual output meters This 5 80 volts The weld current is variable from 30 to 575 version does have fully functional engine protection amps for low oil pressure high oil temperature and alter nator output with associated lights A field installed Dual Output Meter and Gauge Kit CONTROLS AND SETTINGS K 1768 1 is available for the K1639 1 Commander 500 The kit includes dual output meters oil pressure gauge oil temperature gage and alternator amme ter Return to Section TOC Retum t
228. ride this feature The amount of reserve fuel remaining in the tank after the first shutdown will vary from machine to machine The operator must deter mine the amount of fuel remaining before restarting the machine Running out of fuel may require bleeding the fuel injection pump NOTE Before starting the engine open the fuel shut off valve pointer to be in line with hose FUEL CAP Remove the plastic cap covering from the fuel tank filler neck and install the fuel cap ENGINE COOLING SYSTEM The Deutz engine is air cooled by a belt driven axial blower The oil cooler and engine cooling fins should be blown out with compressed air or steam to maintain proper cooling See the engine Operator s Manual for procedures and frequency BATTERY CONNECTION WARNING Wwe GASES FROM BATTERY can explode Ww Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect nega tive cable from old battery first and connect to new battery last CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING BOOSTER connect positive lead to battery first then connect negative lead to negative battery lead at engine foot 4 BATTERY ACID can burn eyes and skin Wear gloves and eye protection and be c
229. s a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 8 Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover Z plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards
230. sing the 3 8 wrench remove the two bolts and flat washers holding the bearing in place 9 Remove the stator from the engine It may be necessary to pry and slide it free COMMANDER 500 LINCOLN Return to Section Retum to Section TOC 5 8 9 8 Return to Section TOC to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 80 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT CONTINUED FIGURE F 40 ROTOR REMOVAL FLEX PLATE ROTOR ROTOR REMOVAL PROCEDURE Refer to Figure F 40 for rotor removal 1 Support the rotor with the hoist 2 Using the 5 8 wrench remove the flex plate bolts lock washers and four blower seg ments WARNING The rotor will be free to fall when the bolts are removed 3 Using the hoist carefully remove the rotor and flex plate assembly REASSEMBLY NOTES Reassemble the rotor and stator to the Commander 500 by carefully retracing the dis assembly procedure steps in reverse order Keep the following special points in mind as you proceed Lead Reconnection Checklists are provided here as an aid to reassembly BLOWER SEGMENT 4 INSTALL ROTOR Support the rotor with the hoist Install the blower segments and flex plate to the engine flywheel INSTALL STATOR Be sure the engine is blocked securely and the stator is supported with the hoist Install the stator to the engine with th
231. sing the analog ohmmeter connect the 11 Reconnect all leads previously removed negative meter probe to the terminal 42 Torque the capacitor nuts to 50 60 inch diode module See Figure F 23 Connect pounds the positive meter probe to the heat sink E The resistance should be very high over 13 If finished testing perform the 50 000 ohms Replacement procedure 10 Using the analog ohmmeter connect the positive meter probe to the terminal on the diode module Connect the negative meter probe to the heat sink The resistance should be low approximately 300 ohms Also check diode D3 right side or D4 left side for an open or shorted condition See the Wiring Diagram 1r SB 8 8 E cic Return to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN F 50 F 50 TROUBLESHOOTING amp REPAIR CHARGING CIRCUIT TEST WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum to Master TOC 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
232. stalled 115 volt duplex receptacle Two kits are required K899 1 SPARK ARRESTER KIT Easily mounts to standard muffler K1816 1 FULL KVA ADAPTER KIT Plugs into the 120 240V NEMA 14 50R receptacle on the case front which accepts 4 prong plugs and converts it to a NEMA 6 50R receptacle which accepts 3 prong plugs K1768 1 DUAL OUTPUT METERS AND GAUGES Dual output meters provide preset ability of voltage for wire welding and current for stick welding Measures both current and voltage when welding Gauges include battery ammeter engine temperature and engine oil pressure Fuel gauge is not available in kit form STICK WELDING ACCESSORIES K704 Accessory Kit which includes Electrode holder and cable Ground clamp and cable Headshield K857 Remote Control Kit is optional for remote cur rent control TIG WELDING ACCESSORIES Magnum TIG Torch Magnum Parts Kit and Argon gas K930 ALL TIG Module not required for scratch start DC TIG welding K936 1 Control Cable K870 Foot Amptrol Also available K963 1 2 Hand Amptrol K814 Arc Start Switch K937 22 Control Cable Extension K937 45 Control Cable Extension K844 1 Water Valve COMMANDER 500 LINCOLN 8 Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC C 3 C 3 ACCESSORIES SEMIAUTOMAT
233. t aussi au pistolet de soudage Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs
234. t procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing and replacing stud type diodes to the aluminum heat sinks on the Commander 500 Retum to Section TOC Retum to Master TOC MATERIALS NEEDED 7 16 Wrench 1 2 Wrench 1 Open end wrench Penetrox A13 joint compound T12837 1 2 gm tube Loctite 271 Slip type torque wrench E2827 2 abrasive disc or fine steel wool This procedure should take approximately 25 minutes to perform Retum to Master TOC 8 9 8 Retum to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 71 F 71 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER BRIDGE DIODE REMOVAL AND REMOVAL AND REPLACEMENT CONTINUED FIGURE F 32 POWER MODULE OUTPUT RECTIFIER BRIDGE ASSEMBLY DETAILS PROCEDURE Refer to Figure F 32 1 2 3 Turn the engine off Perform the Output Panel Removal as described the Case Cover Removal pro cedure Perform the Power Module Capacitor Discharge procedure Using the 7 16
235. tart button must be depressed for a minimum of two seconds Do not press it while the engine is running since this can cause damage to the ring gear and or starter motor 3 FUEL LEVEL GAUGE AND LIGHT g K1639 2 only Displays the level of diesel fuel in the 25 gallon 94 6 liter fuel tank The yellow light turns on when the fuel gage reaches the reserve level Once the reserve level is reached the engine protection system will shut down the engine after 30 minutes of operation The machine can be restarted and operated for an additional 30 minutes before the protection system will shut down the engine This ability to override the engine protection allows the operator to finish up if necessary The operator must watch the fuel level closely to prevent running out of fuel and having to bleed the system 4 ENGINE TEMPERATURE GAUGE K1639 2 Std K1639 1 Opt AND LIGHT The gauge displays the engine oil temperature The yellow temperature light remains off under normal operating temperatures If the light turns on the engine protection system will shut down the engine Check for restrictions at the engine cooling air inlets and outlets Consult the engine Operator s Manual Check for loose or disconnected leads at the temperature sender located on the engine Check the engine cooling blow er belt Also check to be sure that the welder loads are within the rating of the welder The light will remain on when the engine has been sh
236. tarter solenoid may be faulty The engine may be hard to crank due to a mechanical fail ure in the engine See the Engine Starting Diag nostic Chart The engine cranks but will not start Check for adequate fuel supply Make sure the fuel shut off valve is in the open position The engine oil temperature may be too high Check cooling sys tem The battery voltage may be too low The shutdown solenoid may be faulty Perform the Shutdown Solenoid Test The Peripheral PC board may be faulty With the RUN STOP switch in the RUN position the Peripheral PC board should nor mally supply 10VDC to the shut down solenoid via leads 224 and 262 See the Wiring Diagram The Pull Coil PC board may be faulty The engine may be in need of mechanical repair See the Engine Starting Diag snostic Chart 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 Call 1 800 833 9353 COMMANDER 500 LINCOLN Retum to Section Return to Section TOC 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 10 F 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this m
237. th the 7 16 wrench remove the ground wire from the output panel assembly If the ground wire is not in the way it can remain attached Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 63 F 63 TROUBLESHOOTING amp REPAIR POWER MODULE OUTPUT RECTIFIER BRIDGE ASSEMBLY REMOVAL AND REPLACEMENT CONTINUED FIGURE F 28 POWER MODULE CAPACITOR LEAD REMOVAL Refer to Figure F 28 for Steps 8 12 8 Using the 7 16 wrench loosen the nuts on the positive terminals of the power capaci tors Then remove the nuts lock washers and flat washers from the terminals where the positive straps connect to the power module PC board Flip the straps out of the way Also disconnect diode lead D3 right side power module and D4 left side power module With the phillips screw driver remove plug and lead assembly for P J 50 right side or P J51 left side Cut any necessary cable ties 10 11 12 COMMANDER 500 LINCOLN A REMOVE LEADS Disconnect the thermostat leads Separate lead 249 on the right side Cut any nec essary cable ties Disconnect leads 14A and 13A at their in line connectors left side only With the 1 2 wrench disconnect the bolt lock washer and flat washer from the shunt at choke lead W11 Cut the
238. that problem BE BAD 15 16 17 18 23 25 23A 25 CV Mode do you have proper OCV Is the A meter or V meter illuminated n TIG Mode do you have proper OCV N gt OCV too high ANALOG POWER SUPPLY MAY BE BAD Check VOLTAGE FEEDBACK wire 208B A meter Y CORRECT Y that problem Check the MODE gk OK SELECT rotary switch and wires 214 218 220 CONTROL PCB MAY BE BAD N amp 222 LINCOLN amp COMMANDER 500 In CC Mode do you have proper OCV Return to Section TOC Return to Master TOC 15 15 TROUBLESHOOTING amp REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE A WARNING 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 For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum to Master TOC 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD Q JE 5 9 DESCRIPTION PIE 3 gt This procedure will
239. 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 NOTE Unshaded areas of Block Logic Diagram are the subject of discussion COMMANDER 500 LINCOLN 8 Retum to Section Return to Section TOC 5 8 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC E 3 E 3 THEORY OF OPERATION FIGURE E 3 WELD WINDINGS RECTIFIER POWER MODULES A
240. tuds on the machine base then cock it slightly to remove it Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 3 Retum to Master F 79 F 79 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT CONTINUED FIGURE F 39 STATOR REMOVAL STATOR ENGINE MOUNTING BOLTS amp LOCK WASHERS E gr A A Noo FLYWHEEL SPLASH PLATE BOLTS 4 ET FAN MOUNTING NUT FOOT STATOR REMOVAL PROCEDURE First cut any necessary cable ties in order to 5 Using two 3 4 wrenches remove the nut free the stator leads from the bundle of leads lock washer and carriage bolt holding the running to the control box Refer to Figure F 39 alternator mounting foot to the machine for stator removal base Do this on each side 1 Using the 1 2 wrench remove the four fan 6 Using the 3 8 wrench remove the three blade mounting bolts and lock washers bolts from the flywheel splash plate Remove the plate 2 Using the 1 1 8 wrench remove the fan nut Remove the fan noting its direction for 7 Support the stator with the hoist Place reassembly wooden blocks under the engine to support it when the stator is removed 3 Using the gear puller remove the fan hub 8 Using the 17mm wrench remove the bolts and lock washers holding the stator to the engine 4 U
241. ules and E 3 Analog Power Supply Board and Weld Control Board E 4 Insulated Gate Bipolar Transistor IGBT E 5 Pulse Width e dete d uve etude RN ERU PUT RE bu d du E 6 Chopper Technology E 7 FIGURE E 1 MULTI WELD 500 BLOCK LOGIC DIAGRAM Retum to Master TOC WORK THREE PHASE TERMINAL RECTIFIER COMMANDER 500 TO WELD CONTROL BOARD ELECTRODE TERMINAL PWM SIGNALS 2 ANALOG POWER SUPPLY BOARD gt O _ d MECHANICAL ROTATION Y 4 2 8 E 5 4 CONTROL ENGINE STARTER ALTERNATOR TH OUTPUT PROCESS RANGE ARC ST e R LIGHT CONTROL CONTROL SELECTOR 42 VAC TO 14 PIN AMPHENOL FOR WIRE FEEDER RUN STOP SWITCH AUXILIARY WINDINGS zzoodcro 240 RECEPTACLE 120 RECEPTACLES 2 Retum to Master TOC COMMANDER 500 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC THEORY OF OPERATION FIGURE E 2 BATTERY ENGINE ROTOR
242. um permis sible current of the 240 VAC output is 50 A The 240 VAC output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 50 A per output to two separate 120 VAC branch cir cuits The output voltage is within 10 at all loads up to rated capacity NOTE The 120 240V receptacle has two 120V outlets of different phases and cannot be paralleled The Commander has two 20A 120VAC 5 20R duplex receptacles and one 50A 120 240 14 50R receptacle The 120 240 VAC receptacle can be split for single phase 120 VAC operation The auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the cur rent capacity of the associated receptacle STANDBY POWER CONNECTIONS The Commander 500 is suitable for temporary stand by or emergency power using the engine manufac turer s recommended maintenance schedule The Commander 500 can be permanently installed as a standby power unit for 240 volt three wire 50 amp service Connections must be made by a licensed electrician who can determine how the 120 240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes The follow ing information can be used as a guide by the electri cian for most applications Refer to the connection dia gram shown i
243. ut down due to an over temperature condition 5 OIL PRESSURE GAUGE K1639 2 Std A K1639 1 Opt AND LIGHT gauge displays the engine oil pressure when the engine is running The yellow oil pressure light remains off with proper oil pressure If the light turns on the engine protection system will stop the engine Check for proper oil level and add oil if necessary Check for loose or disconnected leads at the oil pressure sender located on the engine The light will go on and stay on when the RUN STOP switch is switched to the RUN position with the engine not running 6 ENGINE ALTERNATOR AMMETER 1639 2 Std K1639 1 Opt AND LIGHT The yellow engine alternator light is off when the bat tery charging system is functioning normally If the light turns on the engine protection system will shut down the engine Check the engine cooling blower belt Also the alternator or the voltage regulator may not be oper ating correctly The light may also come on due to a faulty flashing circuit The light will remain on when the engine has been shut down due to a fault in the alter nator regulator or the cooling blower belt 7 IDLER SWITCH Has two positions as follows A In the HIGH position the engine runs at the high idle speed controlled by the governor B Inthe AUTO lt position the idler oper ates as follows a When switched from HIGH to AUTO or after starting the engine the engine will oper
244. utput and process range selector It compares these commands to the current and volt age feedback information it receives from the shunt STATOR f us AUXILIARY 120VAC RECEPTACLES 2 THERMAL OUTPUT PROCESS RANGE CONTROL CONTROL SELECTOR 42 VAC TO 14 PIN AMPHENOL FOR WIRE FEEDER WINDINGS 240VAC RECEPTACLE and output terminal circuits The circuitry on the Weld Control PC board determines how the output should be controlled to optimize welding results and it sends the correct PWM signals to the IGBT driver circuits The Weld Control PC board also commands the thermal light and the voltmeter and ammeter some items may be optional NOTE Unshaded areas of Block Logic Diagram are the subject of discussion COMMANDER 500 LINCOLN 8 Return to Section Retum to Section TOC 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC THEORY OF OPERATION FIGURE E 5 IGBT OPERATION BODY REGION lt DRAIN DRIFT REGION n lt BUFFER LAYER p INJECTING LAYER DRAIN A PASSIVE INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT is a type of transistor IGBTs 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 curr
245. w 2 SNC GND SERIAL DATA V exo aV 4 m p PAGE 1 OF 5 GENERAL INFORMATION 0015 2 561 i ELECTRICAL SYMBOLS PER E1537 pos 619 amp 766 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED eant RESISTORS Ohms 0805 UNLESS OTHERWISE SPECIFIED LABELS 0 6 NOTES c D DIODES 2A 200V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET O pawns OWER SUPPLY SOURCE POINT 1 NA COMPONENTS NOT INSERTED G3900 2C4 VERSIONS A 14 NB COMPONENTS NOT INSERTED ON 63660 2 VERSIONS ANO CORRECTION 77 d FILENAME 5000749 63660 2 G3900 2C 7777 FRAME CONNECTION 8 INSERTED ON 03900 20 VERSIONS THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO THIS SCHEMATIC USED IN G3660 2C AND G3900 2C BOARDS EARTH GROUND CONNECTION gt NC ADDITIONAL COMPONENTS NOT INSERTED ON 63900 24 VERSION AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO DESIGNED BY IB FC SS AM EC UNLESS OTHERWISE SPECIFIED ToLeRaNcE 996948 THE LINCOLN ELECTRIC co 0 ANALOG WELD CONTROL HOLES SIZES E 2056 om ee 51 I I CLEVELAND OHIO U S A suse FPGA MEMORY amp INTERFACE 5 p SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE PLACE DECIMALS IS 002 7 7 2000 01 WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BO
246. wrench remove the appro priate stator leads and diode pigtail lead from the stud on the output rectifier bridge glastic insulator bracket The bottom diodes require a 1 2 wrench to remove the double heavy leads Label the leads for reassembly if more than one is removed 5 COMMANDER 500 LINCOLN Using the 1 wrench loosen the appropriate diode and remove the diode that is to be replaced Clean the area on the heat sink around the diode mounting surface using a putty knife or similar tool DO NOT SCRATCH THE DIODE MOUNTING SURFACE Polish the heat sink s mounting surface using an abrasive disc E2827 2 or fine steel wool to provide a bright clean surface where the diode seats on the heat sink Wipe the surface clean with a lint free cloth or paper towel F 72 F 72 TROUBLESHOOTING amp REPAIR Q o8 E i OUTPUT RECTIFIER BRIDGE DIODE REMOVAL AND 0 1 REMOVAL AND REPLACEMENT CONTINUED 2 8 8 EJE 8 Inspect the mounting surfaces of each new NOTE The diode threads must be clean and 5 diode Remove all burrs and wipe clean free of defects so that it can be finger tightened amp Do not use steel wool or any abrasive before applying torque slip type torque cleanser on the diode mounting surface wrench must be used to tighten the diode 9 Apply a thin 0 003 to 0 007 uniform 10 Tighten the diode to the specifications in layer of Penetrox A13 joint compound the following table T1283
247. y Do not leave the external supply connected to terminals 227 and 232L for longer than three seconds Component damage could result COMMANDER 500 LINCOLN The solenoid should deactivate when the 12VDC is removed If the solenoid does not operate properly check for a mechanical restriction in the link age Using the external 12VDC supply apply 12VDC to the smaller idler solenoid terminals for the hold in coil 226A to 232S Push in the solenoid plunger With 12 VDC applied to the hold in coil the plunger should stay in until the 12 VDC is removed If the linkage is intact and the solenoid does not operate correctly when the 12VDC is applied the solenoid may be faulty Replace Replace harness leads to the correct termi nals See Figure F 5 and the Wiring Diagram Replace any previously removed wire wraps Close and secure the right side engine ser vice access door Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 23 TROUBLESHOOTING amp REPAIR SHUTDOWN SOLENOID TEST WARNING 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 For your safety and to
248. y con nections See the Wiring Diagram The wire feeder may be faulty 3 Perform the Stator Voltage Return to Section TOC Retum to Master TOC The battery does not stay charged Check for loose or faulty con 1 The battery charging circuit may nections at the battery and be faulty Perform the engine charging system Charging Circuit Test The battery may be faulty Check or replace Retum to Master TOC 5 8 9 8 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 Call 1 800 833 9353 Retum to Section TOC Retum to Master TOC COMMANDER 500 LINCOLN 8 F 9 F 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual Retum to Section TOC Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC PROBLEMS SYMPTOMS The engine will not crank when the start button is pushed POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS 1 Check for loose or faulty battery cable connections 2 The battery may be low or faulty 3 The START button may be faulty RECOMMENDED COURSE OF ACTION 1 The starter motor or s

Lincoln Electric SVM153-A Welding System User Manual

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