Lincoln Electric 500 Welder User Manual


  Open as PDF
of 56
 
F-1
DIAGRAMS
F-1
COMMANDER 500
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia-
gram for your particular machine is pasted inside the machine on one of the enclosure panels.
GND-H
6D
3
GND-F
5A
AUXILIARY POWER
GND-D
12
11
10
EMPTY
CB6
10A
EMPTY
EMPTY
42A
42
31
GND-E
42A
5J
OUTPUT
31
CONTROL
32
CCW
236C
8
POLARITY
SWITCH
1
31
32
RECTIFIER BRIDGE
50A
TO THE LAMINATION
TO SLIP RING NEAREST
POSITIVE BRUSH CONNECTED
CONTROL
IDLER
5B
6D
5E
5C
5
6D
200D
200A
256
200E
200C
SHOWN IN
5P
300V
12
201
HOUR
200B
201A
231
236
201B
CB4
6B
GOLD
SILVER
ALT.
TEMP.
LOW
PRESS.
GOLD
75
PINCH POT
BACK
FROM
277
278
GOLD
SILVERSILVER
-
BRUSH
+
3200MFD
GND-G
257
238
SOLENOID
5
"HIGH" POSITION
METER
-
GND-J
232R
5H
POWER MODULE
236
231
RIGHT SIDE
ON BOTTOM LEFT
OF CONTROL BOX
SILVER
J12
CB1
20A
8
J11
SILVER
HOT (GOLD)
11
CB3
50A
3A
HOT (GOLD)
5G
WELDER
3
TEMP.
12
5C
GROUNDING BOLT
ON ENGINE BLOCK
STUD ON ENGINE
MOUNTING FOOT
LEFT SIDE
1
42A
41A
232P
GOLD
SILVER
SENSOR
COIL
HOLD
COIL
PULL
SHUTDOWN
SENSOR
COIL
SENSOR
SWITCH
FUEL LVL.
OIL TEMP. SENSOR & SWITCH
OUTPUT PANEL
262
GROUND STUD ON
SOL.
SOL.
OIL PRESSURE SWITCH & SENSOR
SWITCH
WK
233
234
265
SENSE
NEG
EXC
MOTOR
STARTING
281
5R
FRAME
POS
242D
239
229
5N
236C
232
236A
RUN
STOP
232H
32
HIGH
+
232C
242B
GND-J
SHOWN IN
SWITCH
SHOWN IN
RUN/STOP
"ALWAYS ON" POSITION
32
5J
GND-J
FUEL
GND. STUD ON
BOTTOM RIGHT OF
238
232K
4
8
5B
5E
20-250A
TIG
30-575A
2
STICK
CONTROL PANEL
GND. SCREW ON
1
500A
350A
200A
TEMP
OIL
PRESS.
S
242B
CHRG.
241A
228A
CORRESPONDING SETTINGS
FOR TAP NUMBERS
COMMANDER 500 WIRING DIAGRAM FOR 10838 AND BELOW
COMMA
NDER 500 WIRING DIAGRAM
(AS VIEWED FROM THE FRONT)
6A
3
41
ROTOR
CONTROL BOX
START BUTTON
242D
AUTO
242A
229A
232B
S
242C
238
BATT.
"RUN" POS.
265
32
5S
239
238
IDLE
224
228
241
POSITION
POSITIVE POLARITY
SWITCH SHOWN IN
DIRECTIONS
IN OPPOSITE
TOROID TWICE
PASS THROUGH
LEADS 3 & 6A
247 246
245
232L
232M
232K
232N
232A
3
6A
232A
227
S
OIL
6A
243
+
STARTER
STATOR
ALTERNATOR
AUXILIARY WINDINGS
3
"INSULATED STUD"
120V AUXILIARY POWER
6A
9
9
10
WIRE
14 TO 40V
EMPTY
8
90A
A
STUD
12VDC
1
INSULATED
5
GND-C
5
11
115/230V
3
GND-D
5A
GND-E
222
213
214
215
216
(VIEWED FROM REAR)
SELECTOR SWITCH
MOUNTING FOOT
12V BATTERY
STUD ON ENGINE
COIL
HOLD
(-)
-
PULL
226A
(+)
227
206A
ELECT.
+
206A
W2
W2
W3
W3
STATOR
WELD
WINDINGS
W5
W4
W5
W4
W1
W1
W6
W6
217
S5
218
12
11
1
2
220
C1
3
6A
5R
J1
6
GND-H
ENGINE GROUND
BACK OF CONTROL BOX
GND STUD ON RIGHT SIDE
6
9
16
R1
76
VIEWED
FROM
BACK
77
3
6
9
CB2
20A
3
3
232L
232M
6A
AUXILIARY
NEUTRAL STUD
GND-G
BACK OF CONTROL
BOX "LEFT SIDE"
236B
6F
201
BRUSH
-
3
1
2
3
4
1
2
85
4
1
1
8
5
4
1
5
2
3
4
1
10
6
10
J6
J11
J2
3
4
1
J10
J5
J8
J9
J13
J7
2
PROGRAMMING MACHINE SELECT
9
16
J12
3
4
1
J10
3
4
1
3
4
1
1
8
6
PROGRAMMING
9
16
1
8
J31
220
2
2
2
2
1
8
2
1
7
2
1
5
2
1
6
MODE
AMPHENOL
77A
76A
75A
2
4
77
76
75
CONTROL POT
VOLT METER
M
1
M
2
M
3
M
4
M
5
M
6
M
9
M
1
0
1
5
6
10
J4
AM METER
M
1
M
2
M
3
M
4
M
5
M
6
M
9
M
1
0
POWER SUPPLY
1 2
34
J41
J42
1
5
1
0
5
A
1
7
5
J
1
1
5
A
1
6
1
0
1
A
1
8
1
1
6
A
1
1
8
A
13
14
2
5
2
3
2
5
A
2
3
A
9
16
1
8
BATTERY
BOARD
J65
PULL COIL BD.
J43
B1
B2B3
B4
PERIPHERAL BD.
WELD BOARD
401
403
405
VIEWED
277
278
10K
279
2
4
4A
2A
WELDING
TERMINALS
CONTROL
3
4
278
279
277
2
1
J6
204S
206S
SHUNT
206S
261
404
THERMAL
HOT START PINCH
MISC CONTROL
POWER
4
0
3
5
T
5L
402
232
208B
SWITCH
116A
105A
115A
101A
5G
118A
251
252
253
250
G
208B
257
256
261A
260A
226
232W
2
7
0
5L
5T
232S
232J
2
6
2
B
2
2
4
A
4
0
5
271
270
281A
200
401
2
1
3
2
1
4
232T
232R
262A
262B
281A
241A
233A
228A
234A
262A
224A
239
281
241
233
228
234
262
224
226A
200B
6F
5P
200D
201A
200A
239A
226
200
6D
5H
200C
201B
200E
232T
232S
+
+
+
+
P52
J52
208A
+
+
C4
C3
P51
RIGHT SIDE
300 AMP
MODULE
HEATSINK
PCB 2
D2 DIODE
MODULE
TS2
249
251
B7
B3
B2
B1
J51
987
654
123
16
15
23A
25A
789
456
321
D4
PC BOARD TO
HEAT SINK CONN.
PC BOARD TO
HEAT SINK CONN.
POS
+
+
C2
C1
P50
LEFTSIDE
300 AMP
MODULE
HEATSINK
PCB 6
D1 DIODE
MODULE
13A
14A
TS1
250
249
B7
B3
B2
B1
J50
18
17
23
25
789
456
321
D3
PC BOARD TO
HEAT SINK CONN.
PC BOARD TO
HEAT SINK CONN.
POS
208B
41A
5J
L1 CHOKE
POS.
POS.
POS.
POS.
+
50MV=400AMPS
260A
260
3
6A
3
3
6A
6A
GAUGES
OPTIONAL ON
STANDARD MODEL
W4 & W5
W2 & W3
W1 & W6
261A
204S
DENOTES ITEMS
INCLUDED ON DELUXE
MODELS ONLY
GOLD
SILVER
LOW
FUEL
252
253
GND-C
232D
2
3
2
J
NEG.
NEG.
NEG.
NEG.
W10
W9
W8
W7
3 TURNS
THRU
TOROID
GND-G
987
654
123
ON STANDARD MODELS,
LEADS 238 & 236C ARE TO BE
BOLTED TOGETHER AND
TAPED. LEADS 228A, 241A,
242B, 232K AND 229A ARE TO
BE TAPED INDIVIDUALY AND
TIED INTO HARNESS.
J10
GND-B
3 TURNS
THRU
TOROID
STATOR
42V WINDING
41A
31
1
6
12
7
J32
2
2
9
A
2
2
9
2
3
3
A
2
3
9
A
2
3
4
A
2
7
1
2
4
7
2
4
6
2
4
5
2
4
3
PCB2
PCB3
PCB1
PCB4
PCB8
5S
265
232N
227
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
232D
232W
ENGINE HARNESS
MULTI-LEAD
3
4
1
3
4
1
J30
6
404
402
14
13
150
GND-F
GND-H
GND-A
GND-K
G3777
9-01
208
31
32
4B
21
77B
21
2B
75B
GND-A
41A
42A
76B
WORK
115VAC
CONTACTOR
WORK
REMOTE
CONTROL
42VAC
GROUND
AMPHENOL 1
VOLTMETER
AMMETER
M
1
M
2
M
3
M
4
M
5
M
6
M
9
M
1
0
M
1
M
2
M
3
M
4
M
5
M
6
M
9
M
1
0
206B
METER KIT OPTIONAL
ON STANDARD MODEL
BYPASS
FILTER
ASSEMBLY
GND-K
J
A
D
C
H
B
K
E
F
G
I
1
2
3
4
5
6
7
8
9
10
M1
M2
M3
M4
M5
M6
M9
M10
M1
M2
M3
M4
M5
M6
M9
M10
1
2
3
4
5
6
7
8
9
10
M1
M2
M3
M4
M5
M6
M9
M10
M1
M2
M3
M4
M5
M6
M9
M10
1
6
4
3
J3
GND-K
2
3
2
P
9
8
232F
232G
232E
I
NEG.
NEG.
2B
4B
GND-B
A
B
C
D
E
F
76B
75B
REMOTE
CONTACTOR
GROUND
AMPHENOL 2
CONTROL
2A
4A
75A
76A
77A
77B
THRU TOROID ONCE
+
WELD LEAD TO PASS
+
WELD
LEAD
II I
2
3
4
222
213
214
215
216
OLDER MACHINES MAY BE
SELECTOR SWITCH
217
S5
218
6
5
7
8
220
A
9
(VIEWED FROM REAR)
WIRED AS SHOWN:
ON STANDARD
MODELS, LEADS
242D & 229 ARE
TO BE TAPED
G4357
G3834
 previous next