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ELECTRICAL DIAGRAMS
G-3
COMMANDER 500
SCHEMATIC - COMPLETE MACHINE - COMMANDER 500
EN-170
SOLID EDG
E
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE
SCALE:
DO NOT SCALE THIS DRAWING
ON 3 PLACE DECIMALS IS ± .002
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.
DESIGN INFORMATION
t
DRAWN BY:
WITH PUBLISHED STANDARDS.
DATE:
ON 2 PLACE DECIMALS IS ± .02
MATERIAL TOLERANCE (" ") TO AGREE
ON ALL ANGLES IS ± .5 OF A DEGREE
SUBJECT:
ENGINEER:
EQUIPMENT TYPE:
DRAWING No.:
DP
DP
COM. CONTROL COMMANDER 300 & 500
MACHINE SCHEMATIC
G
NONE
11-22-99
REFERENCE:
SUPERSEDING:
APPROVED:
3834
Chg. Sheet No."X" INFO.
5000762
XA
XB-UF
XC-UF
THREE PHASE
RECTIFIER
3200uf
300vdc
ROTOR FIELD
IGBT MODULE - EMMITTER
IS COMMON TO HEATSINK
SHUNT
50MV=400 AMPS
206S
204S
L1 CHOKE
DIODE
MODULE
D4
CURRENT LEVEL
FEED BACK SIGNAL
2400uf
100vdc
2400uf
100vdc
POSITIVE
OUTPUT
TERMINAL
NEGATIVE
OUTPUT
TERMINAL
ARC VOLTAGE FEEDBACK
BY-PASS
PC BOARD
206B
208
5A
120 V AC
240 V AC
120 V AC
AC AUX.
POWER
42 VOLT AC
WIRE FEEDER
POWER
41
42
FOUR POLE 1800 RPM ALTERNATOR
13
14
(J13-3) 105A
(J13-1) 115A
(J13-2) 101A
(J13-4) 116A
(J13-5) 118A
80V DC INPUT POWER
77 (J7-1)
76 (J7-2)
75 (J7-3)
R2
ARC
CONTROL 10K
279 (J9-3)
278 (J9-2)
277 (J9-1)
(J12-7) 256
(J12-8) 257
IDLER SWITCH
(J10-5) 2
(J10-4) 4
WELD TERMINALS SWITCH
(J2-1) 213
(J2-3) 215
(J2-4) 216
260A (J12-9)
261A (J12-10)
IDLER HOLD COIL
226 (J12-15)
WELD CONTROL
PC BOARD
ANALOG
POWER PC
BOARD
120 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
(J11-5) 250
(J11-4) 251
THERMOSTATS ON
CHOPPER MODULES
NORMALLY CLOSED
(J11-1) 252
(J11-6) 253
THERMAL
SHUTDOWN
13 (J41-1)
14 (J41-2)
12 VOLT
BATTERY
232 (J43-5)
105A (J42-2)
115A (J42-5)
101A (J42-7)
116A (J42-9)
118A (J42-10)
BATTERY
PC BOARD
(J43-11) 200
ROTOR
FLASHING
(J43-9) 5L
ENGINE
STARTER
SOLENOID
START
BUTTON
SWITCH
RUN-STOP SWITCH
SHOWN IN RUN POS.
204S (J6-1)
206S (J6-2)
208B (J12-16)
23A
(J12-4)
25A
(J12-3)
5J (J42-4)
5G (J13-7)
15 (J42-1)
16 (J42-6)
5V
15V
COM
15V
15V TO GND.
FRAME
GROUND
77A (J10-1)
76A (J10-2)
75A (J10-3)
W2
W2
W3
W3
STATOR
WELD
WINDINGS
W5
W4
W5
W4
W1
W1
W6
W6
3
5
6
IGBT MODULE - EMMITTER
IS COMMON TO HEATSINK
DIODE
MODULE
D3
+20V
2400uf
100vdc
2400uf
100vdc
PERIPHERAL
PC BOARD
PULL COIL
PC BOARD
17 (J42-3)
18 (J42-8)
23
(J12-2)
25
(J12-1)
5T (J31-9)
(J31-5) 224A
(J32-9) 229
(J32-10) 229A
232J (J31-4)
405 (J31-11)
(J32-5) 233A
(J32-6) 234A
239A (J32-8)
(J31-6) 262B
270 (J31-8)
271 (J32-7)
403 (J31-3)
403 (J65-3)
SENSOR
SENSOR
SENSOR
SWITCH
FUEL LVL.
TEMPERATURE
OIL PRESSURE
SWITCH
HIGH
TEMP.
LOW
PRESS.
(J32-1)
247
(J32-2)
246
(J32-3)
245
LOW
FUEL
FUEL
TEMP.
OIL
PRESS.
S
228A
241A
S
238
BATT
CHRG.
METER
S
(J43-15)401
J43-16) 402
405 (J65-5)
402 (J65-2)
(J12-12) 404
404 (J65-4)
227 (B1)
IDLE SOL.
PULL COIL
SHUT DOWN
PULL COIL
265 (B3)
5S (B4)
232N (B2)
SHUT DOWN HOLD COIL
(J32-4)
243
ALT.
+12 VOLTS FROM THE BATTERY VIA
THE RUN / STOP SWITCH.
(J43-8) 270
(J43-14) 271
229A
SENSE
NEG
EXC.
POS
+
ENGINE
ALTERNATOR
ENGINE
STARTER
281A (J43-3)
+12
INSULATED
STUD
OUTPUT
SELECTOR
SWITCH
CC
CV
500A PIPE
TIG
(J2-5) 217
(J2-6) 218
(J2-7) 220
(J2-8) 222
350A PIPE
250A PIPE
150A PIPE
90A PIPE
(J2-2) 214
+
-
201
200B
200A
249
232W (J12-14)
HOUR METER
+
21
WIREFEEDER
VOLTMETER
POLARITY
SWITCH
206A
208A
231
236
+
SLIP RINGS
160 VDC
+12V
+12V
+
ROTOR RESISTANCE= 25- 27 OHMS
6F
5P
262
262A
401 (J65-1)
232R
232E232P
232G
232F
_
+
236C
236A
236B
232H
232
(J32-12)
232P
A
M
P
S
V
O
L
T
D
I
S
P
L
A
Y
S
(J4-1 THRU 10)
M1 THRU M10
(J5-1 THRU 10)
M1 THRU M10
TOROID-
SENSES AC POWER &
"TRIGGER" CURRENT
FROM LN25 TO
ACTIVATE IDLER
REMOTE
CONTROL 10K
10 V
-15 V (W/O POT.)
0 V
(TO AMPHENOL)
R1
OUTPUT
CONTROL 10K
10 V
0-10 V
0 V
0 - .1V WHEN ON
15 V
0 V
(TO AMPHENOL)
(TO AMPHENOL)
2A
4A
2A
4A
0 V
15 V
(232D,
232T &
232W
MULTI
LEAD)
232S
(232D, 232T & 232W
MULTI LEAD)
232T
232D
232A
+12 INS. STUD
232L
232M
+12 INS. STUD
232J
232B
232C
+12 INS. STUD
232K
242A 242C
T
W
I
S
T
E
D
P
A
I
R
T
W
I
S
T
E
D
P
A
I
R
T
W
I
S
T
E
D
P
A
I
R
C
E
CHOPPER
PC BOARD
GATE SIGNAL
23A (J51-9)(J51-7) 25A
(J51-3) 16
(J51-1) 15
IGBT
C
E
CHOPPER
PC BOARD
GATE SIGNAL
23 (J50-9)
(J50-7) 25
(J50-3) 18
(J50-1) 17
IGBT
+20V
31
32
41A
A
B
C
D
E
F
77A
21
42A
75A
GND-A
4A
2A
76A
77B
76B
75B
REMOTE
GROUND
AMPHENOL
CONTROL
INPUT TO
AMPHENOL
115VAC
CONTACTOR
WORK
REMOTE
CONTROL
42VAC
GROUND
AMPHENOL
J
A
D
C
H
B
K
E
F
G
I
77B
76B
75B
GND-B
4B
2B
4B
2B
NOTE: COMMANDER 500
USES (2) 300 AMP
CHOPPER MODULES &
COMMANDER 300 USES
(2) 200 AMP CHOPPER
MODULES.
208B
404
232A
.3 Ω
.3 Ω
21Ω
21Ω
G-3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G4357
G3834