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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.
ELECTRICAL DIAGRAMS
G-19
COMMANDER 500
PC BOARD ASSEMBLY - WELD CONTROL PC BOARD
SOLID EDG
E
EN-170
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:
Chg. Sheet No.
ENGINEER:
EQUIPMENT TYPE:
DRAWING No.:
APM
ILD
MAP
COMMON ANALOG CONTROL
WELD CONTROL PCB ASSEMBLY
G
1:5X
1-27-2000
REFERENCE:
SUPERSEDING:
G3660-1
APPROVED:
"X" INFO.
3660-2
7-7-2000
8-4-2000P
UNLESS OTHERWISE SPECIFIED:
RESISTANCE = OHMS
FOR PARTS ORDERS SEND:
(1) G3660-2 WELD CONTROL PC BOARD ASSEMBLY
(1) S18250-743 PLUG & LEAD ADAPTER
(1) S25110PRINT PARTS ORDER INSTRUCTION SHEET
BUY AS
IDENTIFICATION CODE
G3660-2C4
}
PART NO.
}
2
2
2
2
2
2
N.F.
N.B.
3
4
N.C.
(4.84)
(7.84)
SCHEMATIC REFERENCE -G3661_2C3
N.G.
N.H.
V
R155,R156,R157,R158,R159
R160
R161,R162,R163,R164,R165
R166
63 S25001-1213SMT 3 R167,R168,R169 RESISTOR,SMD,121K,1/4W,1206,1%,TR
64 S25000-2211SMT 5 R170,R171,R172,R173,R174 RESISTOR,SMD,METAL FILM,1/10W,2.21K,1
65 S25001-7500SMT 1 R175 RESISTOR,SMD,750OHMS,1/4W,1206,1%,TR
66 S25001-2002SMT 3 R176,R177,R178 RESISTOR,SMD,20K,1/4W,1206,1%,TR
67 S25000-3321SMT 5 R179,R180,R181,R182,R183 RESISTOR,SMD,METAL FILM,1/10W,3.32K,1
68 S25004-2430SMT 4 R184,R185,R186,R187 RESISTOR,SMD,1W,243OHMS,1%
69 S25000-2002SMT 1 R188 RESISTOR,SMD,METAL FILM,1/10W,20.0K,1
R190,R191,R192,R193,R194
R195,R372
R196,R197,R198,R199,R200
R201,R202,R203,R204,R205
R206,R207
72 S25000-1822SMT 2 R208,R209 RESISTOR,SMD,METAL FILM,1/10W,18.2K,1
73 S25000-2670SMT 1 R211 RESISTOR,SMD,METAL FILM,1/10W,267OHMS
74 S25000-3322SMT 2 R213,R214 RESISTOR,SMD,METAL FILM,1/10W,33.2K,1
75 S25000-2213SMT 5 R215,R216,R217,R218,R369 RESISTOR,SMD,METAL FILM,1/10W,221K,1%
76 S25000-1503SMT 1 R219 RESISTOR,SMD,METAL FILM,1/10W,150K,1%
77 S25000-3922SMT 5 R220,R221,R222,R223,R371 RESISTOR,SMD,METAL FILM,1/10W,39.2K,1
78 S25000-3323SMT 2 R224,R225 RESISTOR,SMD,METAL FILM,1/10W,332K,1%
79 S25000-6813SMT 1 R226 RESISTOR,SMD,METAL FILM,1/10W,681K,1%
80 S25000-6812SMT 2 R227,R228 RESISTOR,SMD,METAL FILM,1/10W,68.1K,1
81 S25001-7681SMT 3 R229,R230,R231 RESISTOR,SMD,7.68K,1/4W,1206,1%,TR
R232,R233,R234,R235,R236
R237,R379
83 S25000-2212SMT 4 R238,R239,R240,R242 RESISTOR,SMD,METAL FILM,1/10W,22.1K,1
84 S25000-4322SMT 4 R241,R320,R321,R322 RESISTOR,SMD,METAL FILM,1/10W,43.2K,1
85 S25003-47R5SMT 5 R245,R246,R247,R248,R249 RESISTOR,SMD,1W,47.5OHMS,1%
R250,R251,R252,R253,R254
R255,R256,R257,R258,R259
87 S25008-4321SMT 2 R260,R261 RESISTOR,SMD,PREC,MF,1/10W,4.32K,0.5%
88 S25010-3SMT 3 R262,R263,R264 RESISTOR,SMD,MF,1W,20.0K,1%,SURGE
89 S25001-1211SMT 1 R265 RESISTOR,SMD,1.21K,1/4W,1206,1%,TR
90 S25000-6191SMT 2 R266,R267 RESISTOR,SMD,METAL FILM,1/10W,6.19K,1
R269,R270,R271,R272,R273
R274,R275,R276,R277,R278
R279,R280,R281,R282,R283
R284
92 S25000-4R70SMT 3 R285,R286,R287 RESISTOR,SMD,METAL FILM,1/10W,4.70OHM
93 S25000-5621SMT 1 R288 RESISTOR,SMD,METAL FILM,1/10W,5.62K,1
94 S25008-9091SMT 3 R289,R290,R291 RESISTOR,SMD,PREC,MF,1/10W,9.09K,0.5%
95 S18380-14 4 R292,R293,R294,R295 THERMISTOR,PTC,500OHMS,28mA
96 S25008-4751SMT 1 R296 RESISTOR,SMD,PREC,MF,1/10W,4.75K,0.5%
97 S25007-2150SMT 1 R297 RESISTOR,SMD,PREC,MF,1/10W,215OHMS,0.
98 S25007-6040SMT 1 R298 RESISTOR,SMD,PREC,MF,1/10W,604OHMS,0.
99 S25001-4751SMT 1 R299 RESISTOR,SMD,4.75K,1/4W,1206,1%,TR
100 S25000-2001SMT 1 R300 RESISTOR,SMD,METAL FILM,1/10W,2.00K,1
91 S25008-1002SMT 16 RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.5%
RESISTOR,SMD,METAL FILM,1/10W,511OHMS
86 S25004-2430SMT 10 RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.1%
82 S25000-5110SMT 7
71 S25000-3011SMT 12 RESISTOR,SMD,METAL FILM,1/10W,3.01K,1
70 S25000-1500SMT 7 RESISTOR,SMD,METAL FILM,1/10W,150OHMS
62 S25001-1000SMT 6 RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR
61 S25000-28R7SMT 6 RESISTOR,SMD,METAL FILM,1/10W,28.7OHM
NOTE: G3990-2 MUST BE REVIEWED WHEN
MODIFYING THIS BOARD.
NOTES:
N.A.
CAUTION:
THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC
ELECTRICITY. LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING.
N.B. PLACE CONNECTOR KEYING PLUG, OVER HEADER PIN, IN
LOCATION SHOWN. PLUG SHOULD BE INSERTED BELOW
CONNECTOR TOP SURFACE (6 PLACES).
N.C. SECURE P.C. BOARD ASSEMBLY IN PLACE WITH ITEM (4).
(2 PLACES, 5.3 +/- .5 IN. LBS).
N.F. PLACE BARCODED ASSEMBLY NUMBER IDENTIFICATION AND
BARCODED SERIAL NUMBER IDENTIFICATION IN AREA SHOWN.
N.G. PROGRAM ITEM (140) WITH ITEM (7).
N.H. PROGRAM ITEM (142) WITH ITEM (8).
N.J. PARTS SHOWN MUST BE COMPLETELY COVERED
WITH ENCAPSULATION.
N.J.
N.F.
ITEM PART NO. QTY PC BOARD REFERENCE DESIGNATORS DESCRIPTION
1 G3660-C 1 WELD CONTROL PCB BLANK
2 S24671 7 PLUG,KEYING PLUG
3 M19436-2 1 POTTING TRAY
4 S8025-80 2 SELF TAPPING SCREW
5 E2527 170 g EPOXY ENCAPSULATING RESIN
6 E3539
AS REQ.
ELECTRICAL INSULATING COMPOUND
7 S24762-5 1 X30 SOFTWARE
8 S24763-8 1 X33 SOFTWARE
C1,C2,C3,C4,C7,C8,C9
C10,C11,C12,C13,C14,C15
C16,C17,C18,C19,C20,C21,C22,
C23,C24,C25,C26,C28,C29
C30,C31,C32,C33,C34,C35
C36,C37,C38,C39,C40,C41
C42,C43,C44,C45,C46,C47
C48,C49,C50,C51,C52,C53
C54,C55,C56,C57,C58,C59
C60,C61,C62,C63,C64,C65
C66,C67,C68,C69,C70,C71
C72,C73,C74,C75,C76,C77
C78,C79,C80,C81,C82,C83
C84,C85,C86,C87,C88,C89
C90,C91,C92,C93,C94,C95
C96,C97,C98,C99,C100,C101
C133,C141,C142
C108,C109,C110,C111,
C112,C113,C114,C115
C116
C102,C103,C104,C105,C106
C107
12 S25024-6SMT 2 C117,C118 CAPACITOR,SMD,TANTALUM,22MF,16V,10%,S
13 S25020-4SMT 1 C119 CAPACITOR,SMD,CERAMIC,820pF,50V,5%,CO
C120,C121,C122,C123,C124
C125
15 S25020-8SMT 2 C126,C127 CAPACITOR,SMD,CERAMIC,0.056MF,50V,10%
16 S25020-16SMT 1 C128 CAPACITOR,SMD,CERAMIC,0.018MF,50V,1%,
17 S25024-1SMT 1 C129 CAPACITOR,SMD,TANTALUM,0.47MF,50V,10%
18 S25024-5SMT 3 C130,C131,C132 CAPACITOR,SMD,TANTALUM,4.7MF,35V,10%,
19 S25024-3SMT 1 C134 CAPACITOR,SMD,TANTALUM,2.2MF,20V,10%,
20 S25020-10SMT 2 C135,C136 CAPACITOR,SMD,CERAMIC,4700pF,50V,10%,
21 S25020-1SMT 1 C137 CAPACITOR,SMD,CERAMIC,0.022MF,50V,1%,
22 S25024-7SMT 2 C138,C139 CAPACITOR,SMD,TANTALUM,47MF,20V,10%,S
23 S25020-17SMT 1 C140 CAPACITOR,SMD,CERAMIC,0.27MF,50V,10%,
D1,D2,D3,D4,D5,D6,D7,D8,D9
D10,D11,D12
D13,D14,D15,D16,D17,D18
D19,D20,D21,D22,D23,D24
D25,D26,D27,D28,D29,D30
D31,D32
D33,D34,D35,D36,D37,D38
D39,D40,D41,D42,D43,D44
D45,D46,D47,D48
D49,D50,D51,D52,D54,D55
D61,D63,D64
28 S25040-4SMT 3 D56,D57,D62 DIODE,SMD,DUAL,0.200A,70V,UFR
29 S25049-2SMT 2 D58,D59 DIODE,SMD,1A,30V,SMA,SCHOTTKY
30 S25040-3SMT 1 D60 DIODE,SMD,DUAL,6A,200V,DPAK,CC,ULTRA-
31 S25044-5SMT 2 DZ1,DZ2 ZENER DIODE,SMD,3W,18V,5%, SMB
32 S25044-3SMT3DZ3,DZ4,DZ14 ZENER DIODE,SMD,3W,12V,5%, SMB
DZ5,DZ6,DZ7,DZ8,DZ9,DZ10
DZ11
34 S25044-4SMT 2 DZ12,DZ13 ZENER DIODE,SMD,3W,15V,5%, SMB
35 S25044-1SMT 1 DZ15 ZENER DIODE,SMD,3W,5.1V,5%, SMB
36 S18248-12 1 J1 CONNECTOR,MOLEX,MINI,PCB,12-PIN
37 S24020-8 2 J2,J13 CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
33 S25045-1SMT 7 ZENER_DIODE,SMD,225mW,12V,5%,SOT-23
27 S25049-1SMT 9 DIODE,SMD,0.5A,30V,SOD-123,SCHOTTKY
26 S25040-5SMT 16 DIODE,SMD,DUAL,0.200A,70V,UFR
25 S25040-2SMT 20 DIODE,SMD,1A,400V,DO-214BA/AC
24 S25040-6SMT 12 DIODE,SMD,DUAL,0.200A,70V,UDR,CC,SOT-
14 S25024-2SMT 6 CAPACITOR,SMD,TANTALUM,1.0MF,35V,10%,
11 S25020-5SMT 6 CAPACITOR,SMD,CERAMIC,2700pF,50V,5%,X
10 S25020-2SMT 9 CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%
FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS
9 S25020-3SMT 102 CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X
38 S24020-6 3 J3,J10,J11 CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
39 S24020-10 2 J4,J5 CONNECTOR,MOLEX,MINI,PCB,10-PIN,TIN
40 S24020-2G 1 J6 CONNECTOR,MOLEX,MINI,PCB,2-PIN,GOLD
41 S24020-4 3 J7,J8,J9 CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN
42 S24020-16 1 J12 CONNECTOR,MOLEX,MINI,PCB,16-PIN,TIN
43 S15000-22SMT 1 OCI1 OPTOCOUPLER,SMD,PHOTO-TRANSISTOR,70V,
Q1,Q2,Q3,Q4,Q5,Q6,Q7,Q8,Q9
Q10,Q11,Q12,Q14
Q15,Q16,Q17,Q18,Q19,Q20
Q21,Q22
46 S25051-1SMT 1 Q23 TRANSISTOR,SMD,NMF,SOT-223,1.5A,100V,
47 S25051-2SMT 1 Q24 TRANSISTOR,SMD,NMF,D2PAK,18A,200V,IRF
R1,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
R2,R3,R4,R5,R6,R7,R8,R9
R10,R11,R12,R13,R14,R17
R63
50 S25000-4750SMT 6 R18,R19,R20,R21,R22,R23 RESISTOR,SMD,METAL FILM,1/10W,475OHMS
R50,R51,R52,R53,R54,R55
R56,R57,R58,R59,R60,R61
R64,R65,R66,R67,R68,R69
R70,R71,R72,R73
52 S25000-8251SMT 5 R62,R243,R244,R268,R381 RESISTOR,SMD,METAL FILM,1/10W,8.25K,1
53 S25001-1301SMT 4 R74,R75,R76,R77 RESISTOR,SMD,1.3K,1/4W,1206,1%,TR
R78,R79,R80,R81,R82,R83
R84,R85,R86,R87,R88,R89
R90,R91
55 S25000-2000SMT 4 R92,R93,R94,R210 RESISTOR,SMD,METAL FILM,1/10W,200OHMS
R95,R96,R97,R98,R99,R100
R101,R102,R103,R212
57 S25000-1212SMT 2 R105,R106 RESISTOR,SMD,METAL FILM,1/10W,12.1K,1
R107,R108,R109,R110,R111
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
R139,R140,R141,R142,R143
R144,R145,R146,R148,R149
R150,R151,R152,R153,R154
60 S25000-4752SMT 5 R147,R301,R302,R303,R304 RESISTOR,SMD,METAL FILM,1/10W,47.5K,1
59 S25000-1001SMT 15 RESISTOR,SMD,METAL FILM,1/10W,1.00K,1
58 S25000-1001SMT 38 RESISTOR,SMD,METAL FILM,1/10W,10.0K,1
56 S25000-6811SMT 10 RESISTOR,SMD,METAL FILM,1/10W,6.81K,1
54 S25001-4750SMT 14 RESISTOR,SMD,475OHMS,1/4W,1206,1%,TR
51 S25000-1000SMT 22 RESISTOR,SMD,METAL FILM,1/10W,100OHMS
RESISTOR,SMD,METAL FILM,1/10W,4.75K,1
49 S25000-1501SMT 15 RESISTOR,SMD,METAL FILM,1/10W,1.50K,1
48 S25000-4751SMT 26
45 S25050-2SMT 8 TRANSISTOR,SMS,PNP,SOT23,0.5A, 40V,MM
44 S25050-1SMT 13 TRANSISTOR,SMD,NPN,0.5A,40V,SOT-23,MM
BUY PER E3867
TEST PER E3869-C
100 S25000-2001SMT 1 R300 RESISTOR,SMD,METAL FILM,1/10W,2.00K,1
101 S25000-2801SMT 1 R305 RESISTOR,SMD,METAL FILM,1/10W,2.80K,1
102 S25000-2210SMT 2 R306,R307 RESISTOR,SMD,METAL FILM,1/10W,221OHMS
103 S25001-1501SMT 3 R308,R309,R310 RESISTOR,SMD,1.5K,1/4W,1206,1%,TR
104 S25000-1503SMT 2 R316,R317 RESISTOR,SMD,METAL FILM,1/10W,1.82K,1
105 S25000-1003SMT 2 R318,R319 RESISTOR,SMD,METAL FILM,1/10W,100K,1%
106 S25001-1001SMT 2 R323,R324 RESISTOR,SMD,1K,1/4W,1206,1%,TR
107 S25000-39R2SMT 1 R325 RESISTOR,SMD,METAL FILM,1/10W,39.2OHM
108 S25000-4753SMT 2 R326,R370 RESISTOR,SMD,METAL FILM,1/10W,475K,1%
R327,R328,R329,R330,R331
R332,R333,R334
110 S25000-10R0SMT 4 R335,R336,R337,R338 RESISTOR,SMD,METAL FILM,1/10W,10.0OHM
111 S25007-2431SMT 1 R339 RESISTOR,SMD,PREC,MF,1/10W,2.43K,0.1%
112 S25007-1301SMT 1 R340 RESISTOR,SMD,PREC,MF,1/10W,1.30K,0.1%
113 S25007-1023SMT 1 R341 RESISTOR,SMD,PREC,MF,1/10W,102K,0.1%,
114 S25000-5111SMT 1 R342 RESISTOR,SMD,METAL FILM,1/10W,5.11K,1
115 S25001-2370SMT 2 R343,R344 RESISTOR,SMD,237OHMS,1/4W,1206,1%,TR
116 S25008-6812SMT 1 R345 RESISTOR,SMD,PREC,MF,1/10W,68.1K,0.5%
117 S25008-1503SMT 1 R346 RESISTOR,SMD,PREC,MF,1/10W,150K,0.5%,
118 S25008-1212SMT 1 R347 RESISTOR,SMD,PREC,MF,1/10W,12.1K,0.5%
119 S25000-9091SMT 1 R348 RESISTOR,SMD,METAL FILM,1/10W,9.09K,1
120 S25007-6812SMT 2 R349,R350 RESISTOR,SMD,PREC,MF,1/10W,68.1K,0.1%
121 S25007-9091SMT 1 R351 RESISTOR,SMD,PREC,MF,1/10W,9.09K,0.1%
122 S25000-1330SMT 1 R352 RESISTOR,SMD,METAL FILM,1/10W,133OHMS
123 S25008-1502SMT 1 R353 RESISTOR,SMD,PREC,MF,1/10W,15.0K,0.5%
124 S25007-9092SMT 2 R354,R355 RESISTOR,SMD,PREC,MF,1/10W,90.9K,0.1%
125 S25000-22R1SMT 1 R356 RESISTOR,SMD,METAL FILM,1/10W,22.1OHM
126 S25010-1SMT 1 R357 RESISTOR,SMD,MF,2.21K,1/4W,1%,SURGE
127 S25000-3320SMT 1 R358 RESISTOR,SMD,METAL FILM,1/10W,332OHMS
128 S25003-0R15SMT 1 R359 RESISTOR,SMD,1W,0.15OHMS,1%
R360,R361,R362,R363,R364
R365,R366,R367,R383
130 S25007-3321SMT 1 R368 RESISTOR,SMD,PREC,MF,1/10W,3.32K,0.1%
131 S25056-2SMT 4 R380,R561,R619,R766 TRIMMER,SMD,MT,1/4W,2K,10%,LINEAR
132 S15128-27SMT 1 X1 IC,OP-AMP,SINGLE,PRECISION,LT1097S8
X2,X3,X39,X40,X41,X42,X51
X5 5
X4,X5,X6,X7,X16,X22,X46
X47,X52,X56
135 M15458-6SMT 1 X8 IC,SMD,PWM-CONTROL
X9,X10,X11,X14,X17,X24,X34
X3 5,X36
137 S15128-11SMT 2 X15,X43 IC,SMT,COMPARATOR,QUAD,2901D
138 S25065-1SMT 1 X20 IC,SMD,MULTIPLEXER,2 TO 1 LINE DATA,H
139 S25057-3SMT 3 X27,X53,X57 POT,DIGITAL,SMD,10K,QUAD,TSSOP-24
140 S25069-2SMT 1 X30 IC,SMD,CMOS,EEPROM,SERIAL,SPI,64Kx8,S
141 S25070-5SMT 1 X31 IC,SMD,FPGA,XCS20,TQFP,144PIN
142 S25069-5SMT 1 X33 IC,SMD,EEPROM,CMOS,CONFIGURATION,256K
143 S15128-10SMT 1 X44 IC,SMD,VOLTAGE REF,ADJ, PECISION,431I
144 S25067-1SMT 1X45 IC,BIPOLAR,TIMER,SOIC-14
145 S15018-11SMT 1 X50 IC,SMD,CMOS,SWITCH,ANALOG,QUAD,201(SS
146 S25057-2SMT 1 X54 POT,SMD,DIGITAL,10K,1-CHNL,SOIC-8
147 S25001-1821SMT 1 R311 RESISTOR, SMD, 1.82K, 1/4W,1206,1%,TR
148 S25001-1502SMT 1 R312 RESISTOR, SMD, 15K, 1/4W,1206,1%,TR
136 S15018-6SMT 9 IC,SMD,CMOS,SWITCH,ANALOG,QUAD, 4066B
134 S15128-18SMT 10 IC,OP-AMP,SMT,QUAD,HIGH-PERF,33074D
133 S15128-4SMT 8 OP-AMP,SMD,QUAD, GEN-PURPOSE,224D
129 S25001-2001SMT 9 RESISTOR,SMD,2K,1/4W,1206,1%,TR
109 S25002-2000SMT 8 RESISTOR,SMD,200OHMS,1/3W,MF,1%,S1210
G-19
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