Filter
Top Products
General Description .......................................................................................................................E-2
Battery, Starter, Engine, Rotor, Stator, Pull Coil Board and Peripheral
Board – Engine Protection .....................................................................................................E-2
Weld Windings, Rectifier, Power Modules and Feedback ..........................................................E-3
Analog Power Supply Board and Weld Control Board ...............................................................E-4
Insulated Gate Bipolar Transistor (IGBT) Operation...................................................................E-5
Pulse Width Modulation ..............................................................................................................E-6
Chopper Technology Fundamentals ...........................................................................................E-7
Section E-1 Section E-1
TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
COMMANDER 500
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
ENGINE ROTOR
STATOR
AUXILIARY WINDINGS
W
E
L
D
W
I
N
D
I
N
G
MECHANICAL
ROTATION
STARTER
ALTERNATOR
ENGINE
SENSORS
OUTPUT PROCESS/RANGE
1
2
0
V
A
C
120VAC
RECEPTACLES (2)
240VAC
RECEPTACLE
SLIP
RINGS
ANALOG
POWER SUPPLY
BOARD
ARC
WELD
CONTROL
BOARD
CONTROL
CONTROL SELECTOR
PWM
SIGNALS (2)
VOLTMETER
AMMETER
BATTERY
S
H
U
T
D
O
W
N
I
D
L
E
R
PERIPHERAL
BOARD
BATTERY
BOARD
PULL
COIL
BOARD
SOL
SOL
TO
IDLE
HOLD
COIL
42 VAC TO 14 PIN AMPHENOL
THREE-PHASE
RECTIFIER
CHOKE
IGBT
WORK
TERMINAL
ELECTRODE
TERMINAL
+
+
SHUNT
F
E
E
D
B
A
C
K
____
POWER MODULES
(2)
TO WELD
CONTROL
BOARD
FOR WIRE FEEDER
COMMANDER 500
(2) (2)
80 VDC
(2)
20 VDC
THERMAL
LIGHT
TO WELD
CONTROL
BOARD
10
VDC
10
VDC
120
VDC
1/2
BATTERY
BD
RUN/STOP
SWITCH
FIGURE E.1 – MULTI-WELD 500 BLOCK LOGIC DIAGRAM