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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 Chopper
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
battery voltage is fed through 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.
E-2 E-2
THEORY OF OPERATION
COMMANDER 500
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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.2 - BATTERY, ENGINE, ROTOR, STATOR, PULL COIL BOARD
AND PERIPHERAL BOARD – ENGINE PROTECTION
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.