Theory Of Operation - Lincoln Electric BIG RED 500 Service Manual

E-2
FUEL
SOLENOID
OIL
TEMP.
ENGINE
ENGINE
SWITCH
+ +
SHUTDOWN
PROTECTION
LIGHT RELAY
OIL
TIME
PRESSURE
DELAY
SWITCH
RELAY
RUN / STOP
SWITCH
GENERAL DESCRIPTION
The BIG RED 500 and 600 machines are diesel engine
driven welders capable of producing DC constant cur-
rent output for stick welding, arc gouging, and DC TIG
welding. They are also capable of producing 6000
watts of auxiliary power via an independent auxiliary
rotor and stator.
The generator is a dual stator and rotor design with two
sealed bearings for maintenance free service. The
rotors are copper wound design with two slip rings and
brushes. The stators are would entirely with heavy
gauge copper wire and insulated with NEMA class F
insulation material.

THEORY OF OPERATION

FIGURE E.1 - GENERAL DESCRIPTION
TO
HOT START
RELAY
OIL
OIL
FUEL
TEMP.
PRESSURE
SENSOR
SENSOR
SENSOR AND
AND
AND
GAUGE
GAUGE
GAUGE
MECHANICAL
COUPLING
DIESEL
ENGINE
STARTER
ENGINE
SOLENOID
ALTERNATOR
START
BUTTON
12 VDC
BATTERY
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
BIG RED
THREE PHASE
RECTIFIER
+
TAPPED
REACTOR
SELECTOR
STICK/TIG
SWITCH
AUXILIARY
STATOR
65 VAC
ROTOR
SHAFT
AUXILIARY
WELD
ROTOR
ROTOR
WELD
STATOR
FIELD
RECTIFIER
FINE
CURRENT
CONTROL
PART OF
STICK/TIG
115/230 VAC
SWITCH
RECEPTACLES
TO
HOT
TAPPED
START
REACTOR
RELAY
12 VDC
® 500/600
HOT
START
CIRCUIT
PART OF
SWITCH
65 VAC
150 VAC
FIELD
FEEDBACK
AUXILIARY
ROTOR
FLASHING
CIRCUIT
E-2
+