Lincoln Electric COMMANDER SVM153-A Service Manual page 138

G-2
WIRING DIAGRAM - COMMANDER 500
6A
LEADS 3 & 6A 3
PASS THROUGH
TOROID TWICE
IN OPPOSITE
DIRECTIONS
+
WELD LEAD TO PASS
THRU TOROID ONCE
6A
260
3
261
204S
+
WELD
206S
260A
LEAD
261A
L1 CHOKE
ELECT.
206A
206B
BYPASS
GND-K
FILTER
ASSEMBLY
14
208
208B
WORK
13
208A
SWITCH SHOWN IN
POSITIVE POLARITY
POSITION
+
POLARITY
21
SWITCH
-
206A
J
31
115VAC
A
32
I
41A
42VAC
K 42A
VOLTMETER
H
WORK 21
E
77B
REMOTE
CONTROL F 76B
G 75B
CONTACTOR
D 4B
C 2B
GROUND B GND-A
AMPHENOL 1
AMMETER
77A
A
77B
REMOTE 76A
CONTROL B 76B
75A
METER KIT OPTIONAL
C 75B
2A
CONTACTOR ON STANDARD MODEL
D 2B
4A
E 4B
F
GROUND GND-B
AMPHENOL 2
3 TURNS
THRU
TOROID
206S
204S
1
1 5
1 3
2 2
J6 J6
J3 SHUNT
4
J4 10 J11
6
THERMAL
AM METER
WELD BOARD
PCB3
J1
4
4 3 3 3
2
2 J8 1 J9 1
HOT START PINCH
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
6A
3
W4 & W5
P50
D3 HEATSINK
POS. +
B1
3 2 1
POS B2
6 5 4
C1
W7 B3
9 8 7
RECTIFIER BRIDGE
B7
NEG. PC BOARD TO
250
HEAT SINK CONN.
TS1
D1 DIODE
NEG.
MODULE 249
17
PC BOARD TO
NEG.
HEAT SINK CONN. 1 2 3 18
W3 W2
J50
4 5 6 W3
C2 LEFTSIDE
W8
7 8 9 23
300 AMP
PCB 6 MODULE
25
+
POS.
STATOR
WELD
W4
WINDINGS
P51
D4 HEATSINK W4
POS. +
B1
W5
3 2 1
POS
B2
6 5 4 W5
C3
W9
B3 9 8 7
B7
PC BOARD TO
NEG.
249
HEAT SINK CONN.
TS2
D2 DIODE
NEG.
MODULE 251
14A
15
PC BOARD TO
NEG.
HEAT SINK CONN. 16
1 2 3
4 5 6
C4 RIGHT SIDE 23A
7 8 9
W10
300 AMP J51
25A
PCB 2 MODULE
POS. +
13A
POWER MODULE
3
6A
31
32
41A
42A
208B
M1
M1 1
M2 2 M2
M3 3 M3
M4 4 M4 77
M5 5 M5
M6 6 M6
7
8
M9
M9 9
M10
M10 10
M1 1 M1
M2 2 M2
M3 3 M3
M4 4 M4
M5 5 M5
M6 6 M6
7
8
M9 9 M9
M10 10 M10
243 247
252 GOLD
GOLD GOLD
LOW
WELDER ALT.
PRESS.
TEMP.
253
3 TURNS SILVER SILVER SILVER
THRU
TOROID
232F 232G
232P
4 2
77A 76A 75A
1 5
1 4 1 1 3 3
6 5 8 4 4
J2 J5 10 J10 J10 PERIPHERAL BD.
6
AMPHENOL
VOLT METER
MODE
75
77
J7
76
CONTROL POT
16
8 J31
9 8 5
16
1 4
8 J13 1
J12
MISC CONTROL POWER
ELECTRICAL DIAGRAMS
COMMANDER 500 WIRING DIAGRAM
CORRESPONDING SETTINGS
W2 & W3 W1 & W6
FOR TAP NUMBERS
(AS VIEWED FROM THE FRONT)
200A 350A
AUXILIARY POWER
11 12
150 A
500A GND. SCREW ON
10 1
CONTROL PANEL
STICK
90A 9 2
30-575A
WIRE
TIG
14 TO 40V 8 3
20-250A
OLDER MACHINES MAY BE
WIRED AS SHOWN:
EMPTY
EMPTY
EMPTY
SELECTOR SWITCH
EMPTY
(VIEWED FROM REAR)
SELECTOR SWITCH
(VIEWED FROM REAR)
217
S5
W2
218
217
12 11 216
218 1
10 215
220
2 C1 9 214
220 3 8 213
W1
W1
222
STATOR 42V WINDING
W6
W6
42
41
41A
J41
1 2
6A
1
5
13
3 201
14
3 4
BRUSH
6 10
POWER SUPPLY
J42
PCB2
5J
ROTOR
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
31
32
41A
42A
5J
OUTPUT WELDING TERMINALS
CONTROL SWITCH
CONTROL
VIEWED SHOWN IN
CCW FROM "ALWAYS ON" POSITION
R1 BACK
4
PINCH POT
4A
VIEWED
FROM
BACK 10K
75 2A 2
76
279
277 277 278 278
ON STANDARD MODELS,
DENOTES ITEMS LEADS 238 & 236C ARE TO BE
BOLTED TOGETHER AND
INCLUDED ON DELUXE
TAPED. LEADS 228A, 241A, 232B 232C
238 238A
242B, 232K AND 229A ARE TO
236C
MODELS ONLY BE TAPED INDIVIDUALY AND
TIED INTO HARNESS.
BATT. OIL OIL
CHRG. PRESS. FUEL
TEMP
12VDC 232R
INSULATED S I S I S I
246 245
STUD
GOLD GOLD 232L
242A
228A 242C
LOW
TEMP.
FUEL
232M
242B 229A
232K GAUGES
SILVER SILVER
OPTIONAL ON
241A 232K
STANDARD MODEL
NOTE: MAY NOT APPEAR ON
232E 232N
SOME DELUXE MACHINES.
232A
NOTE: LEADS 229 AND 229A MAY
BE SPLICED TOGETHER ON SOME
MACHINES. LOW FUEL SHUTDOWN
WILL BE DISABLED ON THESE
MACHINES.
PCB1
PROGRAMMING
1 1 3 3
4 4 6
J30
7
12 1
9
8
9
16
1 6
1
J32
J43
6A
3
GND-F
5A
120V AUXILIARY POWER
"INSULATED STUD"
6A
ON BOTTOM LEFT
OF CONTROL BOX
6D
GND-C
GND-D
GND-E
20A
9
31
CB1
S5
3A
31
6 5 216
50A SILVER
3
7 4
215
11
6A J12
8 A 3 214
AUXILIARY
CB3
3
9 2 213 NEUTRAL STUD
BACK OF CONTROL
222 9
20A
BOX "LEFT SIDE" HOT (GOLD)
GND-G
SILVER
8
CB2
J11
GND-F
10A
6B
50A
GND-H
6D
CB6 6A 8
5E
HOT (GOLD)
42A CB4
5B
5C
5
12
200B
GND-G
200A 200D
BRUSH
200E
+ 1 6F
200C 6D
200E 200A
3200MFD 2
300V
6D 200D
201B 200C 3
-
262A 4 262
201A
228A 228
5
241
241A 6
5P
201
201B 7 201A
6F
5H 8 5P
232S
232T 9
226 10 226A
200 11 200B
232T 224A 12 224
234
234A 13
233A 14 233
MULTI-LEAD
281A 15 281
239A 16 239
232W
232D
IDLER
P52 J52
CONTROL
HOUR
NOTE: IDLER SWITCH MAY NOT
METER APPEAR ON SOME MACHINES.
256
LEAD 256 & 257 WILL BE
-
CONNECTED TOGETHER, AND
HIGH
AUTO IDLE WILL BE DISABLED ON
THESE MACHINES.
232S
AUTO
NOTE: 238A, 236A, CB5
MAY APPEAR ON SOME 232L
MACHINES IN PLACE OF
232R
262A SHOWN IN
OLD 236A.
"HIGH" POSITION 257
262B
32
232M
START BUTTON
20A
238A
CB5
236A 236A
236
236B
5H
5J
231
RUN/STOP RUN
GND-G SWITCH
SHOWN IN STOP
5G 242D
"RUN" POS.
GND. STUD ON
232A
5L BOTTOM RIGHT OF
232H
232J
CONTROL BOX
5T
GND-J
232D
232
GND-J
238
265
227
238
32
236C
265 227
STARTER
232N
5S SOLENOID
BATTERY
BOARD
B4 B3 B2 B1
PCB4
239
POS
ALTERNATOR
3 3 32
1 1
238
PULL COIL BD.
239
5S
PCB8
4 4 6
J65
5R GND STUD ON RIGHT SIDE
242B
GND-A BACK OF CONTROL BOX
GND-B
GND-K
G-2
3
STATOR AUXILIARY WINDINGS
6 3
5A 5
GND-E
5B GND-C
11
115/230V
J10
GND-D
5E
12
5
5C
NOTE: ON SOME MACHINES, LEADS
6D & 6F, 5H & 5P MAY BE CONNECT-
ED OUTSIDE THE J52/P52 IN-LINE
CONNECTOR.
ENGINE HARNESS
226A
+ HOLD
COIL
+ PULL 227
COIL
SOL.
IDLE
+ PULL 265
COIL
SHUTDOWN SOL.
GND-H
HOLD
+
COIL
224 262
OIL PRESSURE SWITCH & SENSOR
228 234
SENSOR
SWITCH
G WK
OIL TEMP. SENSOR & SWITCH
233
241
SENSOR ON STANDARD
MODELS, LEADS
SWITCH
242D & 229 ARE
TO BE TAPED
229
FUEL LVL.
SENSOR
242D
236
GROUND STUD ON
OUTPUT PANEL
231
5R
GND-K
STARTING 12V BATTERY
(+)
MOTOR
STUD ON ENGINE
MOUNTING FOOT
SENSE 281 LEFT SIDE
EXC
STUD ON ENGINE
(-)
MOUNTING FOOT
NEG RIGHT SIDE
-
+
5N
GROUNDING BOLT
ON ENGINE BLOCK
FRAME
GND-H ENGINE GROUND
B
G3777
COMMANDER 500