Lincoln Electric COMMANDER 500 IM644-A - Manual (Page 37)

F-1 DIAGRAMS F-1
COMMANDER 500
NO
TE:
This diag
ram is f
or ref
erence only
.
It ma
y not be accur
ate f
or all machines co
v
ered b
y
this man
ual.
The specific dia-
g
ram f
or y
our par
ticular machine is pasted inside the machine on one of the enclosure panels
.
WIRING DIAGRAM:
5M
6D
6C
9
GND-E
201B 200E 5H 6D 200C 200 226 237 224A
12
262A 234A 228A 233A 241A 281A
237A
6 12
264
232D
263
4B
2B
OPTIONAL ON STANDARD MODEL
-
1
3
91
E F G I
HOT (GOLD)
SILVER
J11
HOT (GOLD)
17
Y
SILVER
CONTROL HARNESS
R
TOROID
18
200B P30 233 228 234 200D 281 224 241 201A 262B 5P 200A 239 226A 237A
VIEWED
41
75B
42
OUTPUT
31
CONTROL
(BLACK)
15
32
NEUTRAL
30VAC
CCW
BK
CONTROL HOT(BLACK) BROWN
14
16
BK
PRIMARY 120VAC
BR
30VAC CONTROL BR
13 YELLOW R
5D
IGBT DRIVER PCB2 BOLTED TO
RED
42VAC
HEATSINK
PCB POWER
76C
76
236C
FROM BACK
278A
PINCH POT
278
277
21B
+
-
2
31 32 4E 2D
J
77
4D
A
242I
D
POLARITY
C
SWITCH
277
H
278
1
25
22
75
23
21
31
32
TOROID
18
17
J14 RECTIFIER BRIDGE
SHUNT
-
50MV=400AMPS
14
13
1
5G
2
3
Y
4
6E
5
6
P16
78
16
15
J16
50A
TO THE LAMINATION TO SLIP RING NEAREST POSITIVE BRUSH CONNECTED
CONTROL
IDLER 5B
6D
5E
42VAC KIT
5C
5
42
SWITCH CONTROL
6D
200D
200A
256
200E
SHOWN IN
5P
12
201
HOUR
200B
201A
231
236 232D
201B
CB4
6B
1
3
GOLD
SILVER
ALT.
TEMP.
LOW PRESS.
GOLD
4
6
CB5
9
239A
CB2
20A
3
3
232L
232M
6A
AUXILIARY NEUTRAL STUD
5F
BACK OF CONTROL BOX "LEFT SIDE" 5D
232
236B
6F
201 BRUSH
5A
31
43
2 3
10A
-
BRUSH
+
5F
242
238
SOLENOID
5
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
"HIGH" POSITION
METER
-
5K
263
5F
CONTROL HARNESS
5H
POWER MODULE
76B
S6
236
231
6H
RIGHT SIDE
CB1
20A
OPTIONAL
OF CONTROL BOX ON BOTTOM LEFT
GND-C
CB6
6C
EMPTY
GND-B
GND-D
A
6
5
16
281A
229A
5G
77B
J11
SILVER
11
50A
6E
CB3
8
3A
WITH 42V VAC KIT
23A
A B C D E F
25A
67
LOW
3
FUEL
G3583
5C
5
ENGINE HARNESS
12
5C
GROUNDING BOLT ON ENGINE BLOCK
STUD ON ENGINE MOUNTING FOOT
LEFT SIDE
XE
1
2C
75B
4
76C RF BYPASS PCB
41
42
6
CAP.
MULTI-LEAD
108A
232P
17
18
B
21C
GOLD
SILVER
K
SENSOR
COIL HOLD COIL PULL
SHUTDOWN
SENSOR
COIL
SENSOR SWITCH
FUEL LVL.
OIL TEMP. SENSOR & SWITCH
OUTPUT PANEL
262B
WELD STUD ON
SOL.
SOL.
OIL PRESSURE SWITCH & SENSOR
SWITCH
WK
233 234
262
SENSE
NEG EXC
MOTOR STARTING
281
5R
FRAME
POS
G 242D
239
229
5N
236C
248 232J
236A RUN STOP
264
232H
32
HIGH
+
242I
232C
242B
110A
109A
5K SHOWN IN
SWITCH SHOWN IN RUN/STOP
242E
"ALWAYS ON" POSITION
32
5J
5K
5L
229B
8
FUEL
B3
256
GND. STUD ON
B4
BOTTOM RIGHT OF
238
248
239A
236C
232
232K
1
J9
5
1
5L
J8
106A
107A
104A
102A
101A
103A
4
104A
102A
216
103A
222
218
219
213
217
220
214
101A
106A
105A
107A
108A
215
76
242H
242I 8
5E 5B
4
15-250 TIG 30-575A
8
STICK
CONTROL PANEL GND. SCREW ON
7 500A
0A 35
250A
REMOTE 77
LOCAL
SWITCH SHOWN IN
TEMP
OIL
PRESS.
S
242B
CHRG.
241B
228B
7
6
1
J5
15A
3B
6A
COMMANDER 500 WIRING DIAGRAM
3
CORRESPONDING SETTINGS FOR TAP NUMBERS
(AS VIEWED FROM THE FRONT)
6A
3
4 5
42B
6
BLACK
RED
CONTROL HARNESS
OPTIONAL
ROTOR
CONTROL BOX
2B 4B
5G
START BUTTON
224A
2C
226
262A
4C
J6
237
90
242D
AUTO
77C
242A
"LOCAL" POSITION
229C
232B
S
232D
CONTROLLED
242C
238
BATT.
"RUN" POS. 262
232N B2
B1
229
J30
32
5S
239 238
IDLE 224 228 241
77E 21C 2E
3 2 1
5
HEAT SINK
J13
CAP.
POSITION
POSITIVE POLARITY
J12
SWITCH SHOWN IN
6A
3
DIRECTIONS IN OPPOSITE
6A
TOROID TWICE PASS THROUGH LEADS 3 & 6A
6A
3
RIGHT
1
247
232E
246
232F
245
232G
232A
232G
232L
232F
232M
232E
232K
232N
WELDING SOURCE
3
6A
ALWAYS ON REMOTELY 232A
227
229B S
OIL
BLACK
6A
243
229A
229
J18
228A
241A
P18
4 J60
1
2D
4D
6 4
77D
75D
3
J62
76D
1
4E
2E 77E
75E
3
76E
TOROID
+
STARTER
STATOR
ALTERNATOR
AUXILIARY WINDINGS
1
P40
J40
6E
3
RED
"INSULATED STUD" AUXILIARY POWER
6A
GND-E
AUXILIARY POWER
75E 242H 41 42 76E
3
+
3 4
WIRE 30-575A
150
EMPTY
2
90A
A
LEADS 238 & 236C TO BE BOLTED TOGETHER AND TAPED ON STANDARD MODEL.
STUD
12VDC
1
INSULATED
5
50K
TOROID
229C
229B
241B
228B
6 5 J61
1
8
4C
77C
GND-C 5
11
115/230V
3
GND-D
5A
GND-B
203
222
213
67
214 215
216
(VIEWED FROM REAR) SELECTOR SWITCH
BYPASS PCB
MOUNTING FOOT
12V BATTERY
STUD ON ENGINE
PCB1 DRIVER IGBT
CAP. CAP.
BOLTED TO HEATSINK
4
EMPTY
EMPTY
6 4 5
3
COIL HOLD
(-)
-
PULL
226A
(+)
227
67
3
6A
261
260
LEADC 203 TO
PASS THRU TOROID
CONTROL
67A ELECT. WORK
+
67A
115VAC CONTACTOR
77D 76D
WORK
75D
W2
W2
W3
W3
REMOTE CONTROL 42VAC GROUND AMPHENOL 1 REMOTE CONTACTOR GROUND
AMPHENOL 2
STATOR
WELD
WINDINGS
W5
W4
W3
W5
W4
W2
LEFT
W1
15
W1
1
W6
W6
W3
217
23A
S5
16
R2
218
2
6
5
7
25A
219
8
220
A
9
MULTI-LEAD
CHOKE
L1
P14
HEAT SINK
22 21
13 14
23 25
4
6A
ONE TIME
W6 W1
W1 W6
W2
250 ohms
25 watts
ENGINE PROTECTION PCB
5M
ENGINE GROUND
BACK OF CONTROL BOX GND STUD ON RIGHT SIDE
J7
J2
6
5
4
9
10
DISPLAY PCB
J4
16
CONTROL PCB
6
J3
J1
8
242H
5R
OPTIONAL ON STANDARD MODEL R1 76B
75A
VIEWED FROM BACK
75
3
5
105A
21A
2
22A
3 2
90
4 1
91
110A
109A
CONTROL TRANSFORMER
232
41
200C 300V 3200MFD
200
242 1 9
246
260
245
261
247
234A
243
5J
233A
77B
GOLD SILVER
ENHANCED DIAGRAM