Lincoln Electric SVM168-B service manual PC Board Troubleshooting Procedures, Electric Shock

Page 43

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F-3

 

TROUBLESHOOTING & REPAIR

F-3

 

 

 

 

 

 

PC BOARD TROUBLESHOOTING PROCEDURES

 

 

 

 

 

- Remove the PC board from the static-shielding bag

 

 

WARNING

 

 

and place it directly into the equipment. Donʼt set the

 

 

 

PC board on or near paper, plastic or cloth which

 

 

ELECTRIC SHOCK

 

 

can kill.

could have a static charge. If the PC board canʼt be

 

•

Have

an electrician install and

installed immediately, put it back in the static-shield-

 

ing bag.

 

 

 

service this equipment. Turn the

- If the PC board uses protective shorting jumpers,

 

 

input

power OFF at the fuse box

 

 

before working on equipment. Do

donʼt remove them until installation is complete.

 

 

not touch electrically hot parts.

- If you return a PC board to The Lincoln Electric

 

 

 

 

Company for credit, it must be in the static-shielding

 

 

CAUTION

bag. This will prevent further damage and allow prop-

 

 

er failure analysis.

 

Sometimes machine failures appear to be due to PC

4. Test the machine to determine if the failure

board failures. These problems can sometimes be

symptom has been corrected by the

traced to poor electrical connections. To avoid prob-

replacement PC board.

 

lems when troubleshooting and replacing PC boards,

 

It is desirable to have a spare (known good)

please use the following procedure:

NOTE:

 

1. Determine to the best of your technical ability

PC board available for PC board troubleshooting.

 

NOTE: Allow the machine to heat up so that all

 

that the PC board is the most likely component

 

causing the failure symptom.

electrical components can reach their operating

 

2. Check for loose connections at the PC board to

temperature.

 

 

5. Remove the replacement PC board and

 

assure that the PC board is properly connected.

substitute it with the original PC board to

 

3. If the problem persists, replace the suspect PC

recreate the original problem.

 

 

board using standard practices to avoid static

a. If the original problem does not reappear by

 

electrical damage and electrical shock. Read

 

substituting the original board, then the PC

 

the warning inside the static resistant bag and

 

board was not the problem. Continue to look

 

perform the following procedures:

 

for bad connections in the control wiring

PC board can be damaged by static electricity.

 

harness, junction blocks, and terminal strips.

 

 

- Remove your bodyʼs static

b. If the original problem is recreated by the

 

 

charge before opening the static-

 

substitution of the original board, then the PC

 

 

 

 

 

shielding bag. Wear an anti-static

 

board was the problem. Reinstall the

 

 

wrist strap. For safety, use a 1

 

replacement PC board and test the machine.

 

 

Meg ohm resistive cord connected

6. Always indicate that this procedure was

 

 

to a grounded part of the

followed when warranty reports are to be

 

ATTENTION

equipment frame.

submitted.

 

 

Static-Sensitive

- If you donʼt have a wrist strap,

NOTE:

Following this procedure and writing on the

 

Devices

 

Handle only at

touch an un-painted, grounded,

warranty report, “INSTALLED AND SWITCHED PC

 

Static-Safe

part of the equipment frame. Keep

BOARDS TO VERIFY PROBLEM,” will help

avoid

 

 

touching the frame to prevent

denial of legitimate PC board warranty claims.

 

 

Workstations

static build-up. Be sure not to

 

 

 

touch any electrically live parts at

 

 

 

 

 

the same time.

 

 

 

 

- Tools which come in contact with the PC board must

 

 

 

 

 

 

 

 

be either conductive, anti-static or static-dissipative.

 

 

 

RANGER® 10,000 & RANGER® 10,000 PLUS

Page 42 Page 44
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Page 42 Page 44
Contents Ranger 10,000 /10,000 Plus Powered equipment SafetyFor Engine Fumes and Gases ARC Rays can burnCylinder may explode If damaged Welding and Cutting Sparks can cause fire or ExplosionIii Précautions DE Sûreté Master Table of Contents for ALL Sections Installation Section Table of ContentsSection A-1 Height Width Depth Weight InstallationHorsepower Operating Speed RPM Towing Safety PrecautionsSpark Arrester Machine GroundingCan cause fire or explosion PRE-OPERATION ServiceGasoline Vehicle MountingLifting Welding Output CablesTotal Combined Length of Electrode and Work Cables Angle of OperationWelder Operation Connection of Lincoln Electric Wire FeedersInstructions StackingMotor Starting Auxiliary Power120/240 Volt Dual Voltage Receptacle Duplex ReceptaclesNot USE These Devices With a Ranger 10,000 These Devices Without Additional Resistive Type LoadsStandby Power Connections Simultaneous Welding and PowerFigure A.1 Ranger 10,000 & Ranger 10,000 Plus Section B-1 Operation SectionOperation Operation Engine SwitchWelder Controls Function and Operation Control Dial Polarity SwitchRange Switch Kohler Honda Robin / Subaru 20 H.P. CommandStopping the Engine STARTING/SHUTDOWN InstructionsBREAK-IN Period Starting the EngineStick Constant Current Welding Wire Feed Welding Processes Constant VoltageTIG Constant Current Welding Summary of Welding Processes Start Switch Wire FEED, LN-15Section C-1 Accessories SectionOptional Equipment Field Installed AccessoriesPlasma Cutting Recommended EquipmentStick TIG WeldingRanger 10,000 & Ranger 10,000 Plus Section D-1 Maintenance SectionSafety Precautions MaintenanceKohler Honda OIL Filter Change AIR Cleaner and Other MaintenanceSlip Rings Engine AdjustmentsBattery Overspeed is HazardousElement Pre-CleanerOil Filter Air FilterFigure D.1 Major Component Location Section E-1 Theory of Operation SectionTheory of Operation Theory of Operation BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler SolenoidFigure E.3 Rotor Field Feedback and Auxiliary Power Rotor Field Feedback and Auxiliary PowerFigure E.4 Weld WINDING, REACTOR, and Range Switch Weld WINDING, REACTOR, Range SwitchOutput BRIDGE, Choke Polarity SWITCH, and Output Terminals Ranger 10,000 & Ranger 10,000 Plus Section F-1 Troubleshooting & Repair SectionHOW to USE Troubleshooting Guide Troubleshooting & RepairElectric Shock PC Board Troubleshooting ProceduresOutput Problems Troubleshooting GuideOutput Problems Field Winding Voltage Test Adjustment Test Troubleshooting Guide Output Problems Engine Problems Make sure the leads are looped Charging Circuit Test Welding Problems Ranger 10,000 & Ranger 10,000 Plus Test Description Rotor Voltage TestMaterials Needed Test Procedure Rotor Resistance Test Figure F.2 Location of Rotor Slip Rings Rotor Resistance TestTroubleshooting & Repair Ranger 10,000 & Ranger 10,000 Plus Auxiliary and Field Winding Test To test the 115 VAC winding Auxiliary and Field Winding TestTo test the 230 VAC winding To test the field winding Ranger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Test Output Rectifier Bridge Test 26TROUBLESHOOTING & REPAIRF-26Figutpure F.4 Locationctifof Output Rectifier Leads Charging Circuit Test Figure F.5 Location of Voltage Regulator Charging Circuit TestEngine Throttle Adjustment Test Figure F.6 Blower Paddle Marked for STROBE-TACH Method Engine Throttle Adjustment TestFigure F.7 Oscilloscope Method Normal Open Circuit Voltage Waveform 115 VAC Supply Scope SettingsHigh Idle no Load Output Control AT Maximum Machine Loaded Typical DC Weld Output Waveform CV ModeMachine Loaded to 200 Amps AT 20 VDC Machine Loaded to 200 Amps AT 26 VDC Typical DC Weld Output Waveform CC ModeMachine Loaded to 225 Amps AT 25 VDC Typical AC Weld Output WaveformAbnormal Open Circuit Weld Voltage Waveform CV Mode Abnormal Open Circuit DC Weld Voltage Waveform Normal Open Circuit Weld Voltage Waveform CV Mode Normal Open Circuit DC Weld Voltage Waveform CC Mode Normal Open Circuit AC Weld Voltage Waveform Ranger 10,000 & Ranger 10,000 Plus Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementFigure F.9 Brush LEADS/BRUSHES Retained with Cable TIE Slip RingsRanger 10,000 & Ranger 10,000 Plus Printed Circuit Board Removal Replacement Figure F.10 Printed Circuit Board Location Printed Circuit Board Removal and ReplacementPrinted Circuit Board Removal ReplacementRanger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Removal Replacement Output Rectifier Bridge Removal Remove the case top, then reinstall the fuel capSection TOC Ranger 10,000 & Ranger 10,000 Plus Instructions ENGINE/ROTOR Removal and ReplacementFigure F.12 Component LOCATIONS, ENGINE/ROTOR Removal ENGINE/ROTOR RemovalEngine and Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from Stator THRU-BOLT Rotor Removal ProcedureReassembly Procedure Replacement KIT S20788Retest After Repair Electrical Diagrams Electrical Diagrams SectionSection G-1 Wiring Diagram Code 11041 only -M20226 Electrical DiagramsRanger 10,000 Honda Wiring Diagram Code 11095 only M20301Ranger 10,000 Wiring Diagram Code 11398 M21269 Ranger 10,000 Plus L13105 Schematic Entire Machine Codes 11395 and 11398 L13105L13103 Schematic Entire Machine CDE 11394 L13103Schematic Entire Machine Code 11095 & 11253 only L12257 L12249 Schematic Entire Machine Code 11151 only L12249-1Electrical Diagrams Electrical Diagrams
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