Lincoln Electric SVM128-A service manual Theory of Operation, ALTERNATOR, and Protection, Circuits

Page 50

E-2

E-2

THEORY OF OPERATION

to SectionTOC

to Master TOC

 

FIGURE E.2 – BATTERY, STARTER, ENGINE ALTERNATOR, AND PROTECTION CIRCUITS

 

 

 

 

 

 

 

 

 

 

 

 

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PROTECTION

 

 

 

SELECTOR

 

 

 

 

 

RELAY

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

REED

 

 

 

 

IDLER

 

 

 

 

RELAY

NEGATIVE

 

 

 

 

 

 

 

 

 

 

 

 

BOARD

 

 

 

 

CR2

 

 

 

 

 

 

 

 

 

 

 

OUTPUT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TERMINAL

 

 

 

 

 

 

 

 

 

 

115 & 230VAC

 

 

 

 

 

 

 

 

 

 

 

 

RECEPTACLES

 

 

 

 

 

 

IDLER

 

 

 

 

 

 

 

 

 

 

 

 

SOLENOID

 

 

 

 

 

 

 

TOC

 

 

 

OIL

 

 

GENERATOR

 

 

 

 

TOC

 

TEMPERATURE

PRESSURE

 

 

 

FRAME

 

 

 

 

 

GAUGE

SWITCH

 

 

 

 

 

CURRENT

 

 

FUEL

 

 

SERIES

 

 

 

 

 

 

INJECTION

 

 

COILS

 

 

 

 

TRANSFORMER

 

 

PUMP

 

 

 

 

 

 

 

 

to Section

to Master

 

 

 

 

 

 

BRUSHES & COMMUTATOR

 

ALTERNATOR

STATOR

 

 

 

ENGINE

MECHANICAL

GENERATOR

ARMATURE

ROTOR

 

 

IGNITION

 

 

COUPLING

ARMATURE

SHAFT

 

 

 

ENGINE

 

 

 

 

 

 

SWITCH

 

 

 

 

SLIP

 

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ALTERNATOR

 

 

 

 

 

 

 

RINGS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INTERPOLE

 

 

 

 

 

 

 

 

 

COILS

RESIDUAL

 

 

 

 

 

 

STARTER

 

 

MAGNETISM

FLASHING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MOTOR

 

 

FIELD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SHUNT

 

 

 

 

 

 

 

 

 

 

 

WINDINGS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIELD

 

 

 

 

 

BATTERY

 

 

 

 

 

RECTIFIER

 

 

 

 

 

 

 

 

 

GENERATOR

 

 

 

 

 

 

 

 

 

 

 

FIELD CONTROL

 

 

POSITIVE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT

 

 

 

 

 

 

 

 

 

 

 

 

TERMINAL

TOC

TOC

 

 

 

 

 

 

 

 

 

 

 

Section

Master

GENERAL DESCRIPTION

 

BATTERY, STARTER, ENGINE

 

The SA-250 is a heavy duty, engine driven DC arc

ALTERNATOR, AND PROTECTION

to

to

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welding power source capable of providing constant

CIRCUITS

 

 

 

current output for stick welding or

DC TIG welding.

The 12VDC battery powers the starter motor and,

Also, a total of 3000 watts of auxiliary power is available

 

 

at the 115 or 230VAC receptacles.

 

 

through the ignition switch, the engine protection cir-

 

 

 

 

 

 

 

cuitry. In the event of a low oil pressure or a high

 

 

 

 

 

 

 

coolant temperature condition, the engine protection

 

 

 

 

 

 

 

system shuts the engine off. The protection relay mon-

 

 

 

 

 

 

 

itors the oil pressure switch and the coolant tempera-

 

 

 

 

 

 

 

ture sensor. If either sensor “faults,” the protection relay

 

 

 

 

 

 

 

deactivates the fuel injection pump, and the engine

to Section TOC

to Master TOC

 

 

 

 

 

shuts down. The engine alternator supplies “charging”

 

 

 

 

 

current for the battery circuit.

 

 

 

 

 

 

 

 

 

 

 

 

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

 

 

 

 

 

SA-250

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Image 50
Contents SHIELD-ARCTMSA-250 Safety SA-250Electric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications SA-250Storing Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service Exhaust Spark Arrester Cooling SystemMuffler TrailerElectrical Output Connections Welding Cable ConnectionsCircuit Breakers Auxiliary Power RECEPTACLES, PLUGS, and HAND-HELD EquipmentMachine Grounding SA-250 Table of Contents Operation Section Operating Instructions Safety InstructionsOperation General DescriptionRecommended Applications Operational Features and ControlsDesign Features WelderWelding Capability LimitationsControls and Settings WELDER/GENERATOR ControlsControl of Welding Current Current Range SelectorDiesel Engine Controls Figure B.3 Diesel Engine ControlsStarting the Engine Engine OperationBefore Starting the Engine Check and fill the engine fuel tankBREAK-IN Period Stopping the EngineCold Weather Starting Welding Operation After you finish weldingTable B.1 Range Settings for Wire SIZE/SPEED Auxiliary Power 12B-12Table of Contents Accessories OPTIONS/ACCESSORIES TIG Welding Accessories Semiautomatic Welding AccessoriesConnection of Lincoln Electric Wire Feeders Connection of the LN-7 toPIN Amphenol Connection of the LN-25 to Unused Lead IndividuallyFigure C.4 SA-250/LN-25 Across the ARC Connection Diagram Control K487-25 Table of Contents Maintenance Routine and Periodic Maintenance Engine MaintenanceFigure D.1 OIL Drain and Refill Eliminate Air from the Fuel System HOW to Eliminate AIR from the Fuel System Self-vent method Figure D.4 Eliminating AIR from the Fuel SystemFigure D.5 Engine Coolant Drain Plug Figure D.6 Tightening the FAN Belt First 25-50 Hours Daily or BeforeStarting Engine EveryBattery Maintenance Cleaning the BatteryWELDER/GENERATOR Maintenance Idler Maintenance Figure D.5 Major Component Locations SA-250 Table of Contents Theory of Operation Section Circuits Theory of OperationALTERNATOR, and Protection Excitation Flashing Auxiliary and Field Feedback CoilsEngine Idler Circuit Interpole and Series Coils Fine Current AdjustmentCurrent Range Selector DC Generator Machines Mechanical CouplingSA-250 Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures PC Board can be damaged by static electricityDetailed in the beginning of this manual Troubleshooting GuideObserve Safety Guidelines Shunt Field Winding Test Field Shunt Winding Test Output Problems Function Problems Function Problems Troubleshooting & Repair Problems Possible Areas Symptoms Misadjustments Course of ActionWelding Problems Materials Needed Alternator Rotor TestTest Description Test Procedure Slip Rings BrushesFigure F.2 Measuring Rotor Resistance Figure F.3 Measuring Rotor Resistance to Ground Field Shunt Winding Test Field Shunt Winding Test PIN TAB Idler Solenoid Test Idler Solenoid Test Engine Throttle Adjustment Test Engine Throttle Adjustment Test Strobe Tach MethodFrequency Counter Method Oscilloscope MethodAdjusting Screw Locking NUT Flashing the Fields DescriptionProcedure Do not remove brush holderHigh Idle no Load Fine Current Control Rheostat AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115VAC Supply Normal Open Circuit DC Weld Voltage Waveform Machine Loaded Selector Switch AT Maximum Position Typical DC Weld Output Voltage WaveformAlternator Rotor Removal Replacement Replacement Alternator Rotor RemovalLoosen Screws Alternator Cover Slip Rings Brushes Figure F.13 Rotor Removal Replacement Alternator Stator Removal and Replacement Procedure Alternator Stator RemovalField Bridge Rectifier VAC Receptacle Circuit Breaker Genernator Brush HOLDER/COIL Cables Figure F.18 Drill Spot Locations Generator Frame Removal and Replacement Generator Frame Removal See Figure F.19 for steps 4Figure F.20 Wire and Selector Switch Connections Figure F.21 Case Front Removal Rope Sling ENGINE/GENERATOR Mounting Holes Troubleshooting & Repair Generator Armature Removal and Replacement Generator Armature Removal Figure F.23 Blower Paddle RemovalEngine Output AC Auxiliary Power Receptacle OutputRetest After Repair Welder DC OutputSA-250 Electrical Diagrams Section Section G SA-250 Electrical Diagrams Wiring DiagramWire Feed Module Wiring Diagram Idler PC Board M13708 Schematic Idler PC Board M13708 Components SVM Error Reporting Form