Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM148-B service manual Output Rectifier Bridge Removal Replacement, Description

Models: SVM148-B

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F-59

F-59

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE REMOVAL

AND REPLACEMENT

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manu- al.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in removing the output rectifier bridge for maintenance or replacement.

MATERIALS NEEDED

5/16” Nut driver 3/8” Nut driver 1/2” Wrench 7/16” Wrench Penetrox A-13 Wiring Diagram

This procedure requires approximately 50 minutes to perform.

RANGER 300 D AND 300 DLX

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Lincoln Electric SVM148-B service manual Output Rectifier Bridge Removal Replacement, Description

Contents

Safety Depends on You Ranger TM300 D and 300 DLXSafety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion Précautions DE Sûreté Ranger 300 D and 300 DLX Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Ranger 300 D and 300 DLXStoring Safety PrecautionsLocation and Ventilation StackingPRE-OPERATION Engine Service Fuel Battery ConnectionsGases from Battery can explode Engine CoolantWelding Terminals Remote ControlHigh Frequency Generators for TIG Applications Electrical ConnectionsTable A.1 Auxiliary Power RECEPTACLES, PLUGS, and HAND-HELD EquipmentWelding Cable Connections Total Combined Length of Electrode and Work CablesPremises Wiring Figure A.2 Connection of Ranger 300 to Premises Wiring Ranger 300 D and 300 DLX Table of Contents Operation Section Operation Safety InstructionsOperating Instructions Other Features Design Features ALL ModelsFor Auxiliary Power General DescriptionAdditional Features Ranger 300 D K1522-1Controls and Settings WELDER/GENERATOR ControlsOperation Engine Controls Figure B.2 Engine ControlsOperation Engine Operation Before Starting the EngineStopping the Engine Cold Weather Starting and OperationBREAK-IN Period Welding Operation AC/DC TIG Constant Current WeldingDC Wire Feed Welding CV with Ranger 300 DLX Pure EWP Range Appropriate Tungsten Diameter Switch SettingsDC Wire Feed Welding CV with Ranger 300 D Electrode Wire Speed ApproximateSummary of Welding Processes and Machine Settings Summary of Welding Processes and Machine Settings Auxiliary Power Simultaneous Welding and Power Loads120/240 V Dual Voltage Receptacle Duplex ReceptaclesTable of Contents Accessories General Options Accessories TIG Welding Options AccessoriesConnection of Lincoln Electric Wire Feeders ING Terminals Always onPIN Remotely Controlled ING Terminals Remotely Controlled To Work Return Ranger 300 D and 300 DLX Ranger 300 D and 300 DLX Table of Contents Maintenance Safety Precautions Kubota Engine Maintenance Schedule FrequencyEngine Maintenance MaintenanceRoutine and Periodic Fuel Feedfuel Feedpumppumplever Battery Maintenance To prevent Electrical Damage whenWelder / Generator Maintenance Charging the BatteryFigure D.3 Major Component Locations Ranger 300 D and 300 DLX Table of Contents Theory of Operation Section Glow PLUGS, Engine BATTERY, STARTER, EngineTheory of Operation PROTECTION, ROTOR, StatorRotor Field FEEDBACK, Auxiliary and Wire Feeder Power Weld WINDING, Reactor and Range Switch Figure E-4 Weld WINDING, Reactor and Range SwitchReturn to Ranger 300 D and 300 DLX Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Troubleshooting Guide Output ProblemsOn page F-6 Output Problems Field Winding Voltage Test Troubleshooting Guide No DC welding output. AC welding Make sure the polarity mode Troubleshooting & Repair Engine Problems Volts is normal. If 12VDC isProblems Possible Areas Symptoms Misadjustments Course of ActionHigh Speed Solenoid Resistance Test Perform the Fuel Shutdown Shutdown Solenoid Resis Function Problems Perform the Auxiliary 12VDC is Nections at the battery Battery does not stay charged Check for loose or faulty conEngine charging system Welding Problems Test Description Rotor Resistance TestMaterials Needed Rotor Resistance Test Test ProcedureConduct the test with the engine OFF Output Rectifier Bridge Test Output Rectifier Bridge Test Conduct this test with the engine offFuel Shutdown Solenoid Resistance Test Fuel Shutdown Solenoid Resistance Test Figure F.3 Plug J12 LocationHigh Speed Solenoid Test High Speed Solenoid Test Engine Throttle Adjustment Test Engine Throttle Adjustment Test Conduct this procedure with the engine OFFFigure F.7 High Idle Adjustment Frequency Counter Method Oscilloscope MethodAuxiliary and Field Winding Test Test DescriptionTo test the 115 VAC winding Auxiliary and Field Winding TestTo test the 230 VAC winding To test the field winding Figure F.11 14-PIN Amphenol PIN Assignments To test the feeder winding Ranger 300 DLX ModelsRotor Voltage Test Test DescriptionTest Procedure Rotor Voltage TestInstallation Charging Circuit TestAlternator Test Procedure Charging Circuit TestNormal Open Circuit Voltage Waveform 115VAC Supply Scope SettingsHigh Idle no Load Output Control AT Maximum Machine Loaded Typical DC Weld Output Voltage Waveform CV Mode High TAPMachine Loaded to 250 Amps AT 30VDC Typical DC Weld Output Voltage Waveform Machine Loaded to 250 Amps AT 25 VDCTypical AC Weld Output Voltage Waveform Machine Loaded to 250 Amps AT 25VDCAbnormal Open Circuit DC Weld Voltage Waveform Abnormal Open Circuit Weld Voltage Waveform High CV Mode Normal Open Circuit Weld Voltage Waveform High CV Mode High Idle no Load Output Control AT MaximumNormal Open Circuit DC Weld Voltage Waveform Normal Open Circuit AC Weld Voltage Waveform Brush Removal and Replacement DescriptionBrush Removal and Replacement ProcedureSection TOC Field Capacitor AND/OR Rectifier Bridge Removal Replacement DescriptionReplacement Field Capacitor AND/OR Rectifier Bridge RemovalTo Section TOC Control Board Removal and Replacement DescriptionControl Board Removal and Replacement Figure F.16 Printed Circuit Board LocationTo Section TOC Output Rectifier Bridge Removal Replacement DescriptionOutput Rectifier Bridge Removal and Replacement Figure F.17 Output Rectifier ConnectionsReassembly Description Output Capacitor Bank Removal and Replacement Ranger 300 DLX onlyOutput Contactor Removal and Replacement Ranger 300 DLX only Output Contactor Removal and Replacement Figure F.19 Output Contactor LocationTroubleshooting & REPAIRs Stator AND/OR Rotor Removal and Replacement DescriptionStator AND/OR Removal and Replacement Figure F.21 Component LOCATIONS, STATOR/ROTOR RemovalStator Removal Procedure Conduct this procedure with the engine OFFStator AND/OR Rotor Removal and Replacement Rotor Removal ProcedureLead Reconnection Checklist Engine Reassembly NotesFront Panel Retest After Repair Electrical Diagrams Wiring Diagram Ranger 300 D Code R I N G D I a G R a M R a N G E R 3 0 0 DWiring Diagram Ranger 300 DLX Code R I N G D I a G R a M R a N G E R 3 0 0 D LWiring Diagram Ranger 300 DLX Schematic Control PC Board PC Board Assembly Control Board Schematic Bypass PC Board PC Board Assembly Bypass Board SVM Error Reporting Form