Power Module Assembly, Replacement | Lincoln Electric SVM150-A

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F-52

F-52

TROUBLESHOOTING & REPAIR

POWER MODULE ASSEMBLY

REMOVAL AND REPLACEMENT (continued)

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7.Label and remove leads #232 and #233 from the temperature switch.

8.Unscrew plug J50 from the vertical baffle. Using the phillips head screw driver, remove the four screws holding the plug to the vertical baffle. Cut any necessary cable ties. Then pull the plug and leads away from the baffle.

9.Using the 3/8" socket wrench, remove the three screws holding the Power Module heat sink to its brackets on the vertical baf- fle. Remove the glastic fan guard, if present on your machine.

10.Remove the Power Module assembly from the machine.

Replacement

Refer to Figures F.21 and F.22.

1.Mount the heat sink to the brackets on the vertical baffle with the three 3/8" screws. Mount the glastic fan guard, if present.

2.Mount plug J50 to the vertical baffle with four phillips head screws. Connect the plug and screw it together.

3.Install leads #232 and #233 to the tempera- ture switch.

4.Using the 7/16" wrench, attach the negative strap from the power capacitors to the diode module with two bolts, lock washers, and flat washers. Using the 7/16" wrench, tighten the negative strap center nut. Tighten all fasten- ers to 30-40 in-lbs.

5.Using the 7/16" wrench, attach the positive straps from the power capacitors to the Power Module PC board. Tighten the fasten- ers at the positive terminals of the power capacitors to between 50 and 60 in-lbs.

6.Mount heavy leads W8 and W9 to the Power Module PC board with the 7/16" nuts, lock washers, and flat washers. Apply a thin coat- ing of electrical thermal joint compound (Penetrox A-13) to the mating surfaces (but not the threads). Tighten the fasteners to between 12 and 18 in-lbs).

7.Replace any cable ties cut at disassembly.

See the procedures below for removal and replacement of the power module PC board and diode module. When procedures are complete, perform the Case Cover Replacement proce- dure.

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RANGER 250

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Lincoln Electric SVM150-A service manual Power Module Assembly, Removal and Replacement

Contents

Ranger TM Safety Ranger Electric Shock can kill ARC Rays can burnFumes and Gases can be dangerous Welding Sparks can cause fire or explosion Cylinder may explode if damagedIii Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Table of Contents Installation Section Weight InstallationTechnical Specifications Ranger 250 K1725-1/K1725-2 Speed RPM Safety Precautions Location and Ventilation Additional Safety Precautions Electrical Output Connections Welding Output Cables Figure A.1 Ranger 250 Output Connections Standby Power Connections Cable InstallationAuxiliary Power Receptacles Cable Cable Size for Amps Length 100% Duty Cycle Figure A.2 Connection of the Ranger 250 to Premises Wiring Table of Contents Operation Section Safety Instructions OperationOperating Instructions Design Features Controls and Settings Engine Controls Figure B.1 Case Front Panel Controls Before Starting the Engine Engine OperationWelding Controls Check and fill the engine oil level Starting the Engine Stopping the EngineBREAK-IN Period Welder Operation General InformationTable B.1 Typical Ranger 250 Fuel Consumption Pipe Welding Stick WeldingConstant Current CC-STICK Welding Table B.2 Typical Current RANGES1 for Tungsten ELECTRODES2 TIG Welding Auxiliary PowerWire WELDING-CV ARC Gouging Simultaneous Welding and Auxiliary Power Loads Table B.4 Ranger 250 Simultaneous Welding and Power Loads Table of Contents Accessories TIG Welding Accessories OPTIONS/ACCESSORIESField Installed Options Semiautomatic Fcaw and MIG Welding Accessories Connection of Lincoln Electric Wire Feeders Accessories Place the Weld Terminals switch Return to Section TOC To Section TOC Accessories Terminals Remotely Controlled Figure C.7 Ranger 250/LN-742 Connection Diagram Connection of the LN-742 to Ranger 250 see Figure C.7 Ranger Table of Contents Maintenance Routine and Periodic Maintenance Engine Maintenance Table D.2 Onan Engine Maintenance Schedule Frequency Maintenance Required Engine OIL Change AIR Cleaner ServiceAir Pre-Cleaner Service Engine Oil Refill Capacities Fuel Filter Service Air Filter Paper Element ServiceSpark Plug Service Engine Adjustment Overspeed is Hazardous Charging the Battery Battery MaintenanceCleaning the Battery Optional Spark Arrestor WELDER/GENERATOR Maintenance Figure D.1 Major Component Locations Table of Contents Theory of Operation Section Theory of Operation General Description Weld WINDINGS, RECTIFIER, Power Module and Feedback Return to Analog Power Board and Control Board Figure E.4 Analog Power Board and Control Board Insulated Gate Bipolar Transistor Igbt Operation Pulse Width Modulation Minimum OutputMaximum Output Switch 85VDC Diode Chopper Technology Fundamentals Ranger Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures PC Board can be damaged by static electricity Troubleshooting Guide Observe Safety GuidelinesDetailed in the beginning of this manual Test Stator Voltage Test Engine Function Problems Engine Problems Troubleshooting & Repair Engine Problems Welding Problems Case Cover Removal and Replacement Procedure Test DescriptionMaterials Needed Case Cover Removal and Replacement Procedure Removal ProcedureReplacement Procedure Power Module Capacitor Discharge Procedure Power Module Capacitor Discharge Procedure Test Procedure Idler Solenoid Test Idler Solenoid Test Figure F.3 Idler Solenoid Leads Engine Throttle Adjustment Test Engine Throttle Adjustment Test Strobe-Tach Method Figure F.5 High Idle Adjustment Frequency Counter Method Oscilloscope Method Vibratach Method Rotor Resistance Test Rotor Resistance Test Figure F.7 Rotor Brush Leads Slip Rings Brushes Flashing and Rotor Voltage Test Oil Pressure Switch Test Flashing and Rotor Voltage Test Figure F.9 Field Diode Rectifier Bridge and Filter Capacitor Stator Voltage Tests Stator Voltage Tests To test the 120 VAC windingTo test the 240 VAC winding Field Rectifier Bridge Retaining TAB Cable Capacitor To test the field winding Figure F.12 14-PIN Amphenol PIN Assignments To test the feeder winding Choke To test the stator weld windings Analog Power PC Board Voltage Test Analog Power PC Board Voltage Test Figure F.14 Analog Power PC Board +15 VDC +20 VDC+5 VDC 15 VDC Output Rectifier Bridge Test Output Rectifier Bridge Test Figure F.15 Plug J41 and Resistor R3 Locations When all tests are complete Power Module Test Other PC board components could be faultyDescription Power Module Test Figure F.17 Power Module Connections Tor terminal on the power module chopper Check Igbt for Shorts Figure F.19 Diode Module Test Heat Sink Terminals Check Diode Module Flywheel Alternator Test Flywheel Alternator Test Figure F.20 Plug J51 PIN Location Scope Settings Normal Open Circuit Voltage Waveform 120VAC SupplyHigh Idle no Load Normal Open Circuit Voltage Waveform Stick MAX Control POT High Idle no Load Normal Weld Voltage Waveform Stick CC Machine Loaded to 250 Amps AT 25 Volts Normal Open Circuit Voltage Waveform Wire CV TAP Normal Weld Voltage Waveform Wire CV Machine Loaded to 250 Amps AT 28 Volts Description Power Module Assembly Removal and Replacement ProcedureRemoval Power Module Assembly Removal and ReplacementReplacement Power Module PC Board Removal and Replacement Figure F.22 Diode MODULE/POWER Module Assembly Details Figure F.23 Diode Module Mounting Details Power Capacitor Removal and Replacement Power Capacitor Removal and Replacement Output Rectifier Bridge and Choke Removal and Replacement Output Rectifier Bridge and Choke Output Rectifier Output Choke ENGINE/STATOR/ROTOR Removal and Replacement ENGINE/STATOR/ROTOR Removal and Replacement Engine Preparation and Lead Disconnection Troubleshooting & Repair Figure F.28 Stator Leads Front Panel Stator Lead Disconnection Figure F.29 ENGINE/STATOR/ROTOR Assembly Removal Engine/Stator/Rotor Assembly Removal Procedure Stator/Rotor Assembly Removal Figure F.30 Stator and Rotor Removal Reassembly Notes Rotor/Stator/Engine Reassembly Lead Reconnection Checklist General Notes on Reassembly Retest After Repair Auxiliary Power OutputVolt Wire Feeder Power Engine Output Electrical Diagrams Table of Contents Electrical Diagrams Section Ranger 250 Kohler Wiring Diagram Wiring Diagram Ranger 250 Kohler Ranger 250 Onan Wiring Diagram Wiring Diagram Ranger 250 Onan 4ELECTRICAL DIAGRAMSG-4 Control INTER-CONNECTION Diagram Schematic Complete Machine Output Terminal Schematic Analog Control Power Supply Schematic Battery Printed Circuit Board Schematic Bypass Printed Circuit Board Schematic Chopper Printed Circuit Board 19462 M Schematic Display Printed Circuit Board 24660S Schematic Weld Control Printed Circuit Board Sheet Electrical Diagrams Electrical Diagrams Electrical Diagrams Electrical Diagrams SVM Error Reporting Form