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Lincoln Electric SVM150-A service manual Power Module PC Board Removal and Replacement

Models: SVM150-A

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F-53

F-53

TROUBLESHOOTING & REPAIR

POWER MODULE PC BOARD REMOVAL AND REPLACEMENT

FIGURE F.22 – DIODE MODULE/POWER MODULE ASSEMBLY DETAILS

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POWER

MODULE

PC BOARD

DIODE MODULE

HEAT SINK

Removal

1.Perform steps #1 through #6 and #8 from the Power Module Assembly Removal proce- dure.

2.Using the 3/16" allen wrench, remove the four screws and lock washers holding the board to the heat sink. Note the two copper spacers for the center terminals for reassam- bly. See Figure F.22.

3.Remove the PC board.

PLUG J50

ALLEN HEAD

SCREWS (4)

COPPER

SPACERS

TEMPERATURE

SWITCH

Replacement

1.Make sure the mating surfaces between the copper spacers and the heat sink are clean, dry, and free of grease.

2.Apply a thin coating of electrical thermal joint compound (Penetrox A-13) to the mating sur- faces between the copper spacers and the heat sink.

3.Using the torque wrench and 3/16" allen head socket, install the four set screws and lock washers. Note the two copper spacers required for the center terminals. Tighten the screws finger tight, then to between 24 and 28 in-lbs, then again to between 40 and 48 in-lbs.

RANGER 250

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Lincoln Electric SVM150-A service manual Power Module PC Board Removal and Replacement

Contents

Ranger TM Ranger SafetyARC Rays can burn Electric Shock can killFumes and Gases can be dangerous Cylinder may explode if damaged Welding Sparks can cause fire or explosionIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Speed RPM InstallationTechnical Specifications Ranger 250 K1725-1/K1725-2 WeightLocation and Ventilation Safety PrecautionsAdditional Safety Precautions Electrical Output Connections Figure A.1 Ranger 250 Output Connections Welding Output CablesCable Cable Size for Amps Length 100% Duty Cycle Cable InstallationAuxiliary Power Receptacles Standby Power ConnectionsFigure A.2 Connection of the Ranger 250 to Premises Wiring Table of Contents Operation Section Operation Safety InstructionsOperating Instructions Controls and Settings Design FeaturesFigure B.1 Case Front Panel Controls Engine ControlsCheck and fill the engine oil level Engine OperationWelding Controls Before Starting the EngineStopping the Engine Starting the EngineBREAK-IN Period General Information Welder OperationTable B.1 Typical Ranger 250 Fuel Consumption Table B.2 Typical Current RANGES1 for Tungsten ELECTRODES2 Stick WeldingConstant Current CC-STICK Welding Pipe WeldingARC Gouging Auxiliary PowerWire WELDING-CV TIG WeldingTable B.4 Ranger 250 Simultaneous Welding and Power Loads Simultaneous Welding and Auxiliary Power LoadsTable of Contents Accessories Semiautomatic Fcaw and MIG Welding Accessories OPTIONS/ACCESSORIESField Installed Options TIG Welding AccessoriesConnection of Lincoln Electric Wire Feeders Accessories Place the Weld Terminals switch Return to Section TOC To Section TOC Accessories Terminals Remotely Controlled Connection of the LN-742 to Ranger 250 see Figure C.7 Figure C.7 Ranger 250/LN-742 Connection DiagramRanger Table of Contents Maintenance Engine Maintenance Routine and Periodic MaintenanceFrequency Maintenance Required Table D.2 Onan Engine Maintenance ScheduleEngine Oil Refill Capacities AIR Cleaner ServiceAir Pre-Cleaner Service Engine OIL ChangeEngine Adjustment Overspeed is Hazardous Air Filter Paper Element ServiceSpark Plug Service Fuel Filter ServiceOptional Spark Arrestor Battery MaintenanceCleaning the Battery Charging the BatteryWELDER/GENERATOR Maintenance Figure D.1 Major Component Locations Table of Contents Theory of Operation Section General Description Theory of OperationReturn to Weld WINDINGS, RECTIFIER, Power Module and FeedbackFigure E.4 Analog Power Board and Control Board Analog Power Board and Control BoardInsulated Gate Bipolar Transistor Igbt Operation Minimum Output Pulse Width ModulationMaximum Output Chopper Technology Fundamentals Switch 85VDC DiodeRanger Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board can be damaged by static electricity PC Board Troubleshooting ProceduresObserve Safety Guidelines Troubleshooting GuideDetailed in the beginning of this manual Test Stator Voltage Test Engine Function Problems Engine Problems Troubleshooting & Repair Engine Problems Welding Problems Test Description Case Cover Removal and Replacement ProcedureMaterials Needed Removal Procedure Case Cover Removal and Replacement ProcedureReplacement Procedure Power Module Capacitor Discharge Procedure Test Procedure Power Module Capacitor Discharge ProcedureIdler Solenoid Test Figure F.3 Idler Solenoid Leads Idler Solenoid TestEngine Throttle Adjustment Test Strobe-Tach Method Engine Throttle Adjustment TestFrequency Counter Method Figure F.5 High Idle AdjustmentVibratach Method Oscilloscope MethodRotor Resistance Test Figure F.7 Rotor Brush Leads Slip Rings Brushes Rotor Resistance TestFlashing and Rotor Voltage Test Flashing and Rotor Voltage Test Oil Pressure Switch TestFigure F.9 Field Diode Rectifier Bridge and Filter Capacitor Stator Voltage Tests To test the 120 VAC winding Stator Voltage TestsTo test the 240 VAC winding To test the field winding Field Rectifier Bridge Retaining TAB Cable CapacitorTo test the feeder winding Figure F.12 14-PIN Amphenol PIN AssignmentsTo test the stator weld windings ChokeAnalog Power PC Board Voltage Test Figure F.14 Analog Power PC Board Analog Power PC Board Voltage Test15 VDC +20 VDC+5 VDC +15 VDCOutput Rectifier Bridge Test Figure F.15 Plug J41 and Resistor R3 Locations Output Rectifier Bridge TestWhen all tests are complete Other PC board components could be faulty Power Module TestDescription Figure F.17 Power Module Connections Power Module TestCheck Igbt for Shorts Tor terminal on the power module chopperCheck Diode Module Figure F.19 Diode Module Test Heat Sink TerminalsFlywheel Alternator Test Figure F.20 Plug J51 PIN Location Flywheel Alternator TestNormal Open Circuit Voltage Waveform 120VAC Supply Scope SettingsHigh Idle no Load MAX Control POT High Idle no Load Normal Open Circuit Voltage Waveform StickMachine Loaded to 250 Amps AT 25 Volts Normal Weld Voltage Waveform Stick CCNormal Open Circuit Voltage Waveform Wire CV TAP Machine Loaded to 250 Amps AT 28 Volts Normal Weld Voltage Waveform Wire CVDescription Procedure Power Module Assembly Removal and ReplacementRemoval Removal and Replacement Power Module AssemblyReplacement Figure F.22 Diode MODULE/POWER Module Assembly Details Power Module PC Board Removal and ReplacementFigure 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 Output Rectifier Bridge and ChokeOutput Choke ENGINE/STATOR/ROTOR Removal and Replacement Engine Preparation and Lead Disconnection ENGINE/STATOR/ROTOR Removal and ReplacementTroubleshooting & Repair Stator Lead Disconnection Figure F.28 Stator Leads Front PanelEngine/Stator/Rotor Assembly Removal Procedure Figure F.29 ENGINE/STATOR/ROTOR Assembly RemovalFigure F.30 Stator and Rotor Removal Stator/Rotor Assembly RemovalRotor/Stator/Engine Reassembly Reassembly NotesGeneral Notes on Reassembly Lead Reconnection ChecklistEngine Output Auxiliary Power OutputVolt Wire Feeder Power Retest After RepairTable of Contents Electrical Diagrams Section Electrical DiagramsWiring Diagram Ranger 250 Kohler Ranger 250 Kohler Wiring DiagramWiring Diagram Ranger 250 Onan Ranger 250 Onan Wiring DiagramControl INTER-CONNECTION Diagram 4ELECTRICAL DIAGRAMSG-4Output Terminal Schematic Complete MachineSchematic Analog Control Power Supply Schematic Battery Printed Circuit Board Schematic Bypass Printed Circuit Board 19462 M Schematic Chopper Printed Circuit Board24660S Schematic Display Printed Circuit BoardSchematic Weld Control Printed Circuit Board Sheet Electrical Diagrams Electrical Diagrams Electrical Diagrams Electrical Diagrams SVM Error Reporting Form