Lincoln Electric SVM150-A guide

Return to Section TOC

Return to Master TOC

F-54

F-54

TROUBLESHOOTING & REPAIR

DIODE MODULE REMOVAL AND REPLACEMENT

FIGURE F.23 – DIODE MODULE MOUNTING DETAILS

1	2
2 TO 3	5.0-10 IN-LBS.
2 TO 3
TURNS EACH	FINGER TIGHT
SPRING WASHER	5.0-10 IN-LBS.
PLAIN WASHER

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

3

4

12-18 IN.LBS.

Removal

Refer to Figure F.23.

1.Remove the Power Module PC Board as described above.

2.Using the 7/16" wrench, remove the two outer screws, spring washers, and large flat washers from the diode module.

3.Using the 9/64" allen wrench, remove the set screw from the center of the diode module.

4.Remove the diode module from the heat sink.

Replacement

Refer to Figure F.23.

CAUTION

The proper tightening sequence is required to mount the diode module to the heat sink in order to avoid warping the base plate. Apply the prop- er torque to all fasteners.

1.Be sure the heat sink mounting surface is clean, dry, and free of grease.

30-40 IN.LBS.

2.Apply a thin, even coat (.1 to .25mm or .004 to .010 in) of thermal joint compound (Penetrax A-13) to the diode module base plate only, under the plastic body of the mod- ule. Do not apply compound to the area under the mounting holes.

3.Press the module firmly against the heat sink, aligning the mounting holes.

4.Place a spring washer then a flat washer over each outer mounting screw and insert them into the holes. Insert the allen head screw into the center hole. Tighten all three screws finger-tight only. ➀

5.Using the torque wrench and 7/16" socket, tighten each outer screw between 5.0 and 10 in-lbs. ➁

6.Using the torque wrench and 9/64" allen head socket, tighten the center screw between 12 and 18 in-lbs. ➂

7.Now tighten the two outer screws between 30 and 40 in-lbs. ➃

8.Replace the Power Module PC board as described above.

RANGER 250

Image 104

Lincoln Electric SVM150-A service manual Figure F.23 Diode Module Mounting Details

Contents

Ranger TM Safety Ranger Fumes and Gases can be dangerous Electric Shock can killARC Rays can burn Iii Welding Sparks can cause fire or explosionCylinder may explode if damaged Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Ranger 250 K1725-1/K1725-2Weight Speed RPM Safety Precautions Location and Ventilation Additional Safety Precautions Electrical Output Connections Welding Output Cables Figure A.1 Ranger 250 Output Connections Cable Installation Auxiliary Power ReceptaclesStandby Power Connections 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 Operating Instructions Safety InstructionsOperation Design Features Controls and Settings Engine Controls Figure B.1 Case Front Panel Controls Engine Operation Welding ControlsBefore Starting the Engine Check and fill the engine oil level BREAK-IN Period Starting the EngineStopping the Engine Table B.1 Typical Ranger 250 Fuel Consumption Welder OperationGeneral Information Stick Welding Constant Current CC-STICK WeldingPipe Welding Table B.2 Typical Current RANGES1 for Tungsten ELECTRODES2 Auxiliary Power Wire WELDING-CVTIG Welding ARC Gouging Simultaneous Welding and Auxiliary Power Loads Table B.4 Ranger 250 Simultaneous Welding and Power Loads Table of Contents Accessories OPTIONS/ACCESSORIES Field Installed OptionsTIG Welding Accessories 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 AIR Cleaner Service Air Pre-Cleaner ServiceEngine OIL Change Engine Oil Refill Capacities Air Filter Paper Element Service Spark Plug ServiceFuel Filter Service Engine Adjustment Overspeed is Hazardous Battery Maintenance Cleaning the BatteryCharging 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 Maximum Output Pulse Width ModulationMinimum 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 Detailed in the beginning of this manual Troubleshooting GuideObserve Safety Guidelines Test Stator Voltage Test Engine Function Problems Engine Problems Troubleshooting & Repair Engine Problems Welding Problems Materials Needed Case Cover Removal and Replacement ProcedureTest Description Replacement Procedure Case Cover Removal and Replacement ProcedureRemoval 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 To test the 240 VAC winding Stator Voltage TestsTo test the 120 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 +20 VDC +5 VDC+15 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 Description Power Module TestOther PC board components could be faulty 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 High Idle no Load Scope SettingsNormal Open Circuit Voltage Waveform 120VAC Supply 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 Removal Power Module Assembly Removal and ReplacementProcedure Replacement Power Module AssemblyRemoval and Replacement 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 Auxiliary Power Output Volt Wire Feeder PowerRetest After Repair 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