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Lincoln Electric SVM150-A service manual Schematic Complete Machine, Output Terminal

Models: SVM150-A

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G-5

ELECTRICAL DIAGRAMS

SCHEMATIC - COMPLETE MACHINE

CURRENT LEVEL FEED BACK

IGBT MODULE - EMMITTER

SIGNAL TO WELD CONTROL

IS COMMON TO HEATSINK

SHUNT PC BOARD

D4

POSITIVE

50MV=400 AMPS

L1 CHOKE

D1 - THREE PHASE BRIDGE RECTIFIER

OUTPUT

E

C

13

TERMINAL

206S 204S

CURRENT LEVEL

GATE SIGNAL

14

C1

C2

206B

206A

FEED BACK SIGNAL

250 OHMS

2400uf

2400uf

D2 DIODE

CHOPPER 11

25 W

BY-PASS

20V DC

100vdc

100vdc

MODULE

PC BOARD 12

WIREFEEDER

R3

W1

PC BOARD

21

VOLTMETER

25

23

208

POLARITY

PWM SIGNAL FROM

SWITCH

WELD CONTROL

NEGATIVE

208A

PC BOARD

OUTPUT

TERMINAL

W2

W3

TWO POLE 3600 RPM ALTERNATOR

3

AC

120 V AC

SLIP RINGS

POWER

240 V AC

5

200

50 V DC

25

23

11

GND E

200A

+

120 V AC

204S

5V

12

6

C3

D3

206S

105A

105A

800uf

ARC VOLTAGE FEEDBACK

15V

ANALOG

41

150vdc

208B

WELD CONTROL

115A

COM

101A115A

POWER PC

42 VOLT AC

PC BOARD

101A

15V

BOARD

WIRE FEEDER

201

10 V

116A

116A

77

ROTOR FIELD

5H

118A

15V TO GND.

118A

POWER

OUTPUT

0-10 V

R1

76

0 V

42

CONTROL 10K

0 V

250

IDLER SWITCH

5L

75

251 15 V

13

14

42 VOLT AC

10 V

77A

2 15 V

WELD TERMINALS

POWER FOR

REMOTE

-15 V (W/O POT.) 76A

4

SWITCH

ROTOR FIELD CIRCUIT

CONTROL 10K

0 V

0 V

75A

214

CV

279

218

PIPE

MODE

7

CC

SWITCH

ARC

220

CONTROL 10K R2

278

TIG

9

222

277

80V DC BUS VOLTAGE

TOROID-

SENSES WELD

260A

CURRENT AND

210D

25A BATERY

AC POWER TO

261A

232

THERMOSTAT ON

BATERY CHARGER

ACTIVATE IDLER

CIRCUIT BREAKER

233

CHOPPER MODULE

TROUBLE LIGHT

210D

NORMALLY CLOSED

212

209

229

+

DISPLAY

IDLER COIL - PULLS TO

0 - .1V WHEN ON

RUN-STOP SWITCH

BATTERY

215

230

THERMAL

BATTERY

228

LOW IDLE

15 Ω

SHOWN IN RUN POS.

12 VOLT

PC BOARD

231

SHUTDOWN

CHARGING

BATTERY

5F

DISPLAY

221

MODULE

210C

KOHLER

200

ROTOR

IGNITION

FRAME

FLASHING

MODULE

GROUND

210B

5K

START BUTTON

211

225

224B

SWITCH

12 - 14 V

210

ENGINE

ENGINE DIODES

STARTER

ENGINE OIL PRESSURE SWITCH

SOLENOID

OPENS ON LOW OIL PRESSURE

G-5

TOC

ONAN

		ENGINE	KOHLER FUEL
	224		SHUTOFF
		STARTER
			SOLENOID

HOUR METER

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IGNITION+

MODULE

C

L11480

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

RANGER 250

Image 123

Lincoln Electric SVM150-A service manual Schematic Complete Machine, Output Terminal

Contents

Ranger TM Ranger SafetyElectric Shock can kill ARC Rays can burnFumes and Gases can be dangerous Welding Sparks can cause fire or explosion Cylinder may explode if damagedIii 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 Safety Instructions OperationOperating 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 EngineStarting the Engine Stopping the EngineBREAK-IN Period Welder Operation General InformationTable 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 Pulse Width Modulation Minimum OutputMaximum 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 ProceduresTroubleshooting 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 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 Stator Voltage Tests To test the 120 VAC windingTo 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 Power Module Test Other PC board components could be faultyDescription 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 TestScope Settings Normal Open Circuit Voltage Waveform 120VAC SupplyHigh 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 Power Module Assembly Removal and Replacement ProcedureRemoval Power Module Assembly Removal and ReplacementReplacement 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