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E-3

E-3

THEORY OF OPERATION

FIGURE E.3 – WELD WINDINGS, RECTIFIER, POWER MODULE AND FEEDBACK

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D W

L I

EN

WD

I

N

G

WORK

TERMINAL

THREE-PHASE		__
RECTIFIER

TO

CONTROL

BOARD

	+				ELECTRODE
			IGBT		TERMINAL

	4		CHOKE		SHUNT	+
		POWER MODULE
	0					F

	TO					E
		2			S	E
	1		FROM			D
		0		P	I
	0		TOROID			B
					G
	0		CURRENT	W		A
		V			N
			SENSOR	M		C
		D			A
	V					K
		C			L
	D
					S
	C

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STARTER

GAS

ENGINE MECHANICAL ROTATION

FLYWHEEL

ALTERNATOR

OIL

PRESSURE

SWITCH

			ANALOG	CONTROL
			POWER	CONTROL
	ROTOR		POWER	BOARD
			BOARD	BOARD
			BOARD
SLIP
RINGS
			REGULATED VOLTAGES
				ARC OUTPUT MODE
	STATOR			CONTROL CONTROL SELECTOR
	STATOR
FIELD	AUXILIARY	WIRE FEED
WINDING	WINDINGS	PWR WNDG

BATTERY

SOL

I

D

L

	4	4
	4	2
	2	2
	2
	V	V
	V

RUN/STOPE

SWITCH

R

TO CONTROL

BOARD

BATTERY

BOARD

A	2	1	A
C	4	2	C

	0	0	AMPHENOL
	V	V

AA

CC

240VAC 120VAC

RECEPTACLE RECEPTACLE

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WELD WINDINGS, RECTIFIER, POWER MODULE AND FEEDBACK

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The three-phase stator weld windings are connected to a three-phase rectifier bridge. The resultant DC volt- age is applied to parallel capacitors incorporated with- in the power module. These capacitors function as fil- ters and also as power supplies for the IGBT. See IGBT Operation in this section. The IGBT acts as a high-speed switch operating at 20KHZ. This device is switched on and off by the control board through pulsewidth modulation circuitry. See Pulse Width Modulation in this section. This “chopped” DC output

is applied through a choke coil and shunt to the weld- ing output terminals. The choke functions as a current filter. Free-wheeling diodes are incorporated in the power module to provide a current path for the stored energy in the chokes when the IGBT is turned off. See Chopper Technology in this section.

Output voltage and current feedback information is fed to the control board. This information is sensed from the output terminal circuits and the shunt.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

RANGER 250

Image 45

Lincoln Electric SVM150-A service manual Weld WINDINGS, RECTIFIER, Power Module and Feedback, Return to

Contents

Ranger TM Ranger Safety 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 Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Ranger 250 K1725-1/K1725-2 InstallationWeight Speed RPM Location and Ventilation Safety Precautions Additional Safety Precautions Electrical Output Connections Figure A.1 Ranger 250 Output Connections Welding Output Cables Auxiliary Power Receptacles Cable InstallationStandby 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 Safety Instructions OperationOperating Instructions Controls and Settings Design Features Figure B.1 Case Front Panel Controls Engine Controls Welding Controls Engine OperationBefore Starting the Engine 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 Constant Current CC-STICK Welding Stick WeldingPipe Welding Table B.2 Typical Current RANGES1 for Tungsten ELECTRODES2 Wire WELDING-CV Auxiliary PowerTIG Welding ARC Gouging Table B.4 Ranger 250 Simultaneous Welding and Power Loads Simultaneous Welding and Auxiliary Power Loads Table of Contents Accessories Field Installed Options OPTIONS/ACCESSORIESTIG 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 Connection of the LN-742 to Ranger 250 see Figure C.7 Figure C.7 Ranger 250/LN-742 Connection Diagram Ranger Table of Contents Maintenance Engine Maintenance Routine and Periodic Maintenance Frequency Maintenance Required Table D.2 Onan Engine Maintenance Schedule Air Pre-Cleaner Service AIR Cleaner ServiceEngine OIL Change Engine Oil Refill Capacities Spark Plug Service Air Filter Paper Element ServiceFuel Filter Service Engine Adjustment Overspeed is Hazardous Cleaning the Battery Battery MaintenanceCharging the Battery Optional Spark Arrestor WELDER/GENERATOR Maintenance Figure D.1 Major Component Locations Table of Contents Theory of Operation Section General Description Theory of Operation Return to Weld WINDINGS, RECTIFIER, Power Module and Feedback Figure E.4 Analog Power Board and Control Board Analog Power Board and Control Board Insulated Gate Bipolar Transistor Igbt Operation Pulse Width Modulation Minimum OutputMaximum Output Chopper Technology Fundamentals Switch 85VDC Diode Ranger Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & Repair PC Board can be damaged by static electricity PC Board Troubleshooting Procedures 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 Test Procedure Power Module Capacitor Discharge Procedure Idler Solenoid Test Figure F.3 Idler Solenoid Leads Idler Solenoid Test Engine Throttle Adjustment Test Strobe-Tach Method Engine Throttle Adjustment Test Frequency Counter Method Figure F.5 High Idle Adjustment Vibratach Method Oscilloscope Method Rotor Resistance Test Figure F.7 Rotor Brush Leads Slip Rings Brushes Rotor Resistance Test Flashing and Rotor Voltage Test Flashing and Rotor Voltage Test Oil Pressure Switch 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 To test the field winding Field Rectifier Bridge Retaining TAB Cable Capacitor To test the feeder winding Figure F.12 14-PIN Amphenol PIN Assignments To test the stator weld windings Choke Analog Power PC Board Voltage Test Figure F.14 Analog Power PC Board Analog Power PC Board Voltage Test +5 VDC +20 VDC+15 VDC 15 VDC Output Rectifier Bridge Test Figure F.15 Plug J41 and Resistor R3 Locations Output Rectifier Bridge Test When all tests are complete Power Module Test Other PC board components could be faultyDescription Figure F.17 Power Module Connections Power Module Test Check Igbt for Shorts Tor terminal on the power module chopper Check Diode Module Figure F.19 Diode Module Test Heat Sink Terminals Flywheel Alternator Test Figure F.20 Plug J51 PIN Location Flywheel Alternator Test Scope Settings Normal Open Circuit Voltage Waveform 120VAC SupplyHigh Idle no Load MAX Control POT High Idle no Load Normal Open Circuit Voltage Waveform Stick Machine Loaded to 250 Amps AT 25 Volts Normal Weld Voltage Waveform Stick CC Normal Open Circuit Voltage Waveform Wire CV TAP Machine Loaded to 250 Amps AT 28 Volts Normal Weld Voltage Waveform Wire CV Description 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 Replacement 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 Output Rectifier Bridge and Choke Output Choke ENGINE/STATOR/ROTOR Removal and Replacement Engine Preparation and Lead Disconnection ENGINE/STATOR/ROTOR Removal and Replacement Troubleshooting & Repair Stator Lead Disconnection Figure F.28 Stator Leads Front Panel Engine/Stator/Rotor Assembly Removal Procedure Figure F.29 ENGINE/STATOR/ROTOR Assembly Removal Figure F.30 Stator and Rotor Removal Stator/Rotor Assembly Removal Rotor/Stator/Engine Reassembly Reassembly Notes General Notes on Reassembly Lead Reconnection Checklist Volt Wire Feeder Power Auxiliary Power OutputRetest After Repair Engine Output Table of Contents Electrical Diagrams Section Electrical Diagrams Wiring Diagram Ranger 250 Kohler Ranger 250 Kohler Wiring Diagram Wiring Diagram Ranger 250 Onan Ranger 250 Onan Wiring Diagram Control INTER-CONNECTION Diagram 4ELECTRICAL DIAGRAMSG-4 Output Terminal Schematic Complete Machine Schematic Analog Control Power Supply Schematic Battery Printed Circuit Board Schematic Bypass Printed Circuit Board 19462 M Schematic Chopper Printed Circuit Board 24660S Schematic Display Printed Circuit Board Schematic Weld Control Printed Circuit Board Sheet Electrical Diagrams Electrical Diagrams Electrical Diagrams Electrical Diagrams SVM Error Reporting Form