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Lincoln Electric SVM150-A service manual Analog Power Board and Control Board

Models: SVM150-A

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E-4

E-4

THEORY OF OPERATION

FIGURE E.4 – ANALOG POWER BOARD AND CONTROL BOARD

WORK

TERMINAL

THREE-PHASE		__
RECTIFIER

TO

CONTROL

BOARD

D W

L I

EN

WD

I

N

G

+	ELECTRODE
IGBT	TERMINAL

CHOKE	SHUNT	+

	4	POWER MODULE
	0						F

	TO						E

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

C

S

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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
	C	4	2

		0	0
		V	V	AMPHENOL

AA

CC

240VAC 120VAC

RECEPTACLE RECEPTACLE

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ANALOG POWER BOARD AND CONTROL BOARD

The analog power board, which is powered by the two filter capacitors on the power module, supplies various regulated DC voltages to operate the control board cir- cuitry. It also supplies a regulated DC voltage to oper- ate the chopper board.

The control board monitors the operator controls (arc

control, output, and mode selector). It compares these commands to the current and voltage feedback infor- mation it receives from the shunt and output terminal circuits. The circuitry on the control board determines how the output should be controlled to optimize weld- ing results, and it sends the correct PWM signals to the IGBT driver circuit.

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

RANGER 250

Image 46

Lincoln Electric SVM150-A service manual Figure E.4 Analog Power Board and Control Board

Contents

Ranger TM Safety RangerARC Rays can burn Electric Shock can killFumes and Gases can be dangerous Cylinder may explode if damaged Welding Sparks can cause fire or explosionIii Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Section Weight InstallationTechnical Specifications Ranger 250 K1725-1/K1725-2 Speed RPMSafety Precautions Location and VentilationAdditional Safety Precautions Electrical Output Connections Welding Output Cables Figure A.1 Ranger 250 Output ConnectionsStandby Power Connections Cable InstallationAuxiliary Power Receptacles Cable Cable Size for Amps Length 100% Duty CycleFigure A.2 Connection of the Ranger 250 to Premises Wiring Table of Contents Operation Section Operation Safety InstructionsOperating Instructions Design Features Controls and SettingsEngine Controls Figure B.1 Case Front Panel ControlsBefore Starting the Engine Engine OperationWelding Controls Check and fill the engine oil levelStopping the Engine Starting the EngineBREAK-IN Period General Information Welder OperationTable B.1 Typical Ranger 250 Fuel Consumption Pipe Welding Stick WeldingConstant Current CC-STICK Welding Table B.2 Typical Current RANGES1 for Tungsten ELECTRODES2TIG Welding Auxiliary PowerWire WELDING-CV ARC GougingSimultaneous Welding and Auxiliary Power Loads Table B.4 Ranger 250 Simultaneous Welding and Power LoadsTable of Contents Accessories TIG Welding Accessories OPTIONS/ACCESSORIESField Installed Options Semiautomatic Fcaw and MIG Welding AccessoriesConnection 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.7Ranger Table of Contents Maintenance Routine and Periodic Maintenance Engine MaintenanceTable D.2 Onan Engine Maintenance Schedule Frequency Maintenance RequiredEngine OIL Change AIR Cleaner ServiceAir Pre-Cleaner Service Engine Oil Refill CapacitiesFuel Filter Service Air Filter Paper Element ServiceSpark Plug Service Engine Adjustment Overspeed is HazardousCharging the Battery Battery MaintenanceCleaning the Battery Optional Spark ArrestorWELDER/GENERATOR Maintenance Figure D.1 Major Component Locations Table of Contents Theory of Operation Section Theory of Operation General DescriptionWeld WINDINGS, RECTIFIER, Power Module and Feedback Return toAnalog Power Board and Control Board Figure E.4 Analog Power Board and Control BoardInsulated Gate Bipolar Transistor Igbt Operation Minimum Output Pulse Width ModulationMaximum Output Switch 85VDC Diode Chopper Technology FundamentalsRanger Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures PC Board can be damaged by static electricityObserve 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 Power Module Capacitor Discharge Procedure Test ProcedureIdler Solenoid Test Idler Solenoid Test Figure F.3 Idler Solenoid LeadsEngine Throttle Adjustment Test Engine Throttle Adjustment Test Strobe-Tach MethodFigure F.5 High Idle Adjustment Frequency Counter MethodOscilloscope Method Vibratach MethodRotor Resistance Test Rotor Resistance Test Figure F.7 Rotor Brush Leads Slip Rings BrushesFlashing and Rotor Voltage Test Oil Pressure Switch Test Flashing and Rotor Voltage 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 Field Rectifier Bridge Retaining TAB Cable Capacitor To test the field windingFigure F.12 14-PIN Amphenol PIN Assignments To test the feeder windingChoke To test the stator weld windingsAnalog 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 VDCOutput Rectifier Bridge Test Output Rectifier Bridge Test Figure F.15 Plug J41 and Resistor R3 LocationsWhen all tests are complete Other PC board components could be faulty Power Module TestDescription Power Module Test Figure F.17 Power Module ConnectionsTor terminal on the power module chopper Check Igbt for ShortsFigure F.19 Diode Module Test Heat Sink Terminals Check Diode ModuleFlywheel Alternator Test Flywheel Alternator Test Figure F.20 Plug J51 PIN LocationNormal Open Circuit Voltage Waveform 120VAC Supply Scope SettingsHigh Idle no Load Normal Open Circuit Voltage Waveform Stick MAX Control POT High Idle no LoadNormal Weld Voltage Waveform Stick CC Machine Loaded to 250 Amps AT 25 VoltsNormal Open Circuit Voltage Waveform Wire CV TAP Normal Weld Voltage Waveform Wire CV Machine Loaded to 250 Amps AT 28 VoltsDescription Procedure Power Module Assembly Removal and ReplacementRemoval Removal and Replacement Power Module AssemblyReplacement Power Module PC Board Removal and Replacement Figure F.22 Diode MODULE/POWER Module Assembly DetailsFigure 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 RectifierOutput Choke ENGINE/STATOR/ROTOR Removal and Replacement ENGINE/STATOR/ROTOR Removal and Replacement Engine Preparation and Lead DisconnectionTroubleshooting & Repair Figure F.28 Stator Leads Front Panel Stator Lead DisconnectionFigure F.29 ENGINE/STATOR/ROTOR Assembly Removal Engine/Stator/Rotor Assembly Removal ProcedureStator/Rotor Assembly Removal Figure F.30 Stator and Rotor RemovalReassembly Notes Rotor/Stator/Engine ReassemblyLead Reconnection Checklist General Notes on ReassemblyRetest After Repair Auxiliary Power OutputVolt Wire Feeder Power Engine OutputElectrical Diagrams Table of Contents Electrical Diagrams SectionRanger 250 Kohler Wiring Diagram Wiring Diagram Ranger 250 KohlerRanger 250 Onan Wiring Diagram Wiring Diagram Ranger 250 Onan4ELECTRICAL DIAGRAMSG-4 Control INTER-CONNECTION DiagramSchematic Complete Machine Output TerminalSchematic Analog Control Power Supply Schematic Battery Printed Circuit Board Schematic Bypass Printed Circuit Board Schematic Chopper Printed Circuit Board 19462 MSchematic Display Printed Circuit Board 24660SSchematic Weld Control Printed Circuit Board Sheet Electrical Diagrams Electrical Diagrams Electrical Diagrams Electrical Diagrams SVM Error Reporting Form