Lincoln Electric SVM150-A instruction

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Section F-1

Section F-1

TABLE OF CONTENTS

TROUBLESHOOTING & REPAIR SECTION

Troubleshooting & Repair Section	Section F
How to Use Troubleshooting Guide	F-2
PC Board Troubleshooting Procedures	F-3
Troubleshooting Guide	F-4 - F-12
Test Procedures	F-13
Case Cover Removal and Replacement Procedure	F-13
Power Module Capacitor Discharge Procedure	F-15
Idler Solenoid Test	F-17
Engine Throttle Adjustment Test	F-19
Rotor Resistance Test	F-23
Flashing and Rotor Voltage Test	F-25
Stator Voltage Tests	F-28
Analog Power PC Board Voltage Test	F-33
Output Rectifier Bridge Test	F-36
Power Module Test	F-39
Flywheel Alternator Test	F-43
Oscilloscope Waveforms	F-45
Normal Open Circuit Voltage Waveform (120 VAC Supply)	F-45
Normal Open Circuit Voltage Waveform (Stick)	F-46
Normal Weld Voltage Waveform (Stick CC)	F-47
Normal Open Circuit Voltage Waveform (Wire CV Tap)	F-48
Normal Weld Voltage Waveform (Wire CV)	F-49
Replacement Procedures	F-50
Power Module Assembly/Power Module PC Board/
Diode Module Removal and Replacement	F-50
Power Capacitor Removal and Replacement	F-55
Output Rectifier Bridge and Choke Removal and Replacement	F-57
Engine/Stator/Rotor Removal and Replacement	F-60
Retest After Repair	F-68

RANGER 250

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Lincoln Electric SVM150-A service manual Table of Contents Troubleshooting & Repair Section

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 Speed RPM InstallationTechnical Specifications Ranger 250 K1725-1/K1725-2 Weight Location and Ventilation Safety Precautions Additional Safety Precautions Electrical Output Connections Figure A.1 Ranger 250 Output Connections Welding Output Cables Cable Cable Size for Amps Length 100% Duty Cycle Cable InstallationAuxiliary Power Receptacles Standby Power Connections 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 Check and fill the engine oil level Engine OperationWelding Controls Before Starting the Engine Starting 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 Welding ARC Gouging Auxiliary PowerWire WELDING-CV TIG Welding Table B.4 Ranger 250 Simultaneous Welding and Power Loads Simultaneous Welding and Auxiliary Power Loads Table of Contents Accessories Semiautomatic Fcaw and MIG Welding Accessories OPTIONS/ACCESSORIESField Installed Options TIG 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 Engine Oil Refill Capacities AIR Cleaner ServiceAir Pre-Cleaner Service Engine OIL Change Engine Adjustment Overspeed is Hazardous Air Filter Paper Element ServiceSpark Plug Service Fuel Filter Service Optional Spark Arrestor Battery MaintenanceCleaning the Battery Charging the Battery 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 15 VDC +20 VDC+5 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 Engine Output Auxiliary Power OutputVolt Wire Feeder Power Retest After Repair 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