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Lincoln Electric SVM150-A service manual When all tests are complete

Models: SVM150-A

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F-38

F-38

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE TEST (continued)

FIGURE F.16 – OUTPUT RECTIFIER BRIDGE LEAD REMOVAL AND TEST POINTS

		TOP	OUTPUT
	W1	CENTER	RECTIFIER
	W2	CENTER	BRIDGE
	W2		BRIDGE
	W3	BOTTOM

CHOKE

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6.Electrically isolate the output rectifier bridge: Using the 1/2" wrench, remove stator leads W1, W2, and W3 from their bolted connec- tions on the left side of the bridge. Note lead placement for reassembly. Bend the leads out into "free air" so that they do not touch anything. See Figure F.16.

7.Remove any load that may be connected to the weld output terminals.

8.Check all diode assemblies individually for opens or shorts. If any of the checks are not correct, the output rectifier bridge may be faulty. See the Output Rectifier Bridge Removal and Replacement procedure.

When all tests are complete:

1.Replace stator leads W1, W2, and W3 to their respective terminals. Replace lead(s) #252 or #253 previously removed. See Figure F.16.

2.If finished testing, perform the Case Cover Replacement procedure.

RANGER 250

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Lincoln Electric SVM150-A service manual When all tests are complete

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 Installation Technical Specifications Ranger 250 K1725-1/K1725-2Weight Speed RPMSafety Precautions Location and VentilationAdditional Safety Precautions Electrical Output Connections Welding Output Cables Figure A.1 Ranger 250 Output ConnectionsCable Installation Auxiliary Power ReceptaclesStandby Power Connections 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 ControlsEngine Operation Welding ControlsBefore Starting the Engine 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 Stick Welding Constant Current CC-STICK WeldingPipe Welding Table B.2 Typical Current RANGES1 for Tungsten ELECTRODES2Auxiliary Power Wire WELDING-CVTIG Welding ARC GougingSimultaneous Welding and Auxiliary Power Loads Table B.4 Ranger 250 Simultaneous Welding and Power LoadsTable of Contents Accessories OPTIONS/ACCESSORIES Field Installed OptionsTIG Welding Accessories 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 RequiredAIR Cleaner Service Air Pre-Cleaner ServiceEngine OIL Change Engine Oil Refill CapacitiesAir Filter Paper Element Service Spark Plug ServiceFuel Filter Service Engine Adjustment Overspeed is HazardousBattery Maintenance Cleaning the BatteryCharging 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+20 VDC +5 VDC+15 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 ReassemblyAuxiliary Power Output Volt Wire Feeder PowerRetest After Repair 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