Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM150-A Normal Open Circuit Voltage Waveform 120VAC Supply, High Idle no Load

Models: SVM150-A

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F-45

F-45

TROUBLESHOOTING & REPAIR

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (120VAC SUPPLY)

HIGH IDLE – NO LOAD

16.2 ms

0 volts

50V5ms

This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division rep- resents 5 milliseconds in time.

NOTE: Scope probes are connected at machine 120 VAC receptacle.

SCOPE SETTINGS

Volts/Div	50V/Div.
Horizontal Sweep	5 ms/Div.
Coupling	DC
Trigger	Internal

RANGER 250

Image 95

Lincoln Electric SVM150-A Normal Open Circuit Voltage Waveform 120VAC Supply, High Idle no Load, Scope Settings

Contents

Ranger TM Ranger SafetyFumes and Gases can be dangerous Electric Shock can killARC Rays can burn Iii Welding Sparks can cause fire or explosionCylinder may explode if damaged 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 Operating Instructions Safety InstructionsOperation 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 EngineBREAK-IN Period Starting the EngineStopping the Engine Table B.1 Typical Ranger 250 Fuel Consumption Welder OperationGeneral Information 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 Maximum Output Pulse Width ModulationMinimum 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 ProceduresDetailed in the beginning of this manual Troubleshooting GuideObserve Safety Guidelines Test Stator Voltage Test Engine Function Problems Engine Problems Troubleshooting & Repair Engine Problems Welding Problems Materials Needed Case Cover Removal and Replacement ProcedureTest Description Replacement Procedure Case Cover Removal and Replacement ProcedureRemoval 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 To test the 240 VAC winding Stator Voltage TestsTo test the 120 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 Description Power Module TestOther PC board components could be faulty 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 TestHigh Idle no Load Scope SettingsNormal Open Circuit Voltage Waveform 120VAC Supply 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 Removal Power Module Assembly Removal and ReplacementProcedure Replacement Power Module AssemblyRemoval and Replacement 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