Chopper Module Function Test | Lincoln Electric SVM175-A manual

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F-61

TROUBLESHOOTING & REPAIR

F-61

CHOPPER MODULE FUNCTION TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot- ing assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This test will help determine if the chopper module is functioning properly, and receiving the correct input from the output rectifier and control PC board.

This test can only provide meaningful results if the machine is producing normal AC auxiliary output.

MATERIALS NEEDED

Miscellaneous hand tools

Digital Multi-meter

Frequency counter or digital multi-meter with frequency counter function.

Wiring diagram

Control Inner-Connection diagram

RANGER 305D

Image 115

Lincoln Electric SVM175-A service manual Chopper Module Function Test, Description

Contents

RangerTM 305D Electric Magnetic Fields SafetyPowered equipment For Engine Fumes and Gases Electric Shock can kill ARC Rays can burnCan be dangerous For Electrically Welding Sparks canSAFETYCylinder may explode Cause fire or explosion If damaged Transformateur ET À Précautions DE SûretéPrécautions DE Sûreté Pour LES Machines À Souder À Master Table of Contents for ALL Sections Installation Section Table of ContentsSection A-1 Lubrication Emissions Fuel System Governor InstallationHeight Width Depth Weight AIR Cleaner Engine Idler Muffler Protection Model Number AIR CleanerEngine Warranty Engine Protection Angle of Operation Location and Ventilation Safety PrecautionsStoring Stacking High Altitude Operation High Temperature OperationLifting Towing Spark Arrester PRE-OPERATION Engine Service Battery ConnectionOIL Muffler Outlet Pipe Accessories Remote Control Machine GroundingElectrical Output Connections Total Combined Length Welding Output Cables Auxiliary Power ReceptaclesCable Installation Table A.1 Standby Power Connections Installation Premises or residential elec Figure A.2 Connection of Ranger 305D to Premises Wiring Section B-1 Operation Section Operating Instructions Operation Safety InstructionsAdditional Safety Precautions Control and Settings Design FeaturesOperation Figure B.1 Digital Output Meters Wire Feeder Voltmeter Switch Stopping the Engine Diesel Fuel Engine OperationStarting the Engine Before Starting the Engine Downhill Pipe Welding BREAK-IN PeriodStick Welding Table B.2 Typical Current RANGES1 for Tungsten ELECTRODES2 TIG Welding ARC Gouging Auxiliary PowerWire WELDING-CV See Table B.2 for reference settings Ranger 305D Simultaneous Welding and Power Loads Auxiliary Power LoadsSimultaneous Welding Ranger 305D Section C-1 Accessories Welding Accessories Options / AccessoriesField Installed Options TIG Welding Accessories Connection of the Ranger 305D to Electric Wire FeedersWire Feeders Using K867 Universal Connection of Lincoln Ranger 305D Across the ARC Connection of the LN-25 toSee Figure C.2 Ranger 305D with 42 Volt Remote Volt Remote Output Control Module Connection DiagramOutput Control Module See Figure C.3 See Figure C.4 Connection Diagram with K857 Remote Control 7ACCESSORIESC-7 Connection of the LN-8 to Ranger 305D Using K595 Control Cable See Figure C.6 Connection of the LN-742 to Ranger 305D See Figure C.7 Figure C.7 Ranger 305D/LN-742 Connection Diagram Ranger 305D Section D-1 Maintenance Engine Maintenance Safety Precautions Routine and Periodic Maintenance Kubota D722 Diesel Engine Ranger 305D MAINTENANCED-3 Engine Oil Refill capacities Engine Oil ChangeSee Table D.2 Oil Filter Change 5MAINTENANCED-5 Do not remove cap if radiator is AIR CleanerCooling System Tightening the FAN Belt Battery Maintenance Engine Adjustment Checking the Electrolyte Level Cleaning the BatteryCharging the Battery Welder / Generator Gfci Receptacle Testing Resetting Procedure Maintenance Section E-1 Theory of Operation Section Charging System Battery, Engine, Engine ProtectionBattery Theory of Operation Engine Idle System Idle Solenoid Operation Idle Switch Operation AC output Generating PowerFlashing Building Output Weld Control and Feedback Weld Power and ControlWeld Power Technology Fundamentals Electronic Output Contactor Remote output controlDigital Meters Inductor ARC Chopper Technology Fundamentals90 VDC Diode Minimum Output Pulse Width ModulationMaximum Output Troubleshooting & Repair Section Section F Troubleshooting & Repair SectionSection F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING & REPAIRF-2 PC Board can be damaged by static electricity Troubleshooting & RepairPC Board Troubleshooting Procedures 3F-3 Troubleshooting Guide Brush and Slip Ring TestsEngine Throttle Adjus ment Test Engine Throttle Adjustment Problems Possible AreasSymptoms Misadjustments Course of Action Throttle Adjustment test Control Adjustment Test Control Potentiometer ModeSwitch Resistan Test Switch Resistance Test Potentiometer Mode Switch Test Chopper Module Resistance Switch Test, Remote MISC. Weld Issues Potentiometer Test Welding output in any mode Engine Alter Engine and Idle Problems Fuel Solenoid Test. See Fuel Solenoid Test Solenoid Test Perform the Fuel Solenoid TestPerform the Idle Solenoid Test Shutdown Engine and Idle Problems If the solenoid does not hold Engine and Idle Problems Rottle Adjustment Test 21F-21 Case Cover Removal and Replacement ProcedureTest Description Materials Needed Replacement Procedure Case Cover Removal and Replacement Procedure 23F-23 Chopper Module Capacitor Discharge Procedure Perform the Case Cover Removal proce Test Procedure Fuel Shutdown Solenoid Test Fuel Shutdown Solenoid Test 26TROUBLESHOOTING & REPAIRF-26See Figure F.4 Fuel Solenoid Connections 27TROUBLESHOOTING & REPAIRF-27 Ranger 305D 29F-29 Engine Throttle Adjustment Test Strobe-Tach Method Engine Throttle Adjustment Test Engine Throttle Adjustment Test 31TROUBLESHOOTING & REPAIRF-31Frequency Counter Method High idle adjustment Low Idle adjustmentVibratach Method 33F-33 Idler Solenoid Test Idler Solenoid Test 34TROUBLESHOOTING & REPAIRF-34 Description Engine Alternator Test Test Procedure 36TROUBLESHOOTING & REPAIRF-36Engine Alternator Test Brush and Slip Ring Service Procedure Case Cover Replacement Procedure Brush and Slip Ring Service ProcedurePerform the Case Cover Removal Procedure Cleaning slip rings 39F-39 Rotor Resistance and Ground Test Static Rotor Resistance and Ground Test Static 40TROUBLESHOOTING & REPAIRF-40 Also referred to as flying resistance test Rotor Resistance and Ground Test Dynamic Rotor Resistance and Ground Test Dynamic Perform theifbrushnecessaryand.slip ring service procedure 43F-43 Rotor Voltage Test TheEngineS Throttle Adjustment Test . tator Short 44TROUBLESHOOTING & REPAIRF-44Rotor Voltage Test Rotor Voltage Test Ranger 305D Engine Not Running Flashing Voltage Test Flashing Voltage Test Case Cover Removal Procedure Flashing Voltage Test 49TROUBLESHOOTING & REPAIRF-49 Ranger 305D 51F-51 Stator Voltage Tests To test the 120 VAC auxiliary winding Stator Voltage TestsTo test the 240 VAC auxiliary winding Stator Voltage Tests 53TROUBLESHOOTING & REPAIRF-53 To test the three-phase weld winding To test the 42 VAC wire feeder winding 55F-55 Stator Short Circuit & Ground Test Stator Short Circuit & Ground Test Perform Case Cover Removal Procedure 57F-57 Output Rectifier Bridge Test Perform the Chopper Module Capacitor 58TROUBLESHOOTING & REPAIRF-58Dis harge procedure Output Rectifier Bridge Test Figure F.16 SHUNT/RECTIFIER Leads Output Rectifier Bridge Test Table F.1 Diode Test Table Perform the Case Cover replacement Procedure Chopper Module Function Test Chopper Module Function Test Chopper Module Function Test Procedure. CaseCover ReplacementWeld. Control Board PWM Gate Drive Test Ranger 305D Chopper Module Resistance Test Chopper Module Resistance Test Capacitor Discharge ProcedureCase Cover Removal Rocedure Table F.2 Diode Test Table Ohmmeter Reading Ranger 305D Weld Control Board PWM Gate Signal Test Weld Control Board PWM Gate Signal Test Weld Control Feedback Test Weld Control Feedback Test Return to Section Ranger 305D Control Potentiometer and Mode Switch Resis Tance Test Cover Replacement procedure 76TROUBLESHOOTING & REPAIRF-76Control Potentiometer and Mode Switch Resistance Test Perform .the Case cover Removal Procedure Table F.3 Mode Switch Ranger 305D Remote Receptacle Resistance Test Remote Receptacle Resistance Test Perform the Case Cover ReplacementSee Table F.4 Table F.4 Welding Terminal Ohmmeter Ohmmeter Reading Ranger 305D Output Rectifier Bridge and Choke Removal Replacement Output Rectifier Bridge and Choke Removal and Replace 84TROUBLESHOOTING & REPAIRF-84Removal Procedure Discharge procedure Perform the Case Cover Removal Replacing the Output Rectifier Ranger 305D Chopper Module Removal and Replacement Removal Chopper Module Removal and ReplacementProcedure Terminal HL W8 HL W6 Replacement Ranger 305D STATOR/ROTOR Removal and Replacement See Figure F.21 92TROUBLESHOOTING & REPAIRF-92STATOR/ROTOR Removal and Replacement Discharge Pr Cedure Figure F.22 Alternator Leads Figure F.21 Wire Guide Hole Do not Hold the Rotor by the Slip Rings Replacing the Rotor Figure F.23 DISC/RING Location Replacing the Stator Normal Open Circuit Voltage Waveform 120VAC Supply 97TROUBLESHOOTING & REPAIRF-97 Normal Open Circuit Voltage Waveform Stick 98TROUBLESHOOTING & REPAIRF-98MAX Control POT High Idle no Load Normal Weld Voltage Waveform Stick CC 99TROUBLESHOOTING & REPAIRF-99Machine Loaded to 300 Amps AT 27 Volts Normal Open Circuit Voltage Waveform Wire CV TAP 100TROUBLESHOOTING & REPAIRF-100 Normal Weld Voltage Waveform Wire CV 101TROUBLESHOOTING & REPAIRF-101Machine Loaded to 300 Amps AT 28 Volts Retest After Repair Auxiliary Power Output Electrical Diagrams Section G Electrical Diagrams SectionSection G-1 Wiring Diagram Entire Machine Code 10926 G4250 Electrical Diagrams Wiring Diagram Entire Machine Codes 11121 G4571 Ranger 305D- Kubota Wiring Diagram Wiring Diagram Entire Machine Codes 11188, 11275 G4571-1 Ranger 305D- Kubota Wiring Diagram Wiring Diagram Entire Machine Codes 11027 G4226 Ranger 305D CE Kubota Wiring Diagram UK Alternator Wiring Diagram Entire Machine Codes 11122 G4572 Ranger 305D CE Kubota Wiring Diagram UK Wiring Diagram Entire Machine Codes 11039 G4409 Ranger 305D CE Kubota Wiring Diagram Europe Wiring Diagram Entire Machine Codes 11123 G4573 Ranger 305D CE Kubota Wiring Diagram -EUROPE Wiring Diagram Entire Machine Codes 11190, 11315 G4573-1 L11946 +12V Isolated Circuitry for Engine Functions L12212 Machine Schematic L12212-1 L12212-1 L12039 Diagrams L12213 Schematic Entire Machine Code 11122 L12213 page 2 L12213-1 Schematic Entire Machine Codes 11189, 11314 L12213-1 page 2 Schematic Entire Machine Code 11039 L12038 page 1 Schematic Entire Machine Code 11039 L12038 L12214 Schematic Entire Machine Code 11123 L12214 page 2 L12214-1 L12214-1 Schematic Weld Control PC BD ALL Codes G4108-1 PG 1 Schematic Weld Control PC BD ALL Codes G4108-1 PG 2 Schematic Weld Control PC BD ALL Codes G4108-1 PG 3 Schematic Weld Control PC BD ALL Codes G4108-1 PG 4 Schematic Weld Control PC BD ALL Codes G4108-1 PG 5 PC Board Assembly Weld Control PC BD ALL Codes G4107-1 Schematic Pull Coil PC BD ALL Codes G4117-1 PC Board Assembly Pull Coil PC BD ALL Codes L11768-1 Schematic Chopper PC BD ALL Codes M19792-1 54811L PC Board Assembly Chopper PC BD ALL Codes L11845-1