Lincoln Electric SVM150-A Manual do Utilizador

SVM150-ASeptember, 2002Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, your overall

ADDITIONAL SAFETY PRECAUTIONSFALLING EQUIPMENT can causeinjury.• Do not lift this machine using lift bail ifit is equipped with a heavy accessorysuch

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TROUBLESHOOTING & REPAIRF-51 F-51RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-52 F-52RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-53 F-53RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-54 F-54RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

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TROUBLESHOOTING & REPAIRF-56 F-56RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

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TROUBLESHOOTING & REPAIRF-58 F-58RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-59 F-59RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

BATTERY CONNECTIONSBATTERY ACID CAN BURN EYES ANDSKIN.• Wear gloves and eye protection and becareful when working near a battery.Follow the instructi

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TROUBLESHOOTING & REPAIRF-61 F-61RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-62 F-62RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-63 F-63RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-64 F-64RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-65 F-65RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-66 F-66RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-67 F-67RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

RETEST AFTER REPAIRRetest a machine:• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect

G-1 G-1RANGER 250Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCELECTRICAL DIAGRAMSTABLE OF CONTENTS -ELECTRICAL D

To prevent dangerous electric shock, other equipmentto which this engine driven welder supplies powermust:a) Be grounded to the frame of the welder us

ELECTRICAL DIAGRAMSG-2RANGER 250WIRING DIAGRAM - RANGER 250 KOHLERCONTACTORCONTROLSHOWN IN"WELDING ON"POSITIONWIRE FEED POWER WINDING4

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ELECTRICAL DIAGRAMSG-9RANGER 250SCHEMATIC - CHOPPER PRINTED CIRCUIT BOARDFILENAME: M19462_1BA10.0R510.0R9(UNLESS OTHERWISE SPECIFIED)UNLESS OTHE

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ELECTRICAL DIAGRAMSG-11RANGER 250SCHEMATIC - WELD CONTROL PRINTED CIRCUIT BOARD - SHEET 1G-11NOTE: This diagram is for reference only. It may not be a

TABLE A.1 – TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLESCableCable Size for Length250 Amps100% Duty Cycle0-100 ft. (0-30 meters) 1 AWG100-200 ft

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SVM ERROR REPORTING FORMWe need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that wo

INSTALLATIONA-8 A-8RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

Section B-1 Section B-1RANGER 250TABLE OF CONTENTS- OPERATION SECTION -Operation...

OPERATING INSTRUCTIONSRead and understand this entire section before operat-ing your Ranger 250. SAFETY INSTRUCTIONSDo not attempt to use this equipme

DESIGN FEATURES• Single, full-range output control dial.• 4 welding modes: CC-stick, downhill stick welding onpipe, CV wire welding and Touch-Start

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OPERATIONB-5 B-5RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

SAFETYi iRANGER 250FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work require

1. Remove the fuel tank cap.2. Fill the tank approximately 4 inches (100mm) fromthe top of the filler neck to allow for fuel expansion.(Observe the fu

WELDER OPERATIONGENERAL INFORMATION• Do not touch electrically live parts or elec-trodes with your skin or wet clothing.• Do not breathe welding fum

STICK WELDINGThe Ranger 250 can be used with a broad range of DCstick electrodes. The MODE switch provides two stick welding settingsas follows:CONST

TIG WELDINGThe TOUCH START TIG setting of the MODE switch isfor DC TIG (Tungsten Inert Gas) welding. To initiate aweld, the OUTPUT control is first s

The 240 VAC output can be split to provide two sepa-rate 120 VAC outputs with a maximum permissible cur-rent of 33 amps per output to two separate 20

TABLE OF CONTENTS- ACCESSORIES -Accessories ...

OPTIONS/ACCESSORIESFIELD INSTALLED OPTIONSThe following options/accessories are available foryour Ranger 250 from your local Lincoln distributor.K957-

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERSELECTRIC SHOCK can kill.• Do not operate with panels open.• Disconnect NEGATIVE (-) BATTERYLEAD before serv

CONNECTION OF THE LN-25 TO THERANGER 250 “ACROSS THE ARC” (SEE FIGURE C.2.)1. Shut the welder off.2. Connect the electrode cable from the LN-25 to the

ACCESSORIESC-5 C-5RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

SAFETYii iiRANGER 250ARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the ar

CONNECTION OF THE LN-25 TO THE RANGER 250 “ACROSS THE ARC” WITH K857 REMOTE CONTROL(SEE FIGURE C.4.)1. Shut the welder off.2. Connect the electrode ca

CONNECTION OF THE LN-7 TO THERANGER 250 USING K584 CONTROLCABLE (SEE FIGURE C.5.)NOTE: If your LN-7 comes equipped with a K291 orK404 input cable, ref

CONNECTION OF THE LN-8 TO THE RANGER 250 USING K595 CONTROLCABLE (SEE FIGURE C.6.)NOTE: If your LN-8 comes equipped with a K291 orK404 input cable, re

ACCESSORIESC-9 C-9RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

C-10NOTES RANGER 250C-10Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection D-1 Section D-1RANGER 250TABLE OF CONTENTS-MAINTENANCE-Main

SAFETY PRECAUTIONS• Have qualified personnel do all maintenance andtroubleshooting work.• Turn the engine off before working inside themachine.• Re

MAINTENANCED-3 D-3RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

ENGINE OIL CHANGEDrain the oil while the engine is warm to assure rapidand complete draining.1. Remove the oil filler cap and dipstick. Remove theyell

Air Filter Paper Element Service1. Loosen the cover retaining knob and remove thecover.2. Remove the pre-cleaner from the paper element.3. Remove the

RANGER 250FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. I

BATTERY MAINTENANCETo access the battery, remove the screws from the rearbattery tray using a screwdriver or a 3/8" socket. Slidethe battery tra

WELDER/GENERATOR MAINTENANCESTORAGEStore the Ranger 250 in clean, dry, protected areas.CLEANINGBlow out the generator and controls periodically withlo

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection E-1 Section E-1RANGER 250Theory of Operation ...

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THEORY OF OPERATIONE-4 E-4RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return

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RANGER 250PULSE WIDTH MODULATIONThe term PULSE WIDTH MODULATION is used todescribe how much time is devoted to conduction in thecycle. Changing the p

CHOPPER TECHNOLOGYFUNDAMENTALSThe new era of welding machines such as the Ranger250 employ a technology whereby a DC source isturned on and off (chopp

SAFETYiv ivRANGER 250PRÉCAUTIONS DE SÛRETÉPourvotre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques

E-8NOTES RANGER 250E-8Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master T

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection F-1 Section F-1RANGER 250Troubleshooting & Repair Secti

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F-8 F-8RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Retu

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MASTER TABLE OF CONTENTS FOR ALL SECTIONSv vRANGER 250PageSafety...

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TROUBLESHOOTING & REPAIRF-12 F-12RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

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TROUBLESHOOTING & REPAIRF-15 F-15RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-16 F-16RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

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TABLE OF CONTENTS- INSTALLATION SECTION -Section A-1 Section A-1RANGER 250Installation...

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TROUBLESHOOTING & REPAIRF-32 F-32RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-33 F-33RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-34 F-34RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TABLE F.1. – ANALOG PC BOARD OUTPUT VOLTAGE TABLETEST POINTS COMPONENT TESTED VOLTAGE READING1J42 to 6J42 Chopper Power Supply +20 VDC2J42 to 7J42 Wel

TROUBLESHOOTING & REPAIRF-36 F-36RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-37 F-37RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-38 F-38RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

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Read this entire installation section before youstart installation.SAFETY PRECAUTIONSDo not attempt to use this equipment until you havethoroughly rea

TROUBLESHOOTING & REPAIRF-40 F-40RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-41 F-41RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

TROUBLESHOOTING & REPAIRF-42 F-42RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

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TROUBLESHOOTING & REPAIRF-44 F-44RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

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