Lincoln Electric RANGER 250 SVM150-A Service Manual page 122

G-4
CONTROL INTER-CONNECTION DIAGRAM
212 1J43 to ENGINE CONNECTOR BLOCK
ENERGIZES KOHLER FUEL SOLENOID
211 2J43 to S2 START SWITCH
ENERGIZES FUEL SOLENOID WHEN STARTING ENGINE
229 4J43 to 2J34 BATTERY DISPLAY PC BOARD
TO BATTERY CHARGER TROUBLE LIGHT
210B 5J43 to S2 START SWITCH
14V SUPPLY VOLT AGE FROM BATTERY
228 6J43 to 1J34 BATTERY DISPLAY PC BOARD
TO BATTERY CHARGER TROUBLE LIGHT
224B 7J43 to HOUR METER
BATTERY VOLT AGE FROM OIL PRESSURE SWITCH FOR FLASHING CIRCUIT
5K 9J43 to GROUND SCREW
GROUND TO FRAME
200 11J43 to POSITIVE BRUSH HOLDER
ROTOR FLASHING
201D 1J43 to 14J12
IDLER CLAMPING DIODE CIRCUIT
PCB4
BATTERY
PC BOARD
J43
1
C1
C2
13 1J41 to POS TERMINAL ON C2 - 85V SUPPLY
CONTROL CIRCUIT
14 2J41 to NEG TERMINAL ON C2 - 85V SUPPLY
INPUT POWER
11 1J42 toPIN 3 of P50
CHOPPER POWER SUPPLY, 20V
105A 2J42 to3J13
WELD BOARD POWER SUPPLY, +5V TO CIRCUIT GROUND WELD BOARD POWER SUPPLY, +5V TO CIRCUIT GROUND WELD BOARD POWER SUPPLY, +5V TO CIRCUIT GROUND WELD BOARD POWER SUPPLY, +5V TO CIRCUIT GROUND
5L 4J42 to GND. SCREW
FRAME GROUND
115A 5J42 to 1J13
WELD BOARD POWER SUPPLY, +15V TO CIRCUIT GROUND
12 6J42 to PIN 1 of P50
CHOPPER POWER SUPPLY, 20V
101A 7J42 to 2J13
CIRCUIT GROUND
116A 9J42 to 4J13
WELD BOARD POWER SUPPLY, -15V TO CIRCUIT GROUND
118A 10J42 to 5J13
WELD BOARD POWER SUPPLY, +15V TO CASE GROUND
BLOWER BAFLE - SIDE OPPOSITE BLOWER
6 12 KEY
5 11
4 10
3 9 1
2 8
1 7
7
TYPICAL MOLEX
P50 - LEAD END VIEW
CONNECTOR
ELECTRICAL DIAGRAMS
RANGER 250 CONTROL INTER-CONNECTION DIAGRAM
25 1J12 to PIN 7 of P50 CHOPPER PWM SIGNAL
23 2J12 to PIN 9 of P50 CHOPPER PWM SIGNAL
251 7J12 to S4 IDLER CONTROL SWITCH
250 8J12 to S4 IDLER CONTROL SWITCH
261A 9J12 to CURRENT SENSING TOROID
260A 10J12 to CURRENT SENSING TOROID
210D 14J12 to 12J43
215 15J12 to IDLE SOLENOID
208B 16J12 to NEG. OUTPUT STUD
277 1J9 to R2 ARC CONTROL - 10K
278 2J9 to R2 ARC CONTROL - 10K
279 3J9 to R2 ARC CONTROL - 10K
P3 JUMPER PLUG, PINS 1 AND 5
ARE JUMPERED TOGETHER
1
1
1 3
204S 1J6 to SHUNT POS. - W10 SIDE
J6
J1 J3 1
206S 2J6 to SHUNT NEG. - OUTPUT STUD SIDE
7 9 J8
1
1
PCB3
J50 - CONNECTS TO J4
J9
WELD CONTROL
PCB1 300 AMP 1
PC BOARD
CHOPPER MODULE
1
J11
J12
1
214 1J2 to MODE SWITCH - TERM.1 CV
1
J2
218 6J2 to MODE SWITCH - TERM. 2 PIPE
220 7J2 to MODE SWITCH - TERM. 4 TI G
1
222 8J2 to MODE SWITCH - CENTER C1
J5
1
J13 J10
J7
1
77 1J7 to R1 OUTPUT CONTROL
1
76 2J7 to R1 OUTPUT CONTROL
75 3J6 to R1 OUTPUT CONTROL
PCB5
BY-PASS
PCB2
PC BOARD
ANALOG POWER
1
PC BOARD
J41
206B 3J60 to POS. OUTPUT STUD
J60
GND-K 5J60 to GND. SCREW
1 208 8J60 to NEG. OUTPUT STUD
J61
1
1
J42
J62
1
75A 2J62 to 3J10 - 10K REMOTE
75B 3J62 to 14 PIN AMPHENOL PIN G
76A 4J62 to 2J10 - 10K REMOTE
GND K
77A 5J62 to 1J10 - 10K REMOTE
77B 6J62 to 14 PIN AMPHENOL PIN E
75C 8J62 to 6 PIN AMPHENOL PIN C
76B 9J62 to 14 PIN AMPHENOL PIN F
76C 10J62 to 6 PIN AMPHENOL PIN B
GND L
77C 12J62 to 6 PIN AMPHENOL PIN A
12 NEG
CHOPPER POWER SUPPLY
C
REMOTE
20 V DC MEASURED WITH D B
CONTACTOR
CONNECTOR UNPLUGGED CONTROL
3 11 POS CONTROL
E A
F
23
9 NEG TWISTED PAIR - PWM SIGNAL
GROUND
12 V DC MEASURED WITH
KEY
CONNECTOR UNPLUGGED
25 POS
FRONT VIEW OF AMPHENOLS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CHOPPER
PWM SIGNAL - TWISTED PAIR
IDLER CONTROL
AC POWER SENSE FOR IDLER
IDLER CLAMPING DIODE CIRCUIT
OUTPUT TO IDLER SOLENOID, PULLS TO LOW IDLE
ARC VOLTAGE FEEDBACK
ARC
CONTROL
CURRENT LEVEL
FEEDBACK - TWISTED PAIR
231 1J11 to 2J33 THERMAL DISPLAY INDICATOR
THERMAL
233 4J11 to THERMOSTAT ON HEAT SINK
PROTECTION
232 5J11 to THERMOSTAT ON HEAT SINK
230 6J11 to 1J33 THERMAL DISPLAY INDICATOR
MODE
SELECTION
77A 1J10 to 5J62 - 10K REMOTE
76A 2J10 to 4J62 - 10K REMOTE
75A 3J10 to 2J62 - 10K REMOTE
REMOTE INPUTS
OUTPUT 4 4J10 to WELD TERM. SWITCH
CONTROL
2 5J10 to WELD TERM. SWITCH
115A 1J13 to 5J42 -15 VOLT POWER
101A 2J13 to 7J42 CIRCUIT GROUND
105A 3J13 to 2J42 - 5 VOLT POWER POWER INPUTS
116A 4J13 to 9J42 - 5 VOLT POWER FROM ANALOG POWER PC BOARD
118A 5J13 to 10J42 +15 VOLT S MEA. T O CASE GND.
5F 7J13 to CASE FRONT GND. SCREW CASE GND.
TRANSIENT PROTECTION
AND HIGH FREQ BYPASS
ON OUTPUT TERMINALS
2A 1J61 to WELD TERM. SWITCH
AMPHENOL 2
2B 2J61 to 14 PIN AMPHENOL PIN C
REMOTE
2C 3J61 to 6 PIN AMPHENOL PIN D
CONTACTOR
4A 4J61 to WELD TERM. SWITCH
CONTROL
4B 5J61 to 14 PIN AMPHENOL PIN D
4C 6J61 to 6 PIN AMPHENOL PIN E
KEY
REMOTE
OUTPUT CONTROL
GROUND
210 (TO
CONTACTOR
RUN-STOP
CONTROL
C
B A SWITCH)
120 V AC FOR WIRE FEDER 1 3
D
L
K
J 224 (TO HOUR
E 2 4
M
REMOTE N
I METER POS.)
CONTROL F
G 42 V AC FOR WIRE FEDER
H 224A
WELDER HARNESS SIDE
LEAD ENTRY VIEW
21 -WORK SENSE
KEY
RUN STOP
START BUTTON SWITCH - S2
SWITCH - S1 PCB7
IDLER SWITCH - S4
221 (KOHLER ONLY) BATTERY
DISPLAY
J34
212
5J (KOHLER ONLY)
251
229
211
250
210A
211A 210
210A PCB6
210B
THERMAL
210C
DISPLAY
OUTPUT CONTROL
R1
10K
77 76
75
WELD TERMINALS
208A
ARC CONTROL
(CONTACTOR) SWITCH - S3
WIRE FEEDER
R2
VOLTM ETER
10K
SWITCH - S5
21
4
206A
2A
4A
2 277 276 275
3D
AMPHENOL 1 GND C
GOLD
J102
C
C A B
B J100
D D SILVER
K L
6F
J 3E
120/240 V AC
E GND G 5A
A E N M
I
F
F
H G 6E
GOLD
5C
KEY J101
SILVER
5B
GND D
208
SHUNT
208A
208B
NEGATIVE OUTPUT STUD
CASE FRONT - REAR VIEW
221 (TO
BATTERY
RUN-STOP
212A (TOBATTERY
CHARGER TO OIL 221A (TO START
SWITCH)
1 3
CHARGER CIRCUIT
PRESSURE BUTTON SWITCH)
BREAKER) IGNITION SWITCH
212A (TO BATTERY
225 (TO BATTERY
2 4
CIRCUIT +12V
CHARGER CIRCUIT PC BOARD)
BREAKER)
ENGINE SIDE
WELDER HARNESS SIDE
LEAD ENTRY VIEW
LEAD ENTRY VIEW
ENGINE CONECTOR BLOCK ENGINE CONECTOR BLOCK
ONAN P216 ENGINE KOHLER CH20 ENGINE
G-4
HOUR METER
+
228
1
224 224B 5G
5J
1
230
J33
231
WELD MODE SWITCH - S6
C1
214
222 POS. 1 CV-WIRE
1 2
POS. 2 PIPE
218 3
4
POS. 3 CC-STICK
POS. 4 T OUCH START TIG
220
GND M
GND L
GND J
GND G
GND D
GND C
GND B
50 AMP 25 AMP 20 AMP
GND A
3
3A
209
3A
31
CB5 CB7 CB1
5
212A 5A
3E
5B
3D, 32
212
5C
5F
6
42 6B
5G
6B
5H
CB2
CB6 5K GND E
CB8
5L
42A
6F 6E
50 AMP 15 AMP 20 AMP
206A
206B
POSITIVE OUTPUT STID
204S
206S
IGNITION GROUND
TO FUEL TO STOP ENGINE
SHUTOFF
SOLENOID BATTERY
CHARGER
ENGINE SIDE
LEAD ENTRY VIEW
G3817
RANGER 250