Weld Windings, Rectifier, Power Module And Feedback - Lincoln Electric RANGER 250 SVM150-A Service Manual

Lincoln electric welder user manual
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E-3
FIGURE E.3 – WELD WINDINGS, RECTIFIER, POWER MODULE AND FEEDBACK
GAS
ENGINE
STARTER
FLYWHEEL
ALTERNATOR
OIL
PRESSURE
SWITCH
SOL
I
D
BATTERY
L
RUN/STOP
E
SWITCH
R
TO CONTROL
BATTERY
BOARD
WELD WINDINGS, RECTIFIER,
POWER MODULE AND FEEDBACK
The three-phase stator weld windings are connected to
a three-phase rectifier bridge. The resultant DC volt-
age is applied to parallel capacitors incorporated with-
in the power module. These capacitors function as fil-
ters and also as power supplies for the IGBT. See
IGBT Operation in this section. The IGBT acts as a
high-speed switch operating at 20KHZ. This device is
switched on and off by the control board through
pulsewidth modulation circuitry.
Modulation in this section. This "chopped" DC output
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
THEORY OF OPERATION
E
W
MECHANICAL
ROTATION
SLIP
RINGS
STATOR
FIELD
WINDING
4
2
V
2
A
4
C
0
V
A
BOARD
C
240VAC
RECEPTACLE
See Pulse Width
RANGER 250
THREE-PHASE
RECTIFIER
+
4
0
POWER MODULE
D
W
TO
L
I
1
N
0
D
0
I
N
V
G
D
C
ANALOG
POWER
ROTOR
BOARD
REGULATED VOLTAGES
AUXILIARY
WIRE FEED
WINDINGS
PWR WNDG
4
2
V
A
1
C
2
0
AMPHENOL
V
A
C
120VAC
RECEPTACLE
is applied through a choke coil and shunt to the weld-
ing output terminals. The choke functions as a current
filter.
Free-wheeling diodes are incorporated in the
power module to provide a current path for the stored
energy in the chokes when the IGBT is turned off. See
Chopper Technology in this section.
Output voltage and current feedback information is fed
to the control board. This information is sensed from
the output terminal circuits and the shunt.
WORK
TERMINAL
TO
CONTROL
BOARD
ELECTRODE
TERMINAL
IGBT
CHOKE
SHUNT
F
E
E
2
S
D
FROM
0
I
P
B
TOROID
G
W
A
CURRENT
V
N
M
C
SENSOR
D
A
K
C
L
S
CONTROL
BOARD
ARC
OUTPUT
MODE
CONTROL
CONTROL
SELECTOR
E-3
__
__
+

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