Lincoln Electric SVM207-A service manual Ground Wire, Motor Starting, Standby Power Connections

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A-8

INSTALLATION

A-8

 

 

 

 

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All auxiliary power is protected by circuit breakers with the following values:

The 120V has 20 amp circuit breakers for each duplex receptacle. The 240V has 50 amp circuit breakers for each hot lead going the 240V receptacle.

The 480V 3 phase circuit breaker / switch is a 3 phase, 15 amp circuit breaker.

Ground Wire

Periodically check the ground wire at plugs, power cords and auxiliary loads to ensure that the grounding circuit is intact and connected.

MOTOR STARTING

Most 1.5 hp AC single phase motors can be started if there is no load on the motor or other load connected to the machine, since the full load current rating of a

1.5hp motor is approximately 20 amperes (10 amperes for 240 volt motors). The motor may be run at full load when plugged into only one side of the duplex receptacle. Larger motors through 2 hp can be run pro- vided the receptacle rating as previously stated is not exceeded. This may necessitate 240V operation only.

The 480 volt 3 phase output of the RANGER® 3 PHASE is capable of running most 480VAC 3 phase motors up to 10HP. A 10HP motor must be started with no load on the motor and no other load connected to the machine, since the full load current of a 10HP 480VAC 3 phase motor is approximately 12.5 amps. Refer to the reconnect phase output to any load, the ground at the 3 phase receptacle is NOT the neutral of 3 phase connection, and should under no circum- stance be connected to the neutral of any 3 phase load.

STANDBY POWER CONNECTIONS

The RANGER® 3 PHASE is suitable for temporary, standby, or emergency power using the engine manu- facturer’s recommended maintenance schedule.

The RANGER® 3 PHASE can be permanently installed as a standby power unit for 240V-3 wire, sin- gle phase 40 ampere service.

WARNING

(Connections must be made by a licensed electrician who can determine how the 120/240V power can be adapted to the particular installation and comply with all applicable electrical codes.) The following informa- tion can be used as a guide by the electrician for most applications (refer also to the connection diagram shown in Figure A.1).

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1.Install a double pole, double throw switch between the power company meter and the premises dis- connect.

Switch rating must be the same or greater than the customer’s premises disconnect and service over- current protection.

2.Take necessary steps to assure load is limited to the capacity of the RANGER® 3 PHASE by installing a 40 amp 240V double pole circuit break- er. Maximum rated load for the 240V auxiliary is 40 amperes. Loading above 40 amperes will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motor-driven equipment.

3.Install a 50 amp 120/240V plug (NEMA type 14-50) to the Double Pole Circuit Breaker using No. 8, 4 conductor cable of the desired length. (The 50 amp 120/240V plug is available in the optional plug kit.)

4.Plug this cable into the 50 amp 120/240V recepta- cle on the RANGER® 3 PHASE case front.

AUXILIARY POWER WHILE WELDING

Simultaneous welding and power loads are permitted by following Table I. The permissible currents shown assume that current is being drawn from either the 120V or 240V supply (not both at the same time). Also, the “Output Control” is set at “10” for maximum auxil- iary power.

TABLE A.1

SIMULTANEOUS WELDING AND POWER***

Output Selector

Permissible Power

Permissible Auxiliary

 

Setting

Watts (Unity Power

Current in Amperes

 

Factor)

@ 120V *-or- @ 240V

 

 

 

 

 

Max. Stick or Wire

 

 

 

 

Feed Setting

None

0

0

 

 

 

 

 

 

145 Stick Setting

4500

38

23

 

 

 

 

 

 

90 Stick Setting

6500

54**

27

 

 

 

 

 

 

NO WELDING

9500

80**

40

 

*Each duplex receptacle is limited to 20 amps.

**Not to exceed 40A per 120VAC branch circuit

when splitting the 240 VAC output.

***Use of 3-Phase AC power is not recommended while welding.

RANGER® 3 PHASE

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Contents Ranger 3 Phase Safety Ranger 3 PhaseFumes and Gases Welding Cutting Précautions DE Sûreté Safety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Ranger 3 Phase K2337-1 & K2337-2Auxiliary Power Height Width Depth WeightSafety Precautions Machine GroundingSpark Arrester TowingPRE-OPERATION Service GasolineVehicle Mounting Can cause fire or explosionWelding Output Cables Total Combined Length of Electrode and Work CablesHigh Altitude Operation Angle of OperationInstructions Auxiliary Power Volt 3 Phase Receptacle with GroundGfci Duplex Receptacles 120/240 Volt Dual Voltage ReceptacleGround Wire Standby Power ConnectionsAuxiliary Power While Welding TABLE A.1 Simultaneous Welding and PowerConnection of Ranger 3 Phase to Premises Wiring Figure A.3USE These Devices with a Ranger 3 Phase Electrical Device USE with the Ranger 3 PhaseDevices Without Addi Tional Resistive Type Loads Table of Contents Operation Section Engine Switch OperationGENERAL DESCRIPTION Welder Controls Function and OperationPolarity Switch Ranger 3 Phase Approximate Fuel ConsumptionRange Switch Control DialWire Feed Welding Processes Constant Voltage Welding ProcessStick Constant Current Welding TIG Constant Current WeldingStick Auto STARTING/SHUTDOWN Instructions BREAK-IN PeriodStarting the Engine Stopping the EngineTable of Contents Accessories Section Accessories K1745-1 Welding GAS Cylinder LPG Tank HolderWIRE FEED RECOMMENDED EQUIPMENTStick TIGRanger 3 Phase Table of Contents Maintenance Section Maintenance Safety PrecautionsGfci Receptacle Testing and RESET- Ting Procedure AIR Cleaner and Other Maintenance Slip RingsOIL Filter Change Do not attempt to polish slip rings while engine is runningBattery Engine Maintenance Parts KOHLER C23SFram CA79 CHAMPION RC12YCMAINTENANCED-5 Figure D.1 Major Component LocationRanger 3 Phase 1TABLE of CONTENTS-THEORY of Operation Section E-1 General Description Theory of OperationEngine Components and Operation ROTOR, Stator & Control Circuits Figure E.2 ROTOR, Stator and Control CircuitsWeld Circuitry Figure E.2 Weld Circuitry1TABLE of Contents Troubleshooting and Repair F-1 Troubleshooting and Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Return to SectionDiagram Perform the Output Bridge Test Gram Wiring Wiring Diagram Troubleshooting and Repair Figure F.4 and/or the Wiring Test Description Rotor Voltage Test ProcedureMaterials Needed Test Procedure Rotor Voltage TestRotor Resistance Test TEST PROCEDURE Figure F.2 Slip RingsAuxiliary and Field Winding Test To test the 480 VAC 3 Phase winding Probes ReadingAuxiliary Windings To test the 120 VAC windingFigure F.4 Control PC Board Field WindingRanger 3 Phase Output Rectifier Bridge Test Figure F.5 OUTPUT RECTIFIER + Meter Lead Meter ReadingToroid Test Toroid Test Charging Circuit Test Voltage Regulator AC Lead DC Lead Engine Throttle Adjustment Test Engine Throttle Adjustment Test Low Idle Adjustment SolenoidNut Housing Figure F.9 115VAC Supply Waveform High IDLE- no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Scope SettingsHigh Idle no Load Output Control AT Maximum Typical DC Weld Output Waveform CV Mode Machine LoadedTypical DC Weld Output Waveform CC Mode Machine Loaded to 200 Amps AT 26 VDCTypical AC Weld Output Waveform Machine Loaded to 225 Amps AT 25 VDCAbnormal Open Circuit Weld Voltage Waveform CV Mode Abnormal Open Circuit DC Weld Voltage Waveform Normal Open Circuit Weld Voltage Waveform CV Mode Normal Open Circuit DC Weld Voltage Waveform CC Mode Normal Open Circuit AC Weld Voltage Waveform Ranger 3 Phase Brush Removal and Replacement Procedure Brush Removal and Replacement Procedure ProcedureBrush Assembly Bracket Bolts Ranger 3 Phase Printed Circuit Board Removal Replacement Procedure Printed Circuit Board Removal Figure F.10 Door RemovalOutput Rectifier Bridge Removal Replacement Procedure Output Rectifier Bridge Removal Figure F.11 OUTPUT RECTIFIERENGINE/ROTOR Removal and Replacement Procedure ENGINE/ROTOR Removal and Replacement Procedure Procedure Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from StatorReassembly Procedure Retest After Repair Table of Contents Diagram Section Ranger 3-PHASE RaNGEr 3 phaSESchEmaTic cOmplETE machiNE l12259 L12259ElEcTrical DiaGramS