Lincoln Electric SVM207-A service manual Theory of Operation, General Description

Page 36

 

 

E-2

 

 

 

THEORY OF OPERATION

 

E-2

 

 

 

 

 

 

 

 

 

 

 

 

 

TOC

TOC

 

 

 

FIGURE E.2 - ENGINE COMPONENTS AND OPERATION

 

 

 

 

 

 

 

 

SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

 

RANGE

 

 

 

 

Section

Master

 

 

 

 

 

 

 

 

 

254

 

TOROID*

 

 

 

 

 

 

S2

E

 

 

 

 

ELECTRODE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AC

 

 

 

to

 

 

 

 

 

 

 

 

 

 

 

to

 

 

 

 

 

 

 

 

 

 

 

TERMINAL

 

 

 

 

 

REACTOR

 

 

OUTPUT +

 

 

 

 

 

 

 

 

CHOKE

POLARITY

Return

Return

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

--

 

WORK

 

 

 

 

 

 

 

 

 

 

 

AC BRIDGE

 

SWITCH

 

 

 

 

 

FUEL

 

W2

 

C1 WAC

W1

 

 

 

TERMINAL

 

 

STARTER

 

 

 

 

 

 

 

 

 

 

SHUTOFF

 

 

 

 

 

 

 

 

 

 

 

SOLENOID

 

SOLENOID

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WELD WINDINGS

 

 

 

 

 

 

 

 

 

STARTER

MECHANICAL

 

 

 

 

 

AUXILIARY

 

 

 

 

 

 

 

 

 

 

 

WINDINGS

 

 

 

 

 

 

 

ROTAT ION

 

 

 

 

 

 

 

 

 

 

 

 

 

ENGINE

 

SLIP

ROTOR

STATOR

Z

Y

 

 

 

 

 

 

 

 

3

 

 

 

 

 

FLYWHEEL ALTERNATOR/

 

RINGS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

VOLTAGE REGULATOR

 

 

 

 

 

 

 

 

TOC

TOC

 

 

 

 

SOLENOID

7

EXCITER

9

 

 

 

6

 

 

 

 

 

WINDING

 

 

 

X

 

Section

Master

 

 

 

 

IDLER

 

 

 

 

 

 

 

 

CONTROL

3

 

DIODE

 

 

3 6 X

 

TOROID*

 

 

 

 

 

4

 

OIL

 

 

 

 

 

 

 

 

 

 

 

1

 

 

PRESSURE

 

 

 

 

 

 

 

 

 

 

 

ENGINE

 

SWITCH

 

FLASHING

 

 

 

 

 

 

 

 

to

 

 

 

 

 

 

 

 

 

 

 

to

 

SWITCH*

2

HOUR

 

 

 

 

 

 

 

 

 

Return

Return

 

+

-

 

FIELD

 

 

 

 

 

 

Z X Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAPACITOR

 

 

 

 

 

 

 

 

 

 

 

 

METER

 

 

 

 

 

 

 

 

 

 

 

 

BATTERY

OUTPUT

 

 

120 & 230 VOLT

 

 

480 VOLT 3 PHASE

 

 

 

CONTROL

 

 

 

 

 

 

 

 

 

 

 

 

 

BREAKERS AND

 

 

BREAKER AND

 

 

 

 

 

 

 

 

 

RECEPTACLES

 

 

RECEPTACLE

 

 

 

 

 

 

 

 

* Lead 254 - 1 turn through the toroid

 

 

 

 

 

 

 

PRINTED CIRCUIT

Leads 3 & 6 - two turns through the toroid in opposite directions.

 

 

 

 

 

 

 

BOARD

Lead X passes though the toroid in the same direction as lead 6

TOC

TOC

GENERAL DESCRIPTION

 

 

 

 

 

 

 

 

 

When the Engine control Switch is released it returns to

Section

Master

The RANGER® 3 PHASE is a twin cylinder, gasoline

tor. It is capable of AC or DC Stick (SMAW) or TIG

the High Idle position.

 

 

driven, multiprocess arc welder and AC power genera-

to

to

(GTAW)

welding

and

CV Wire

welding, either

When the switch is placed in the Auto Idle position, after

Return

Return

Innershield® or MIG

(GMAW). The AC power genera-

a delay of approximately 10 seconds, the Idler Solenoid

 

 

tor is capable of providing 10,500 Watts continuous, 3

will energize and the engine will drop to low speed.

 

 

Phase 60 Hz. AC 480 volt power or 9500 Watts contin-

Upon striking an arc or drawing of current from any of

 

 

uous, Single Phase 60 Hz. AC 120/240 volt power.

the Auxiliary Power receptcles, the solenoid will release

 

 

 

 

 

 

 

 

and the engine will go to the high idle speed. Once the

 

 

ENGINE COMPONENTS AND OPERATION

load is removed, and after a 10 second delay, it will

 

 

return to the low idle condition.

 

 

 

 

 

 

 

 

 

 

The Engine Control Switch is used to start and stop the

The Hour Meter runs whenever the oil pressure switch

 

 

engine and to select the idle mode (High Idle or Auto

 

 

is closed to help keep track of running time for mainte-

 

 

Idle). The Fuel Shutoff Solenoid is activated at first by

 

 

nance concerns.

TOC

TOC

the Engine Control Switch. Then, as oil pressure builds

 

 

up it is held in by the output of the voltage regulator

Turning the Engine Control Switch to the ‘OFF’ Position

 

 

Sectionto

Masterto

through

the oil pressure

switch. If

the oil pressure

will shut down the machine.

switch opens for any reason, the Fuel Solenoid will

 

 

 

 

 

 

 

 

release and the engine will shut down.

 

 

 

 

 

 

 

 

 

Return

Return

 

 

 

 

NOTE: Unshaded areas of Block Logic

 

 

 

 

 

 

Diagram are the subject of discussion

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RANGER® 3 PHASE

Page 35 Page 37
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Page 35 Page 37
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.3Electrical Device USE with the Ranger 3 Phase USE These Devices with a 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 Theory of Operation General DescriptionEngine 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 Rotor Voltage Test Procedure Test DescriptionMaterials 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 Scope Settings Normal Open Circuit Voltage Waveform 115 VAC SupplyHigh 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
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