Lincoln Electric SVM207-A service manual ROTOR, Stator & Control Circuits

Page 37

 

 

E-3

 

 

 

THEORY OF OPERATION

 

E-3

 

 

 

 

 

 

 

 

 

 

 

 

 

TOC

TOC

 

 

 

FIGURE E.2 - ROTOR, STATOR AND CONTROL CIRCUITS

 

 

 

 

 

 

 

 

RANGE

 

 

 

 

 

 

 

 

 

 

 

SWITCH

254

TOROID*

Section

Master

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S2

E

 

 

 

 

ELECTRODE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AC

 

 

to

to

 

 

 

 

 

 

 

 

 

 

TERMINAL

 

 

 

 

 

REACTOR

 

 

OUTPUT +

 

 

 

 

 

 

 

 

CHOKE

POLARITY

Return

Return

 

 

 

 

 

 

 

 

 

AC

BRIDGE

 

SWITCH

 

 

 

 

 

 

 

 

 

 

--

 

WORK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

ROTOR, STATOR & CONTROL CIRCUITS

 

 

 

 

Approximately 10 seconds after the current stops, the

Section

Master

Once the Engine is running and the oil pressure switch

the Control PC Board. This “flashing” voltage energizes

down to the low idle speed. If the Control Power Switch

 

 

closes, 12 VDC is fed to the rotor slip rings by way of

board will re-energize the solenoid and pull the engine

to

to

the rotor and the resulting spinning magnetic field

is in the High Idle position, the signal from the Toroid is

Return

Return

induces power into the windings of the stator. The

ignored.

where it is rectified and regulated and fed back to the

The Weld Winding provides the power for welding.

 

 

exciter winding voltage is routed to the Control Board

 

 

 

 

rotor slip rings. . This regulated supply is used to control

Different portions are used depending on the weld

 

 

the voltage output of the welder. A diode on the PC

mode selected. The full winding is used for DC welding

 

 

Board is used to isolate the exciter voltage from the

while a tapped off portion (WAC) is used for AC welding.

 

 

engine 12 VDC supply. The Output Control is used to

There is also a tap (C1) used for constant voltage (CV)

 

 

adjust the weld voltage.

welding. The Auxiliary Winding is a 3 phase ‘wye’ con-

 

 

 

 

nected 480 VAC supply. Tapped off of one leg are the

 

 

The Idler Circuit is also controlled by the Control PC

230 VAC single phase and the 120VAC single phase

TOC

TOC

Board. A Toroid is used to sense current draw through

supplies for the various receptacles. Each of the recep-

either the weld circuit or any of the auxiliary receptacles.

tacles including the 3 phase receptacle is protected by

Sectionto

Masterto

When current is sensed, a signal from the Toroid caus-

an appropriately sized Circuit Breaker.

es the PC Board to release the Idler Solenoid and the

 

 

 

 

 

 

 

 

engine goes to high speed.

 

 

 

 

 

 

Return

Return

 

NOTE: Unshaded areas of Block Logic

 

 

Diagram are the subject of discussion

 

 

 

 

 

 

 

 

 

 

 

 

 

RANGER® 3 PHASE

Page 36 Page 38
Image 37
Page 36 Page 38
Contents Ranger 3 Phase Ranger 3 Phase SafetyFumes 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 Technical Specifications Ranger 3 Phase K2337-1 & K2337-2 InstallationAuxiliary Power Height Width Depth WeightMachine Grounding Safety PrecautionsSpark Arrester TowingGasoline PRE-OPERATION ServiceVehicle Mounting Can cause fire or explosionTotal Combined Length of Electrode and Work Cables Welding Output CablesHigh Altitude Operation Angle of OperationInstructions Volt 3 Phase Receptacle with Ground Auxiliary PowerGfci Duplex Receptacles 120/240 Volt Dual Voltage ReceptacleStandby Power Connections Ground WireAuxiliary Power While Welding TABLE A.1 Simultaneous Welding and PowerFigure A.3 Connection of Ranger 3 Phase to Premises WiringUSE 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 Operation Engine SwitchGENERAL DESCRIPTION Welder Controls Function and OperationRanger 3 Phase Approximate Fuel Consumption Polarity SwitchRange Switch Control DialWelding Process Wire Feed Welding Processes Constant VoltageStick Constant Current Welding TIG Constant Current WeldingStick Auto BREAK-IN Period STARTING/SHUTDOWN InstructionsStarting the Engine Stopping the EngineTable of Contents Accessories Section K1745-1 Welding GAS Cylinder LPG Tank Holder AccessoriesRECOMMENDED EQUIPMENT WIRE FEEDStick TIGRanger 3 Phase Table of Contents Maintenance Section Safety Precautions MaintenanceAIR Cleaner and Other Maintenance Slip Rings Gfci Receptacle Testing and RESET- Ting ProcedureOIL Filter Change Do not attempt to polish slip rings while engine is runningEngine Maintenance Parts KOHLER C23S BatteryFram CA79 CHAMPION RC12YCFigure D.1 Major Component Location MAINTENANCED-5Ranger 3 Phase 1TABLE of CONTENTS-THEORY of Operation Section E-1 General Description Theory of OperationEngine Components and Operation Figure E.2 ROTOR, Stator and Control Circuits ROTOR, Stator & Control CircuitsFigure E.2 Weld Circuitry Weld Circuitry1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and RepairReturn to Section PC Board Troubleshooting ProceduresDiagram 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 Rotor Voltage Test Test ProcedureRotor Resistance Test Figure F.2 Slip Rings TEST PROCEDUREAuxiliary and Field Winding Test Probes Reading To test the 480 VAC 3 Phase windingAuxiliary Windings To test the 120 VAC windingField Winding Figure F.4 Control PC BoardRanger 3 Phase Output Rectifier Bridge Test + Meter Lead Meter Reading Figure F.5 OUTPUT RECTIFIERToroid 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 Machine Loaded Typical DC Weld Output Waveform CV ModeMachine Loaded to 200 Amps AT 26 VDC Typical DC Weld Output Waveform CC ModeMachine Loaded to 225 Amps AT 25 VDC Typical AC Weld Output WaveformAbnormal 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 Procedure Brush Removal and Replacement ProcedureBrush Assembly Bracket Bolts Ranger 3 Phase Printed Circuit Board Removal Replacement Procedure Figure F.10 Door Removal Printed Circuit Board RemovalOutput Rectifier Bridge Removal Replacement Procedure Figure F.11 OUTPUT RECTIFIER Output Rectifier Bridge RemovalENGINE/ROTOR Removal and Replacement Procedure ENGINE/ROTOR Removal and Replacement Procedure Procedure Figure F.13 Engine and Rotor Removed from Stator Rotor Removal ProcedureReassembly Procedure Retest After Repair Table of Contents Diagram Section RaNGEr 3 phaSE Ranger 3-PHASEL12259 SchEmaTic cOmplETE machiNE l12259ElEcTrical DiaGramS
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