Lincoln Electric SVM207-A service manual Wiring

Page 45

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F-7

 

TROUBLESHOOTING AND REPAIR

 

 

 

F-7

 

 

 

 

 

 

 

 

 

 

 

 

 

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

 

 

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

ENGINE PROBLEMS

 

 

 

 

 

Engine will not go to high idle when

1. Automatic idler may not function

1. Check that the leads are cor-

attempting to weld or when the aux-

if the auxiliary power is loaded to

rectly

wrapped

through the

iliary power is loaded. Welding out-

less than 100 Watts.

Toroid.

See Wiring Diagram.

put and

auxiliary

power output is

 

2. Perform the Toroid Test.

 

normal when Idler Switch is in the

 

 

 

 

 

 

 

 

“HIGH” position.

 

 

3. The Printed Circuit Board may

 

 

 

 

be faulty. Replace.

 

 

 

 

Engine will not go to high idle when

1. Make sure the welding cables

1. Check for broken or faulty con-

attempting to weld. Welding output

and connections are tight.

nections in the sensing lead

is normal when Idler Switch is in

 

(#254). Make sure the connec-

“HIGH”

position.

Automatic idle

 

tions are tight at the Output

function works properly when the

 

Rectifier

and

the

Polarity

auxiliary power is loaded.

 

Switch.

See

the

Wiring

 

 

 

 

Diagram.

 

 

 

 

 

 

 

2. Make sure the #254 lead is

 

 

 

 

wrapped

properly through the

 

 

 

 

Toroid.

See

the

Wiring

 

 

 

 

Diagram.

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

RANGER® 3 PHASE

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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 WiringElectrical 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 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 Theory of Operation General DescriptionEngine 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 Rotor Voltage Test Procedure Test DescriptionMaterials 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 Scope Settings Normal Open Circuit Voltage Waveform 115 VAC SupplyHigh 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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