Lincoln Electric SVM207-A service manual Toroid Test

Page 60

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F-22

TROUBLESHOOTING AND REPAIR

F-22

 

TOROID TEST (continued)

FIGURE F.6 – TOROID ASSEMBLY

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LEAD ‘X’

LEAD 254

LEAD 6

LEAD 3

LEAD 213A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROL

 

 

 

 

D10

B

 

 

B2

 

 

 

 

 

D16

D21

DZ10 R11 C39 R44 R51

R52 C24 C23 C22 R10

C13

R91

R99 C14

1

 

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L12198-1

 

 

 

 

 

 

 

 

 

J1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TP1

 

 

 

R71

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7

 

 

 

 

 

 

12

 

 

 

C1

 

 

 

 

DZ8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R72

 

 

R96

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R87

 

 

 

 

 

 

 

 

 

 

R95

 

 

 

 

 

 

TP2

 

 

R73

 

 

 

 

 

R82 C19

X3

 

 

C42 C43 C41

 

 

 

 

 

 

 

 

 

 

 

R74

 

 

 

 

 

 

 

 

 

R94

 

 

 

R41

 

 

 

 

R89

 

D28

D15

 

 

 

 

 

 

 

 

R7

 

R100

R101

 

 

R62

 

 

R67

 

 

 

D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R34

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R68

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R97

R65 R66

 

 

C2

 

 

 

R81 R39 C30 R31 D11

 

R43

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R69

 

 

 

 

 

 

X5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R70

 

 

 

 

 

 

 

R49

 

R53

D14

DZ3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R32

 

 

D3

 

 

 

 

 

 

 

 

 

 

 

 

C

 

 

 

R16

 

 

 

 

 

C26

 

 

 

 

 

 

 

 

 

C36

 

 

 

 

 

FTP1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R17

R18 R20 C40 C28 R33

 

 

R23

 

 

 

R57

 

 

 

 

 

 

 

 

C37

 

 

C12

 

 

 

 

 

 

 

 

 

R47

 

 

 

 

 

 

 

 

 

 

 

 

 

B1

 

 

 

 

 

 

X4

 

 

 

 

 

 

 

R56

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C27

Q6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Q3

 

 

Q1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DZ1 DZ9

 

 

 

 

 

A

 

 

DZ7

 

 

 

 

 

 

D1

R5

 

R88

 

R15 R14

C3

R13

R76 R77

D18

R75 R78

 

X1

 

 

C10

D2

 

 

 

R83

 

 

 

 

 

 

 

 

 

 

C4

 

C7

R84

 

 

 

D9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R85

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

3

 

C38 D19

 

 

 

 

 

 

 

 

 

DZ4

DZ5

 

Q4

 

R21

 

R4

 

R58

 

 

 

 

 

 

 

R98

C32 R79 C31 R45 R12 R80 R40 C35 R102

DZ2

D4 R19 R42 R29 DZ11

R48 R46

 

 

 

 

 

 

 

 

 

2

J2

1

Q5

C29

 

 

 

 

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TEST PROCEDURE

1.With a 5/16” nut driver or socket, remove the 6 sheet metal screws from the case top.

2.Remove the rubber gasket (cover seal) from the lift bail.

3.Remove the fuel cap. The rubber gasket for the fill tube will come off with the case top.

4.Remove the case top, then replace the fuel cap.

5.Remove the screws holding the right case side.

6.Remove the right case side by lifting up and out.

7.Start the engine and set it to AUTO and wait for it to drop to low idle (2400 rpm).

8.Plug a trouble light with a 100 watt bulb into one of the 120VAC receptacles.

The machine should go to High Idle.

If it does not, measure the voltage across the toroid leads (260 and 261) at pins 3 and 4 of J2. See Figure F.6. It should be approximately 2.8VAC.

If the voltage is correct, the Control Board may be defective.

If the voltage is not correct, the toroid may be defective.

9. Shut the engine OFF.

NOTE: If the Toroid needs to be replaced, pay close attention to the direction that the various leads are routed through it. See the Wiring Diagram for exact instructions.

RANGER® 3 PHASE

Image 60
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