Lincoln Electric SVM207-A service manual Ranger 3-PHASE, RaNGEr 3 phaSE

Page 92

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G-2

 

 

 

ElEcTrical DiaGramS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G-2

WiriNG DiaGram - cOmplETE machiNE - m20315

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RANGER 3-PHASE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LEADS 3 AND 6:

 

 

 

 

 

213

 

 

 

 

 

 

 

 

 

LEADS 254 PASSES THRU

 

 

 

 

2 TURNS THRU TOROID IN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OPPOSITE DIRECTIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TOROID 1 TIME

 

 

 

6

 

 

LEAD X PASSES THRU TOROID

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

ONCE IN SAME DIRECTION

 

 

 

 

 

 

 

 

 

 

 

 

L1

 

 

 

254

 

 

 

261

AS LEAD 6.

CCW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHOKE

 

 

 

 

 

 

260

OUTPUT

R1

 

 

 

 

 

 

209A

 

GROUND SCREW

 

 

 

 

 

 

 

 

 

 

X

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROL

 

 

 

 

 

 

 

211

 

ON UPPER CASEFRONT

 

 

 

 

 

POSITIVE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

 

10

 

 

 

 

 

 

76A

75A

 

 

 

 

 

 

 

 

 

 

B

 

 

 

 

 

 

 

 

 

 

 

77A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WAC

W1

 

D1

 

 

 

 

 

 

 

 

 

 

 

 

 

208C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

-

S3

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PCB1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

2

 

 

 

 

 

 

 

 

5D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

213A

 

 

 

 

 

 

 

 

 

 

254

 

 

 

 

 

J2

 

 

 

 

 

CB7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

GND-E

GND-J

 

 

 

 

 

S1

 

 

 

 

 

 

4

 

213A

 

 

 

 

25A

 

 

WORK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5F

 

 

 

 

 

 

S2

E

 

 

 

12

 

 

 

7

 

 

 

 

 

 

 

 

 

 

 

 

R1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRODE

 

 

 

 

 

 

 

 

 

8

 

 

 

J1

 

 

 

 

 

IDLER

 

 

 

 

 

 

R3

R5

C1

 

 

 

10

 

 

 

210

 

 

 

 

 

GND-I

 

 

 

 

 

S1

 

 

 

 

 

 

1

 

 

 

 

SOLENOID

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

200A 219

75A 77A 224 215

76A 5E

 

224

224A

 

+

 

 

GND-G

 

GROUND SCREW

 

W2

REACTOR

 

6

3

7

9

 

 

 

 

 

 

GND-C

 

ON LOWER

 

 

 

 

 

 

 

 

 

 

 

 

HOUR METER

215

 

CASEFRONT

 

WAC

C1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GND-D

 

 

 

 

STATOR

 

 

3

6

9

 

7

 

 

 

 

 

 

 

5D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GND-I

W1

 

 

 

 

 

 

 

Z

 

Y

 

 

 

 

 

 

 

5E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GND-E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

224A

208

211

209

 

 

 

3

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

75A

77A

 

 

+

 

 

 

 

 

 

LEAD X FROM STATOR TO

 

 

 

6

 

 

76A

 

224C

 

209A

12 VOLT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PASS THROUGH TOROID

 

 

 

 

 

 

 

 

 

TERMINAL BLOCK

 

J5

BATTERY

 

 

 

 

 

 

GND-D

ONCE (NOT SHOWN)

 

 

 

X

 

 

 

 

B B B

 

 

 

 

 

 

6A

 

IN SAME DIRECTION

 

 

 

 

 

 

 

2

3 4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(SEE CONN.)

1

 

 

 

 

 

 

 

 

AS LEAD 6.

 

 

 

Z

X

Y

 

 

 

 

W

 

 

P5

 

-

 

 

 

 

 

 

 

 

 

 

J2

 

 

 

 

 

 

 

 

 

R

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

V

 

R

 

 

ENGINE

6 CB1

GND-G

 

 

 

 

HOT

120V

 

CB1

 

 

 

 

 

 

 

 

 

 

U

 

 

 

50A

 

 

 

 

 

 

 

GFCI

 

15 AMP

 

 

 

 

 

 

210

 

 

 

 

 

 

FOOT

 

 

 

 

 

 

 

 

NEUT

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

GND-H

 

 

 

 

6B

 

 

 

 

 

 

Z

 

 

 

 

 

OIL

N.A.

 

 

CR1

 

12

 

 

 

5L

 

 

5K

 

 

 

 

 

 

 

219 200A

 

 

 

 

 

 

 

 

 

 

 

 

X

 

 

 

PRESSURE

 

STARTER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SOLENOID

 

 

ENGINE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

+

SWITCH

 

 

 

 

J4

 

11

 

120V

 

 

 

 

 

 

 

 

 

 

 

 

IGNITION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REGULATOR

 

 

 

CROSS

120V/240V

 

 

GFCI

 

 

HOT

 

3B

 

 

 

 

 

 

 

 

 

MODULE

STARTER

 

 

SUPPORT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AC B+

AC

B-

FUEL

 

GND-C

 

 

 

 

 

 

 

 

CB4

 

X

 

 

Z

 

 

ROTOR

 

 

 

 

 

SHUTOFF

 

 

11

 

 

 

J3

 

NEUT

 

20A

 

 

 

 

 

SLIP RING NEAREST LAMINATION

 

 

 

 

 

 

 

CB2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SOLENOID

 

 

50A

5K

CB3

 

 

 

 

 

 

 

 

GND-I

 

480 V

 

 

 

 

FLYWHEEL ALTERNATOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

20A

 

 

5L

 

5

 

 

 

 

 

3-PHASE

 

 

 

ENGINE COMPONENTS

 

 

 

 

 

SILVER COLORED 3A

 

 

 

 

 

 

 

 

3A

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TERMINALS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(WHITE WIRES)

 

 

 

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

 

Section TOC

Master TOC

N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE.

LEAD COLOR CODE:

B = BLACK OR GRAY

U = BLUE

R = RED OR PINK

V = VIOLET

W = WHITE

 

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM

 

 

 

 

 

GENERATOR LEAD END

 

CONNECTOR PIN NUMBERS:

(NOTE CAVITY NUMBERS)

 

 

4

3

12

 

 

7

 

 

 

 

 

211 (CAVITY #3)

 

 

6

3

2

224C (CAVITY #4)

2

1

1

J2

 

J1

 

LOCATING TAB

 

 

208 (CAVITY #2)

 

 

 

 

 

TERMINAL BLOCK

CONNECTION

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ELECTRICAL SYMBOLS PER E1537

C

M20315PRINT

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

raNGEr® 3 phaSE

Page 91 Page 93
Image 92
Page 91 Page 93
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.3Devices Without Addi Tional Resistive Type Loads Electrical Device USE with the Ranger 3 PhaseUSE These Devices with a Ranger 3 Phase 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 Engine Components and Operation Theory of OperationGeneral Description 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 Materials Needed Rotor Voltage Test ProcedureTest Description 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 High Idle no Load Output Control AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115 VAC Supply 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 Stator Reassembly Procedure Retest After Repair Table of Contents Diagram Section Ranger 3-PHASE RaNGEr 3 phaSESchEmaTic cOmplETE machiNE l12259 L12259ElEcTrical DiaGramS
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