Lincoln Electric SVM168-B service manual Theory of Operation Section, Section E-1

Page 35

Return to Master TOC

Return to Master TOC

Return to Master TOC

Section E-1

TABLE OF CONTENTS

Section E-1

 

- THEORY OF OPERATION SECTION -

 

 

 

 

Theory of Operation

...............................................................................................Section E

Battery, Starter, Engine, Excitation, Rotor,

Stator, and Idler Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2 Rotor Field Feedback and Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3 Weld Winding, Reactor, and Range Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4 Output Bridge, Choke, Polarity Switch, and Output Terminals . . . . . . . . . . . . . . . . .E-5

FIGURE E.1 – RANGER® 10,000 BLOCK LOGIC DIAGRAM

SWITCHRANGE

 

 

 

 

AC

CHOKE

POLARITY

ELECTRODE

 

 

REACTOR

CV

OUTPUT

TERMINAL

 

 

AC BRIDGE

 

SWITCH

 

 

 

 

TAP

 

 

 

 

 

 

 

STATOR

 

 

 

WORK

 

MECHANICAL

 

 

 

 

TERMINAL

 

 

 

 

 

 

 

 

ROTAT ION

ROTOR

 

 

 

 

 

STARTER

ENGINE

ROTOR

 

 

 

 

SLIP

 

 

 

 

 

FLYWHEEL

RINGS

 

 

 

 

 

 

ALTERNATOR

 

STATOR

 

 

 

 

 

IDLER

 

 

 

 

 

 

SOLENOID

 

 

 

 

 

 

Return to Master TOC

BATTERY

FIELD

 

CAPACITOR

 

OUTPUT

 

CONTROL

 

PRINTED CIRCUIT

 

BOARD

115 & 230VAC

RECEPTACLES

RANGER® 10,000 & RANGER® 10,000 PLUS

Image 35
Contents Ranger 10,000 /10,000 Plus For Engine SafetyPowered equipment Fumes and Gases ARC Rays can burnIii Welding and Cutting Sparks can cause fire or ExplosionCylinder may explode If damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Section A-1 Table of ContentsInstallation Section Height Width Depth Weight InstallationHorsepower Operating Speed RPM Towing Safety PrecautionsSpark Arrester Machine GroundingCan cause fire or explosion PRE-OPERATION ServiceGasoline Vehicle MountingLifting Welding Output CablesTotal Combined Length of Electrode and Work Cables Angle of OperationWelder Operation Connection of Lincoln Electric Wire FeedersInstructions StackingMotor Starting Auxiliary Power120/240 Volt Dual Voltage Receptacle Duplex ReceptaclesNot USE These Devices With a Ranger 10,000 These Devices Without Additional Resistive Type LoadsStandby Power Connections Simultaneous Welding and PowerFigure A.1 Ranger 10,000 & Ranger 10,000 Plus Operation Operation SectionSection B-1 Welder Controls Function and Operation Engine SwitchOperation Control Dial Polarity SwitchRange Switch Kohler Honda Robin / Subaru 20 H.P. CommandStopping the Engine STARTING/SHUTDOWN InstructionsBREAK-IN Period Starting the EngineTIG Constant Current Welding Wire Feed Welding Processes Constant VoltageStick Constant Current Welding Summary of Welding Processes Start Switch Wire FEED, LN-15Section C-1 Accessories SectionOptional Equipment Field Installed AccessoriesPlasma Cutting Recommended EquipmentStick TIG WeldingRanger 10,000 & Ranger 10,000 Plus Section D-1 Maintenance SectionKohler Honda MaintenanceSafety Precautions OIL Filter Change AIR Cleaner and Other MaintenanceSlip Rings Engine AdjustmentsBattery Overspeed is HazardousElement Pre-CleanerOil Filter Air FilterFigure D.1 Major Component Location Theory of Operation Theory of Operation SectionSection E-1 Theory of Operation BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler SolenoidFigure E.3 Rotor Field Feedback and Auxiliary Power Rotor Field Feedback and Auxiliary PowerFigure E.4 Weld WINDING, REACTOR, and Range Switch Weld WINDING, REACTOR, Range SwitchOutput BRIDGE, Choke Polarity SWITCH, and Output Terminals Ranger 10,000 & Ranger 10,000 Plus Section F-1 Troubleshooting & Repair SectionHOW to USE Troubleshooting Guide Troubleshooting & RepairElectric Shock PC Board Troubleshooting ProceduresOutput Problems Troubleshooting GuideOutput Problems Field Winding Voltage Test Adjustment Test Troubleshooting Guide Output Problems Engine Problems Make sure the leads are looped Charging Circuit Test Welding Problems Ranger 10,000 & Ranger 10,000 Plus Materials Needed Rotor Voltage TestTest Description Test Procedure Rotor Resistance Test Figure F.2 Location of Rotor Slip Rings Rotor Resistance TestTroubleshooting & Repair Ranger 10,000 & Ranger 10,000 Plus Auxiliary and Field Winding Test To test the 230 VAC winding Auxiliary and Field Winding TestTo test the 115 VAC winding To test the field winding Ranger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Test Figutpure F.4 Locationctifof Output Rectifier Leads 26TROUBLESHOOTING & REPAIRF-26Output Rectifier Bridge Test Charging Circuit Test Figure F.5 Location of Voltage Regulator Charging Circuit TestEngine Throttle Adjustment Test Figure F.6 Blower Paddle Marked for STROBE-TACH Method Engine Throttle Adjustment TestFigure F.7 Oscilloscope Method High Idle no Load Output Control AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded to 200 Amps AT 20 VDC Typical DC Weld Output Waveform CV ModeMachine Loaded Machine 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 10,000 & Ranger 10,000 Plus Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementFigure F.9 Brush LEADS/BRUSHES Retained with Cable TIE Slip RingsRanger 10,000 & Ranger 10,000 Plus Printed Circuit Board Removal Replacement Figure F.10 Printed Circuit Board Location Printed Circuit Board Removal and ReplacementPrinted Circuit Board Removal ReplacementRanger 10,000 & Ranger 10,000 Plus Output Rectifier Bridge Removal Replacement Output Rectifier Bridge Removal Remove the case top, then reinstall the fuel capSection TOC Ranger 10,000 & Ranger 10,000 Plus Instructions ENGINE/ROTOR Removal and ReplacementFigure F.12 Component LOCATIONS, ENGINE/ROTOR Removal ENGINE/ROTOR RemovalEngine and Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from Stator THRU-BOLT Rotor Removal ProcedureReassembly Procedure Replacement KIT S20788Retest After Repair Section G-1 Electrical Diagrams SectionElectrical Diagrams Wiring Diagram Code 11041 only -M20226 Electrical DiagramsRanger 10,000 Honda Wiring Diagram Code 11095 only M20301Ranger 10,000 Wiring Diagram Code 11398 M21269 Ranger 10,000 Plus L13105 Schematic Entire Machine Codes 11395 and 11398 L13105L13103 Schematic Entire Machine CDE 11394 L13103Schematic Entire Machine Code 11095 & 11253 only L12257 L12249 Schematic Entire Machine Code 11151 only L12249-1Electrical Diagrams Electrical Diagrams