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Lincoln Electric SVM175-A service manual Theory of Operation Section, Section E-1

Models: SVM175-A

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Section E-1		TABLE OF CONTENTS	Section E-1

	-THEORY OF OPERATION SECTION-
	Theory of Operation		Section E
	General Description		E-2
	Battery, Engine, Rotor, Stator and Engine Protection		E-2
	Engine Idle System		E-3
	Generating Power		E-4
	Weld Power and Control		E-5
	Remote Output Control, Output Contactor, Digital Meters		E-6
	Chopper Technology Fundamentals		E-7
	Pulse Width Modulation		E-8
	Insulated Gate Bipolar Transistor (IGBT) Operation		E-8

FIGURE E.1 – RANGER 305D BLOCK LOGIC DIAGRAM

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12V.

BATTERY

GLOW

PLUG

BUTTON

RUN

STOP

SWITCH

			SHUNT	+
				+
POWER	IGBTs	CHOKE		-
MODULE		CHOKE		-

ENGINE			CHARGING
PROTECTION			CHARGING
LIGHT			SYSTEM LIGHT
			(CODE 10926 ONLY)
ENGINE	ENGINE	GLOW	ENGINE
PROTECTION	ENGINE	GLOW	ENGINE	WELD
CIRCUIT	SENSORS	PLUGS	ALTERNATOR	WELD
				WINDING

PUMP	ENGINE				ROTOR
FUEL	ENGINE
FUEL
SOLENIOD
HOLD COIL
PULL COIL					STATOR
START	STARTER		EXCITER		STATOR	42 VAC		WELD CONTROL			AMP
START	IDLE		EXCITER	120/240 VAC		42 VAC		WELD CONTROL			DISPLAY
BUTTON	IDLE		WINDING AUX.WINDING			WINDING			P.C. BOARD		VOLT
	SOLENOID			240	CURRENT						DISPLAY
	PULL	HOLD		240	SENSOR		14	6
	COIL	COIL	FLASHING	VAC	120		PIN	6
	PULL COIL		FLASHING	RECEPTACLES vac			AMPHENALS	PIN
	PULL COIL
	PC BOARD										IDLE
								OUTPUT	MODE	WELDING	IDLE
								OUTPUT	MODE	WELDING	SWITCH
								CONTROL	SWITCH TERMINAL
								ARC		SWITCH
								CONTROL

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RANGER 305D

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Lincoln Electric SVM175-A service manual Theory of Operation Section, Section E-1

Contents

RangerTM 305D Electric Magnetic Fields SafetyPowered equipment For EngineCan be dangerous Electric Shock can kill ARC Rays can burnFumes and Gases For Electrically Welding Sparks canSAFETYCylinder may explode Cause fire or explosion If damagedTransformateur ET À Précautions DE SûretéPrécautions DE Sûreté Pour LES Machines À Souder ÀMaster Table of Contents for ALL Sections Section A-1 Table of ContentsInstallation Section Lubrication Emissions Fuel System Governor InstallationHeight Width Depth Weight AIR Cleaner Engine Idler Muffler ProtectionModel Number AIR CleanerEngine Warranty Engine ProtectionAngle of Operation Location and Ventilation Safety PrecautionsStoring StackingHigh Altitude Operation High Temperature OperationLifting TowingSpark Arrester PRE-OPERATION Engine Service Battery ConnectionOIL Muffler Outlet PipeElectrical Output Connections Remote Control Machine GroundingAccessories Total Combined Length Welding Output Cables Auxiliary Power ReceptaclesCable Installation Table A.1 Standby Power ConnectionsInstallation Premises or residential elec Figure A.2 Connection of Ranger 305D to Premises WiringSection B-1 Operation SectionOperating Instructions Operation Safety InstructionsAdditional Safety PrecautionsOperation Design FeaturesControl and Settings Figure B.1 Digital Output Meters Wire Feeder Voltmeter SwitchStopping the Engine Diesel Fuel Engine OperationStarting the Engine Before Starting the EngineDownhill Pipe Welding BREAK-IN PeriodStick Welding Table B.2 Typical Current RANGES1 for Tungsten ELECTRODES2TIG Welding ARC Gouging Auxiliary PowerWire WELDING-CV See Table B.2 for reference settingsSimultaneous Welding Auxiliary Power LoadsRanger 305D Simultaneous Welding and Power Loads Ranger 305D Section C-1 AccessoriesWelding Accessories Options / AccessoriesField Installed Options TIG Welding AccessoriesConnection of the Ranger 305D to Electric Wire FeedersWire Feeders Using K867 Universal Connection of LincolnSee Figure C.2 Connection of the LN-25 toRanger 305D Across the ARC Output Control Module See Figure C.3 Volt Remote Output Control Module Connection DiagramRanger 305D with 42 Volt Remote See Figure C.4 Connection Diagram with K857 Remote Control7ACCESSORIESC-7 Connection of the LN-8 to Ranger 305D Using K595 Control Cable See Figure C.6Connection of the LN-742 to Ranger 305D See Figure C.7 Figure C.7 Ranger 305D/LN-742 Connection DiagramRanger 305D Section D-1 MaintenanceEngine Maintenance Safety Precautions Routine and Periodic MaintenanceKubota D722 Diesel Engine Ranger 305D MAINTENANCED-3Engine Oil Refill capacities Engine Oil ChangeSee Table D.2 Oil Filter Change5MAINTENANCED-5 Do not remove cap if radiator is AIR CleanerCooling System Tightening the FAN BeltBattery Maintenance Engine AdjustmentChecking the Electrolyte Level Cleaning the BatteryCharging the Battery Welder / GeneratorGfci Receptacle Testing Resetting Procedure Maintenance Section E-1 Theory of Operation SectionCharging System Battery, Engine, Engine ProtectionBattery Theory of OperationEngine Idle System Idle Solenoid Operation Idle Switch OperationAC output Generating PowerFlashing Building OutputWeld Control and Feedback Weld Power and ControlWeld Power Technology FundamentalsDigital Meters Remote output controlElectronic Output Contactor Inductor ARC Chopper Technology Fundamentals90 VDC DiodeMaximum Output Pulse Width ModulationMinimum Output Section F-1 Troubleshooting & Repair SectionTroubleshooting & Repair Section Section F HOW to USE Troubleshooting Guide 2TROUBLESHOOTING & REPAIRF-2PC Board can be damaged by static electricity Troubleshooting & RepairPC Board Troubleshooting Procedures 3F-3Troubleshooting Guide Brush and Slip Ring TestsEngine Throttle Adjus ment TestEngine Throttle Adjustment Problems Possible AreasSymptoms Misadjustments Course of Action Throttle Adjustment testControl Adjustment Test Control Potentiometer ModeSwitch Resistan Test Switch Resistance TestPotentiometer Mode Switch Test Chopper Module Resistance Switch Test, RemoteMISC. Weld Issues Potentiometer Test Welding output in any modeEngine Alter Engine and Idle ProblemsFuel Solenoid Test. See Fuel Solenoid TestSolenoid Test Perform the Fuel Solenoid TestPerform the Idle Solenoid Test ShutdownEngine and Idle Problems If the solenoid does not hold Engine and Idle Problems Rottle Adjustment Test 21F-21 Case Cover Removal and Replacement ProcedureTest Description Materials NeededReplacement Procedure Case Cover Removal and Replacement Procedure23F-23 Chopper Module Capacitor Discharge ProcedurePerform the Case Cover Removal proce Test ProcedureFuel Shutdown Solenoid Test See 26TROUBLESHOOTING & REPAIRF-26Fuel Shutdown Solenoid Test Figure F.4 Fuel Solenoid Connections 27TROUBLESHOOTING & REPAIRF-27Ranger 305D 29F-29 Engine Throttle Adjustment TestStrobe-Tach Method Engine Throttle Adjustment TestFrequency Counter Method 31TROUBLESHOOTING & REPAIRF-31Engine Throttle Adjustment Test Vibratach Method Low Idle adjustmentHigh idle adjustment 33F-33 Idler Solenoid TestIdler Solenoid Test 34TROUBLESHOOTING & REPAIRF-34Description Engine Alternator TestEngine Alternator Test 36TROUBLESHOOTING & REPAIRF-36Test Procedure Brush and Slip Ring Service Procedure Case Cover Replacement Procedure Brush and Slip Ring Service ProcedurePerform the Case Cover Removal Procedure Cleaning slip rings39F-39 Rotor Resistance and Ground Test StaticRotor Resistance and Ground Test Static 40TROUBLESHOOTING & REPAIRF-40Also referred to as flying resistance test Rotor Resistance and Ground Test DynamicRotor Resistance and Ground Test Dynamic Perform theifbrushnecessaryand.slip ring service procedure43F-43 Rotor Voltage TestRotor Voltage Test 44TROUBLESHOOTING & REPAIRF-44TheEngineS Throttle Adjustment Test . tator Short Rotor Voltage Test Ranger 305D Engine Not Running Flashing Voltage TestFlashing Voltage Test Case Cover Removal ProcedureFlashing Voltage Test 49TROUBLESHOOTING & REPAIRF-49Ranger 305D 51F-51 Stator Voltage TestsTo test the 240 VAC auxiliary winding Stator Voltage TestsTo test the 120 VAC auxiliary winding Stator Voltage Tests 53TROUBLESHOOTING & REPAIRF-53To test the three-phase weld winding To test the 42 VAC wire feeder winding55F-55 Stator Short Circuit & Ground TestStator Short Circuit & Ground Test Perform Case Cover Removal Procedure57F-57 Output Rectifier Bridge TestPerform the Chopper Module Capacitor 58TROUBLESHOOTING & REPAIRF-58Dis harge procedure Output Rectifier Bridge TestFigure F.16 SHUNT/RECTIFIER Leads Output Rectifier Bridge TestTable F.1 Diode Test Table Perform the Case Cover replacement ProcedureChopper Module Function Test Chopper Module Function Test Weld. Control Board PWM Gate Drive Test Procedure. CaseCover ReplacementChopper Module Function Test Ranger 305D Chopper Module Resistance Test Case Cover Removal Rocedure Capacitor Discharge ProcedureChopper Module Resistance Test Table F.2 Diode Test Table Ohmmeter ReadingRanger 305D Weld Control Board PWM Gate Signal Test Weld Control Board PWM Gate Signal Test Weld Control Feedback Test Weld Control Feedback Test Return to Section Ranger 305D Control Potentiometer and Mode Switch Resis Tance Test Cover Replacement procedure 76TROUBLESHOOTING & REPAIRF-76Control Potentiometer and Mode Switch Resistance Test Perform .the Case cover Removal ProcedureTable F.3 Mode SwitchRanger 305D Remote Receptacle Resistance Test See Table F.4 Perform the Case Cover ReplacementRemote Receptacle Resistance Test Table F.4 Welding Terminal Ohmmeter Ohmmeter ReadingRanger 305D Output Rectifier Bridge and Choke Removal Replacement Output Rectifier Bridge and Choke Removal and Replace 84TROUBLESHOOTING & REPAIRF-84Removal Procedure Discharge procedurePerform the Case Cover Removal Replacing the Output RectifierRanger 305D Chopper Module Removal and Replacement Removal Chopper Module Removal and ReplacementProcedure TerminalHL W8 HL W6 ReplacementRanger 305D STATOR/ROTOR Removal and Replacement See Figure F.21 92TROUBLESHOOTING & REPAIRF-92STATOR/ROTOR Removal and Replacement Discharge Pr CedureFigure F.22 Alternator Leads Figure F.21 Wire Guide HoleDo not Hold the Rotor by the Slip Rings Replacing the Rotor Figure F.23 DISC/RING LocationReplacing the Stator Normal Open Circuit Voltage Waveform 120VAC Supply 97TROUBLESHOOTING & REPAIRF-97MAX Control POT High Idle no Load 98TROUBLESHOOTING & REPAIRF-98Normal Open Circuit Voltage Waveform Stick Machine Loaded to 300 Amps AT 27 Volts 99TROUBLESHOOTING & REPAIRF-99Normal Weld Voltage Waveform Stick CC Normal Open Circuit Voltage Waveform Wire CV TAP 100TROUBLESHOOTING & REPAIRF-100Machine Loaded to 300 Amps AT 28 Volts 101TROUBLESHOOTING & REPAIRF-101Normal Weld Voltage Waveform Wire CV Retest After Repair Auxiliary Power OutputSection G-1 Electrical Diagrams SectionElectrical Diagrams Section G Wiring Diagram Entire Machine Code 10926 G4250 Electrical DiagramsWiring Diagram Entire Machine Codes 11121 G4571 Ranger 305D- Kubota Wiring DiagramWiring Diagram Entire Machine Codes 11188, 11275 G4571-1 Ranger 305D- Kubota Wiring DiagramWiring Diagram Entire Machine Codes 11027 G4226 Ranger 305D CE Kubota Wiring Diagram UKAlternator Wiring Diagram Entire Machine Codes 11122 G4572Ranger 305D CE Kubota Wiring Diagram UK Wiring Diagram Entire Machine Codes 11039 G4409 Ranger 305D CE Kubota Wiring Diagram EuropeWiring Diagram Entire Machine Codes 11123 G4573 Ranger 305D CE Kubota Wiring Diagram -EUROPEWiring Diagram Entire Machine Codes 11190, 11315 G4573-1 L11946 +12V Isolated Circuitry for Engine Functions L12212 Machine Schematic L12212-1 L12212-1 L12039 Diagrams L12213 Schematic Entire Machine Code 11122 L12213 page 2 L12213-1 Schematic Entire Machine Codes 11189, 11314 L12213-1 page 2 Schematic Entire Machine Code 11039 L12038 page 1 Schematic Entire Machine Code 11039 L12038 L12214 Schematic Entire Machine Code 11123 L12214 page 2 L12214-1 L12214-1 Schematic Weld Control PC BD ALL Codes G4108-1 PG 1 Schematic Weld Control PC BD ALL Codes G4108-1 PG 2 Schematic Weld Control PC BD ALL Codes G4108-1 PG 3 Schematic Weld Control PC BD ALL Codes G4108-1 PG 4 Schematic Weld Control PC BD ALL Codes G4108-1 PG 5 PC Board Assembly Weld Control PC BD ALL Codes G4107-1 Schematic Pull Coil PC BD ALL Codes G4117-1 PC Board Assembly Pull Coil PC BD ALL Codes L11768-1 Schematic Chopper PC BD ALL Codes M19792-1 54811L PC Board Assembly Chopper PC BD ALL Codes L11845-1