Lincoln Electric SVM207-A manual

Return to Master TOC

Return to Master TOC

E-1TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Engine Components and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Rotor, Stator and Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Weld Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

FIGURE E.1 BLOCK DIAGRAM

to Master TOC

STARTER	FUEL
STARTER	SHUTOFF
SOLENOID	SOLENOID
	STARTER	MECHANICAL
		ROTAT ION

	RANGE
	SWITCH	254	TOROID*
		254	TOROID*
S2	E
S2		AC
		AC
REACTOR		OUTPUT +	CHOKE	POLARITY
		AC BRIDGE		SWITCH
		--
W2	C1 WAC W1
WELD WINDINGS

AUXILIARY

WINDINGS

ELECTRODE TERMINAL

WORK TERMINAL

Return

Master TOC

			ENGINE
		FLYWHEEL ALTERNATOR/
			VOLTAGE REGULATOR
			IDLER
			SOLENOID
	4		OIL
1			PRESSURE
1	ENGINE		SWITCH
	ENGINE	3
	CONTROL	3
	SWITCH*	2
	+	-	HOUR
			METER
	BATTERY		OUTPUT
			CONTROL

SLIP

RINGS

FLASHING

DIODE

FIELD CAPACITOR

	ROTOR	STATOR	Z	Y
	ROTOR	STATOR		3
				3
				5
	EXCITER			6
	WINDING
7	9			X
		3 6 X	TOROID*

Z X Y

120 & 230 VOLT	480 VOLT 3 PHASE
BREAKERS AND	BREAKER AND
RECEPTACLES	RECEPTACLE

Return to

*	Lead 254 - 1 turn through the toroid
PRINTED CIRCUIT	Leads 3 & 6 - two turns through the toroid in opposite directions.
BOARD	Lead X passes though the toroid in the same direction as lead 6

RANGER® 3 PHASE

Image 35

Lincoln Electric SVM207-A service manual 1TABLE of CONTENTS-THEORY of Operation Section E-1

Contents

Ranger 3 Phase Ranger 3 Phase Safety Fumes 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 Height Width Depth Weight InstallationTechnical Specifications Ranger 3 Phase K2337-1 & K2337-2 Auxiliary Power Towing Safety PrecautionsMachine Grounding Spark Arrester Can cause fire or explosion PRE-OPERATION ServiceGasoline Vehicle Mounting Angle of Operation Welding Output CablesTotal Combined Length of Electrode and Work Cables High Altitude Operation Instructions 120/240 Volt Dual Voltage Receptacle Auxiliary PowerVolt 3 Phase Receptacle with Ground Gfci Duplex Receptacles TABLE A.1 Simultaneous Welding and Power Ground WireStandby Power Connections Auxiliary Power While Welding Figure A.3 Connection of Ranger 3 Phase to Premises Wiring Devices 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 Welder Controls Function and Operation Engine SwitchOperation GENERAL DESCRIPTION Control Dial Polarity SwitchRanger 3 Phase Approximate Fuel Consumption Range Switch TIG Constant Current Welding Wire Feed Welding Processes Constant VoltageWelding Process Stick Constant Current Welding Stick Auto Stopping the Engine STARTING/SHUTDOWN InstructionsBREAK-IN Period Starting the Engine Table of Contents Accessories Section K1745-1 Welding GAS Cylinder LPG Tank Holder Accessories TIG WIRE FEEDRECOMMENDED EQUIPMENT Stick Ranger 3 Phase Table of Contents Maintenance Section Safety Precautions Maintenance Do not attempt to polish slip rings while engine is running Gfci Receptacle Testing and RESET- Ting ProcedureAIR Cleaner and Other Maintenance Slip Rings OIL Filter Change CHAMPION RC12YC BatteryEngine Maintenance Parts KOHLER C23S Fram CA79 Figure D.1 Major Component Location MAINTENANCED-5 Ranger 3 Phase 1TABLE of CONTENTS-THEORY of Operation Section E-1 Engine Components and Operation Theory of OperationGeneral Description Figure E.2 ROTOR, Stator and Control Circuits ROTOR, Stator & Control Circuits Figure E.2 Weld Circuitry Weld Circuitry 1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and Repair Return to Section PC Board Troubleshooting Procedures Diagram 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 Rotor Voltage Test Test Procedure Rotor Resistance Test Figure F.2 Slip Rings TEST PROCEDURE Auxiliary and Field Winding Test To test the 120 VAC winding To test the 480 VAC 3 Phase windingProbes Reading Auxiliary Windings Field Winding Figure F.4 Control PC Board Ranger 3 Phase Output Rectifier Bridge Test + Meter Lead Meter Reading Figure F.5 OUTPUT RECTIFIER Toroid 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 Machine Loaded Typical DC Weld Output Waveform CV Mode Machine Loaded to 200 Amps AT 26 VDC Typical DC Weld Output Waveform CC Mode Machine Loaded to 225 Amps AT 25 VDC Typical AC Weld Output Waveform Abnormal 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 Procedure Brush Assembly Bracket Bolts Ranger 3 Phase Printed Circuit Board Removal Replacement Procedure Figure F.10 Door Removal Printed Circuit Board Removal Output Rectifier Bridge Removal Replacement Procedure Figure F.11 OUTPUT RECTIFIER Output Rectifier Bridge Removal ENGINE/ROTOR Removal and Replacement Procedure ENGINE/ROTOR Removal and Replacement Procedure Procedure Figure F.13 Engine and Rotor Removed from Stator Rotor Removal Procedure Reassembly Procedure Retest After Repair Table of Contents Diagram Section RaNGEr 3 phaSE Ranger 3-PHASE L12259 SchEmaTic cOmplETE machiNE l12259 ElEcTrical DiaGramS