Lincoln Electric SVM207-A Welding Process, Stick Constant Current Welding, ARC Gouging

Page 22

B-4

OPERATION

B-4

 

 

 

 

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WELDING PROCESS

For any electrodes the procedures should be kept with- in the rating of the machine. For electrode information see the appropriate Lincoln publication.

STICK (CONSTANT CURRENT) WELDING

Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine. Set the "Polarity” switch to the desired polarity. The “RANGE” switch markings indicate the maximum current for that range as well as the typical electrode size for that range. The “OUTPUT” Control provides fine adjust- ment of the welding current within the select range. For maximum output within a selected range set the “OUT- PUT” Control at 10. For minimum output within a selected range set the “OUTPUT” Control at 5. (“OUT- PUT” Control settings below 5 may reduce arc stabili- ty) For best overall welding performance set the “RANGE” Switch to the lowest setting and the OUT- PUT” Control near the maximum to achieve the desired welding current.

 

RANGE SETTING

TYPICAL

CURRENT RANGE

 

 

ELECTRODE SIZE

 

 

90 MAX.

3/32

50 TO 90 AMPS

 

 

 

 

 

125 MAX.

1/8

70 TO 145 AMPS

 

 

 

 

 

210(DC)/225(AC)

5/32

120 TO 210(DC),

 

MAX.

 

225(AC) AMPS

 

 

 

 

The RANGER® 3 PHASE can be used with a broad range of AC and DC stick electrodes. See “Welding Tips 1” included with the RANGER 3 PHASE for elec- trodes within the rating of this unit and recommended welding currents of each.

TIG (CONSTANT CURRENT) WELDING

The K930-[ ] TIG Module installed on a RANGER 3 PHASE provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding processes. The TIG Module allows full range output control. After flow time is adjustable from 0 to 55 seconds.

When using the RANGER® 3 PHASE for AC TIG weld- ing of aluminum, the following settings and electrodes are recommended:

SETTINGS FOR PURE TUNGSTEN

TUNGSTEN

RANGE SWITCH

APPROXIMATE

DIAMETER (in.)

SETTINGS

CURRENT RANGE

 

 

 

 

 

 

 

1/8

90

or

145

80

-

150 Amps

3/32

90

or

145

45

-

130 Amps

1/16

 

90

 

40 -

80 Amps

 

 

 

 

 

 

 

SETTINGS FOR  1% THORIATED TUNGSTEN

TUNGSTEN

RANGE SWITCH

APPROXIMATE

DIAMETER (in.)

SETTINGS

CURRENT RANGE

 

 

 

 

 

1/8

90, 145, or 210

80

-

225 Amps

3/32

90 or 145

50

-

180

Amps

1/16

90 or 145

45

-

120

Amps

 

 

 

 

 

 

The K930-[ ] TIG Module should be used with the RANGER® 3 PHASE on high idle to maintain satisfac- tory operation. It can be used in the AUTO position but the delay going to flow idle after welding is ceased will be increased if the AFTER FLOW CONTROL is set above 10 seconds.

WIRE FEED WELDING PROCESSES (CONSTANT VOLTAGE)

The Innershield® electrode recommended for use with the RANGER 3 PHASE is NR®-212-MP. The electrode sizes and welding ranges that can be used with the RANGER® 3 PHASE are shown in the following table:

Diameter

Wire Speed

Approximate

(in.)

Range In./Min.

Current Range

 

 

 

 

.035

80

- 110

75A to 120A

.045

70

- 130

120A to 170A

.068

40

- 90

125A to 210A

 

 

 

 

The RANGER® 3 PHASE is recommended for limited “MIG” welding (GMAW - gas metal arc welding). The recommended electrodes are.030” and .035”SuperArc L-50 and L-56. They must be used with a blended shielding gas such as C25 (75% Argon - 25% CO2). The welding ranges that can be used with the RANGER 3 PHASE are shown in the following table:

Diameter

Wire Speed

Approximate

(in.)

Range In./Min.

Current Range

 

 

 

 

.030

80

- 110

75A to 120A

.035

70

- 130

120A to 170A

 

 

 

 

ARC GOUGING

The RANGER® 3 PHASE can be used for limited arc gouging.

Set the Range switch to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table:

CARBON DIAMETER (in)

CURRENT RANGE (DC, electrode positive)

 

 

1/8

30 - 60 Amps

5/32

90 - 150 Amps

3/16

200 - 250 Amps

 

 

RANGER® 3 PHASE

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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 Auxiliary Power InstallationTechnical Specifications Ranger 3 Phase K2337-1 & K2337-2 Height Width Depth WeightSpark Arrester Safety PrecautionsMachine Grounding TowingVehicle Mounting PRE-OPERATION ServiceGasoline Can cause fire or explosionHigh Altitude Operation Welding Output CablesTotal Combined Length of Electrode and Work Cables Angle of OperationInstructions Gfci Duplex Receptacles Auxiliary PowerVolt 3 Phase Receptacle with Ground 120/240 Volt Dual Voltage ReceptacleAuxiliary Power While Welding Ground WireStandby Power Connections TABLE A.1 Simultaneous Welding and PowerConnection of Ranger 3 Phase to Premises Wiring Figure A.3USE These Devices with a Ranger 3 Phase Electrical Device USE with the Ranger 3 PhaseDevices Without Addi Tional Resistive Type Loads Table of Contents Operation Section GENERAL DESCRIPTION Engine SwitchOperation Welder Controls Function and OperationRange Switch Polarity SwitchRanger 3 Phase Approximate Fuel Consumption Control DialStick Constant Current Welding Wire Feed Welding Processes Constant VoltageWelding Process TIG Constant Current WeldingStick Auto Starting the Engine STARTING/SHUTDOWN InstructionsBREAK-IN Period Stopping the EngineTable of Contents Accessories Section Accessories K1745-1 Welding GAS Cylinder LPG Tank HolderStick WIRE FEEDRECOMMENDED EQUIPMENT TIGRanger 3 Phase Table of Contents Maintenance Section Maintenance Safety PrecautionsOIL Filter Change Gfci Receptacle Testing and RESET- Ting ProcedureAIR Cleaner and Other Maintenance Slip Rings Do not attempt to polish slip rings while engine is runningFram CA79 BatteryEngine Maintenance Parts KOHLER C23S CHAMPION RC12YCMAINTENANCED-5 Figure D.1 Major Component LocationRanger 3 Phase 1TABLE of CONTENTS-THEORY of Operation Section E-1 General Description Theory of OperationEngine 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 Test Description Rotor Voltage Test ProcedureMaterials Needed Test Procedure Rotor Voltage TestRotor Resistance Test TEST PROCEDURE Figure F.2 Slip RingsAuxiliary and Field Winding Test Auxiliary Windings To test the 480 VAC 3 Phase windingProbes Reading 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 Normal Open Circuit Voltage Waveform 115 VAC Supply Scope SettingsHigh 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
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