Lincoln Electric SVM168-B Stick Constant Current Welding, TIG Constant Current Welding

Page 23

B-5

OPERATION

B-5

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ForWELDINGany electrodesPROCESSthe 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

40 TO 90 AMPS

145 MAX.

1/8

70 TO 145 AMPS

210(DC)/225(AC)

5/32

120 TO 210(DC),

MAX.

 

225(AC) AMPS

 

 

 

The RANGER® 10,000 can be

used with a broad

range of AC and DC stick electrodes. See “Welding

Tips 1” included with the RANGER® 10,000 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® 10,000 provides high frequency and shielding gas con- trol for AC and DC GTAW (TIG) welding processes. Output control is from the RANGER® 10,000. The out- put control on the TIG Module is not functional. After flow time is adjustable from 0 to 55 seconds.

When using the RANGER® 10,000 for AC TIG welding 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

should

50

-

180 Amps

The K930-[

] TIG Module

be used

with the

1/16

90 or 145

 

45

-

120 Amps

RANGER® 10,000 on high idle to maintain satisfactory operation. It can be used in the AUTO position but the delay going to low idle after welding is ceased will be increased if the AFTER FLOW CONTROL is set above 10 seconds.

For AC TIG Welding, the maximum TIG welding outputNOTE: currents on each range setting will be approxi- mately 50% higher than those marked on the nameplate. This is due to the special nature of the AC TIG welding arc. Do not AC TIG weld on the 225AC range setting. The output current may exceed the rating of the RANGER® 10,000.

WIRE FEED WELDING PROCESSES

(CONSTANT VOLTAGE)

The Innershield® electrode recommended for use with the RANGER® 10,000 is NR®-211-MP. The electrode sizes and welding ranges that can be used with the RANGER® 10,000 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®

10,000 is recommended

for limited “MIG”

welding (GMAW - gas metal arc welding). The recom-

mended electrodes are .030” and .035” 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® 10,000 are shown in the

following table:

 

 

 

Diameter

Wire Speed

Approximate

(in.)

Range In./Min.

Current Range

.030

75

- 300

50A to 130A

.035

100

- 250

90A to 175A

TheARCRANGER®GOUGING10,000 can be used for limited arc goug- ing. 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:

ELECTRODE SETTING

CURRENT RANGE (DC, electrode positive)

 

 

1/8

30 - 60 Amps

5/32

90 - 150 Amps

3/16

150 - 250 Amps

 

 

RANGER® 10,000 & RANGER® 10,000 PLUS

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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 Switch Operation 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
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