Lincoln Electric SVM107-B service manual Weld WINDING, REACTOR, Range Switch

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E-4

E-4

THEORY OF OPERATION

FIGURE E.4 – WELD WINDING, REACTOR, AND RANGE SWITCH

RANGE

SWITCH

 

AC

 

 

ELECTRODE

 

 

 

 

 

OUTPUT

CHOKE

POLARITY

TERMINAL

 

 

REACTOR

AC BRIDGE

 

SWITCH

 

 

 

 

 

 

WORK

STATOR

TERMINAL

MECHANICAL

ROTATION

ROTOR

STARTER ENGINESLIPROTOR

RINGS

Section

to Master

FLYWHEEL

ALTERNATOR

IDLER

STATOR

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SOLENOID

PRINTED

CIRCUT

BOARD

BATTERY

FIELD

CAPACITOR

115 & 230VAC

RECEPTACLES

OUTPUT

CONTROL

FIELD

BRIDGE

WELD WINDING, REACTOR, AND

RANGE SWITCH

The stator weld winding is connected to the reactor and range switch. The inductance in the reactor offers an impedance to current flow. The reactor coil is tapped at various points. As the range switch is ro- tated, different amounts of reactor coil are brought into the current path. As more turns of reactor are brought into the circuit, the more impedance there is to current flow. Simply stated, the more reactor in the circuit, the lower the welding current.

If a constant voltage is desired for wire feeding, then the reactor is bypassed and the range switch is con- nected to a tap on the stator weld winding to provide a lower but “stiffer” output voltage.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

RANGER 8

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Contents Rangertm Safety Electric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Auxiliary Power Welding Output50 100 150 200 250 300 350 Output Amps 20 B50 100 150 200 Installation Instructions AWG Battery ConnectionsOil FuelAngle of Operation Ranger Connection of the LN-7 to the RangerWelder Output Constant CurrentDuplex Receptacles Motor StartingElectrical Device USE with the Ranger Type Common Electrical Devices Possible ConcernsAuxiliary Power While Welding Standby Power ConnectionsConnection of Ranger 8 to Premises Wiring Figure A.1Ranger Table of Contents Operation Section AC/DC TIG Welding Constant Current DC Semiautomatic Wire Feed Welding Constant VoltageAC/DC Stick Welding Constant Current Range Switch settings in the STICK/TIG mode Control SwitchProvides a fine welding current adjustment within Welding voltage control with the Range switch setStarting/Shutdown Instructions Stopping the EngineTIG Constant Current Welding Wire Feed Welding Processes Constant VoltageStick Constant Current Welding Summary of Welding Processes Stick AutoSection C-1Section C-1 Accessories Recommended Equipment Ranger Table of Contents Maintenance Engine OIL Refill Capacities Routine MaintenanceEngine OIL Change Kohler Onan HondaOIL Filter Change Pre-Cleaner Engine AdjustmentsEngine Maintenance Parts Slip RingsFigure D.1 Major Component Locations Ranger Table of Contents Theory of Operation Section Theory of Operation Rotor Field Feedback and Auxiliary Power Weld WINDING, REACTOR, Range Switch Output BRIDGE, Choke Polarity SWITCH, and Output Terminals Ranger Table of Contents Trouble Shooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuideDevices PC board can be damaged by static electricityStatic-Sensitive Handle only atTroubleshooting Guide Output ProblemsObserve Safety Guidelines Detailed in the beginning of this manualTroubleshooting & Repair Troubleshooting & Repair Troubleshooting Guide Troubleshooting & Repair Engine Problems Troubleshooting & Repair Troubleshooting & Repair Welding Problems Ranger Materials Needed Rotor Voltage TestTest Description Test Procedure Rotor Resistance Test Rotor Resistance Test Troubleshooting & Repair Ranger Auxiliary and Field Winding Test To test the 115 VAC winding To test the 230 VAC windingTo test the field winding Ranger Output Rectifier Bridge Test Output Rectifier Bridge Test Charging Circuit Test Charging Circuit Test Engine Throttle Adjustment Test Engine Throttle Adjustment Test Engine Throttle Adjustment Test Oscilloscope Method High Idle no Load Output Control AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115 VAC Supply 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 Brush Removal and Replacement DescriptionBrush Removal and Replacement ProcedureSlip Rings Figure F.10 Brush LEADS/BRUSHES Retained with Cable TIERanger Field Capacitor AND/OR Rectifier Bridge Removal Replacement Replacement Field Capacitor AND/OR Rectifier Bridge RemovalProcedure Rectifier Bridge Removal and Replacement Ranger Printed Circuit Board Removal Replacement Printed Circuit Board Removal and Replacement ProcedurePrinted Circuit Board Removal Ranger Output Rectifier Bridge Removal Replacement Remove the case top, then reinstall the fuel cap Output Rectifier Bridge RemovalSection TOC Ranger ENGINE/ROTOR Removal and Replacement InstructionsENGINE/ROTOR Removal Figure F.14 Component LOCATIONS, ENGINE/ROTOR RemovalEngine and Rotor Removal Procedure Rotor Removal Procedure Figure F.15 Engine and Rotor Removed from StatorReplacement KIT S20788 Reassembly ProcedureRetest After Repair Table of Contents Diagrams Section Dimension Dimension Print Ranger 8 Honda & Kohler RANGER8Diagrams Connection of Ranger 8 to LN-7 & K240 Contactor KITElectrical Diagrams Wiring Diagram Onan NON CSA ModelK1418-2 Ranger 8 Onan CSA Version Wiring Diagram Wiring Diagram Onan CSA ModelK1419-1 Ranger 8 Kohler Wiring Diagram Wiring Diagram Kohler NON CSA ModelK1419-2 Ranger 8 Kohler CSA Wiring Diagram Wiring Diagram Kohler CSA ModelK2160-1 Ranger 8 Honda CSA Wiring Diagram Schematic IDLER/CONTROL PC Board 16482PC Board Assembly IDLER/CONTROL SVM Error Reporting Form