Lincoln Electric SVM150-A User Manual download pdf (Page 44)

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GENERAL DESCRIPTION

The Ranger 250 is a gasoline engine-driven welding

power source capable of producing 250 amps at

25VDC at a 100% duty cycle. The engine is coupled to

a brush-type alternating current generator. This AC

output is rectified and controlled by Chopper

Technology to produce DC current for multi-purpose

welding applications. The Ranger 250 is also capable

of producing 8,000 watts of AC auxiliary power at 100%

duty cycle.

BATTERY, ENGINE, ROTOR, STA-

TOR AND ENGINE PROTECTION

The 12VDC battery powers the engine starter motor

and also supplies power to the battery PC board and

associated circuitry. When the engine, which is

mechanically coupled to the rotor, is started and run-

ning, the 12 VDC battery voltage is fed through the bat-

tery board to the rotor field coil via a brush and slip ring

configuration. This excitation or “flashing” voltage mag-

netizes the rotor lamination. This rotating magnet

induces a voltage in the stationary windings of the main

alternator stator. The stator houses a three-phase weld

winding, a 120/240VAC single-phase auxiliary winding,

a 42VAC wire feeder power winding, and a separate

42VAC field feedback winding that is rectified and

serves as a feedback supply for the rotor field winding.

The engine flywheel alternator supplies charging cur-

rent for the battery circuit. The oil pressure switch mon-

itors engine oil pressure. If a low oil pressure condition

should develop, the engine will shut down and the bat-

tery PC board will disable the rotor flashing current.

The idler solenoid is mechanically connected to the

engine’s throttle linkage. If no welding or auxiliary cur-

rent is being drawn from the Ranger 250, the control

board activates the idler solenoid, which then brings

the engine to a low idle state. When either welding or

auxiliary current is detected at the toroid current sen-

sor, the control board deactivates the idler solenoid and

the engine returns to high RPM.

THEORY OF OPERATION

E-2 E-2

RANGER 250

FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND ENGINE PROTECTION

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

ENGINE

CONTROL

BOARD

ROTOR

STATOR

BATTERY

BOARD

BATTERY

CHOKE

IGBT

MECHANICAL

RO TATI ON

STARTER

ARC

CONTROL

OUTPUT

CONTROL

MODE

SELECTOR

POWER MODULE

THREE-PHASE

RECTIFIER

WORK

TERMINAL

ELECTRODE

TERMINAL

120VAC

RECEPTACLE

240VAC

RECEPTACLE

SLIP

RINGS

CONTROL

BOARD

GAS

OIL

PRESSURE

SWITCH

RUN/STOP

SWITCH

FLYWHEEL

ALTERNATOR

TO CONTROL

BOARD

AMPHENOL

FIELD

WINDING

AUXILIARY

WINDINGS

WIRE FEED

PWR WNDG

D W

ANALOG

POWER

BOARD

FROM

TOROID

CURRENT

SENSOR

SHUNT

SOL

REGULATED VOLTAGES

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Lincoln Electric SVM150-A User Manual Page 44

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