Ranger 10,000 has low weld output and ac output

Changes between AC and DC voltage at the electrodes.



Q: What Type Of Stick Welder Works Best For All-Around Use?

A: A welder with an AC/DC output, whether its an electric arc machine like Miller\'s Thunderbolt or a gas engine drive like Miller\'s Bobcat.

DC welding offers advantages over AC for most Stick applications, including: easier starts; fewer arc outages and sticking; less spatter/better looking welds; easier vertical up and overhead welding; easier to learn "how to weld" and a smoother arc. DC reverse polarity (electrode positive) provides about 10 percent more penetration at a given amperage than AC, while DC straight polarity (electrode negative) welds thinner metals better.

Q: Does An AC Output Have Any Advantages?

A: Yes, if you need to weld on material that\'s become magnetized from friction, such as when hay, feed or water constantly rub against a steel part. A DC output won\'t work because of "arc blow," where the magnetic field blows the molten filler metal out of the weld puddle. Because an AC output alternates between polarities, it enables you to weld magnetized parts.

Rated Output at 20% Duty Cycle 150 A at 16 VAC
150 A at 16 VDC Welding Amperage Ranges AC/DC 10 - 165A Max. Open-Circuit Voltage 80 V Amps Input at Rated Output AC-230V: 21A
DC-230V: 23A You need to configure the machine to specifications of the material you going to weld.That is :
-The material of the job
-And the proper amperage to use for the material.
-For aluminum you will use A/C
-Stainless Steele / Chrome Molly D/C

Aluminum MIG Welding
1. The best feeding of wire for aluminum is done with a spool gun. If you can't use a spool gun, use the shortest gun possible and keep the gun as straight as possible. Use Argon only for shielding gas. Only use a push gun technique when welding aluminum. 2. If you are having feeding problems, one thing you can try is a contact tip that is one size bigger than your wire. 3. The most common wire type is ER4043 for all-purpose work. ER5356 is a stiffer wire (easier to feed), and is used when more rigid, higher-strength weld properties are needed. 4. Clean the aluminum before welding, to remove the oxide layer. Use a stainless steel wire brush used only for cleaning aluminum. 5. Fill the crater at the end of the weld to avoid a crack. One way to do this is to dwell in the weld pool for a second at the end of the weld.

Blow air through cabinet to clean out the dust- low pressure. Check for continuity across the reactor. if you connect one test lead to the terminal "R4", should be a tape label on the connection. The other connection is "S1", you should see less than 10,000 ohms.

Check the weld polarity switch to make sure it is not damaged. If you have AC welding but no DC- check L1 the choke in series with the + connection on the bridge rectifiers.

Also check cable A4 that connects between the bridge rectifiers and the current selector switch. Make sureit is intact, and clean terminations.

By ac you mean receptacles, not ac welding? 
If so what about welding output on AC (DC)?

If welding is OK then you may have breaker or fuse problem.
If welding output is also low or no output your problem is the generator.
You should check your gen rpm to be normal. If so you may have field problem: rectifier, AVR etc.
If you can measure the field DC voltage at rated rpm, if it is missing (very low) try to find any circuit broken.
If you do not succeed answer this instruction in order to give you more.

Make sure the WELD TERMINALS SWITCH is in correct position.: In the WELD TERMINALS
ON position, the output is electrically hot all the time.
In the REMOTELY CONTROLLED position, the output is
controlled by a wire feeder or amptrol device, and is electrically
off until a remote switch is depressed. If you don't have your manual, you can download one at http://www.mylincolnelectric.com/Catalog/operatorsmanualdatasheet.aspx?p=104081

sounds like the transformer winddings which generate the amperage for the arc are breaking down

Replace the power board

I can't give you specifics here, as your info is a little scarce.

Generally, on welding transformers, they are converting standard outlet power to very low voltage - but at very high amperage.

This being the case, the output windings will have much thicker wires than the input.

- So - thicker wires out to welding rectifier plate.

The rectifier will take care of the AC, and convert it, so polarity is not important.
Input will be AC as well, so this doesn't matter either.

Just make sure you identify the windings as pairs - and stick labels on them before fitting.
I use paper labels attatched as flags - then tear them off when finished.

The people supplying the coil should be able to identify the outputs for you.

look for short inside unit,start at breaker and work your way back.

Hi,
Check the current control resistor with an ohm meter. The center terminal should have a smooth rise or fall of resistance when measured to one end or the other of the resistor. If the resistor and the wiring to it are OK, check the shunt in the output it'll be by the "electrode" terminal. If both are OK you probably have a bad control board.

Regards,
Carl