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RANGER® 10,000 & RANGER® 10,000 PLUS
THEORY OF OPERATION
E-2 E-2
BATTERY, STARTER, ENGINE,
ROTOR, STATOR, AND IDLER
SOLENOID
The 12VDC battery powers the starter motor. When
the engine is started and running, the battery circuit
voltage is fed, through the printed circuit board, to the
rotating field coil in the rotor via a brush and slip ring
configuration. This excitation (“flashing”) voltage mag-
netizes the rotor lamination. The rotor is mechanically
coupled to the engine. This rotating magnet induces a
voltage in the stationary windings of the main alterna-
tor (stator). Three separate and isolated windings are
incorporated in the stator lamination assembly. Each
winding set has a different number of turns producing
different magnitudes of AC output voltages. The three
windings are the weld winding, the auxiliary power
winding and the field feedback winding. The field
feedback winding provides rotor current during
machine operation. The output of the RANGER®
10,000 is dependent on two criteria: the engine RPM
and the amount of current in the rotor winding.
The flywheel alternator, located on the engine, supplies
“charging” current for the battery circuit. The battery
circuit provides power for the printed circuit board and
also for the idler solenoid. The idler solenoid is
mechanically connected to the engine throttle linkage.
If no current is being drawn from the RANGER®
10,000, the printed circuit board activates the idler
solenoid, which then brings the engine to a low idle
state. When output current is sensed, either weld or
auxiliary, the printed circuit board deactivates the idler
solenoid, and the engine returns to high RPM.
STARTER ENGINE
B
ATTERY
IDLER
SOLENOID
OUTPUT
CONTROL
MECHANICAL
ROTATION
FIELD
CAPACITOR
ROTOR
S
LIP
RINGS
115 & 230VAC
RECEPTACLES
ROTOR
STATOR
STATOR
REACTOR
RANGE
SWITCH
O
UTPUT
BRIDGE
CHOKE
A
C
AC
POLARITY
SWITCH
E
LECTRODE
TERMINAL
WORK
TERMINAL
FLYWHEEL
ALTERNATOR
C
V
TAP
PRINTED CIRCUIT
BOARD
FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND IDLER SOLENOID
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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