Lincoln Electric RANGER 305 D CE User manual

Technology creates change.
The ability to evolve along
with change is what
distinguishes a successful
product from the rest.
Power source design is
almost entirely devoted
to reliability. Fast power
conversion is important to
obtaining a smooth
welding output, but we
also know that speed is
inconsequential without
reliability. No matter how
fast your machine operates,
if it is not durable, then it is
not usable for welding. And
if it is not welding, you are
not meeting your
production goals and
making a living.
QUICKER RESPONSE
High-speed power conversion allows for quick response to changing
arc conditions.
SMALLER FOOTPRINT
Power electronic components are compact, making equipment size smaller and
therefore more portable.
UNIVERSAL INPUT VOLTAGE
Capable of operating from 208 to 575 volts on virtually any power supply for
versatile, consistent performance.
HIGHLY EFFICIENT
Smaller transformer coils, higher thermal conductivity, and higher operating
frequencies means more efficient output power, and more economical use
of power. This translates to decreased utility costs and increased power
source efficiency.
WAVEFORM CONTROL TECHNOLOGY®COMPATIBLE
Waveform Control Technology®gives the operator improved control over the
characteristics of the welding arc.
Inverters and Choppers
TECHNOLOGY
POWER ELECTRONICS TECHNOLOGY
The inverter technology in
the Invertec® V350-PRO
gives it equivalent power
capabilities as a
conventional
transformer/rectifier
such as the Lincoln
CV-305, but in
a much smaller and
portable machine.
The future of welding is here.
®
The Chopper
Technology®in the
Ranger®305D offers
the same control over
the welding arc as an
inverter machine
NX-1.30 6/06

TECHNOLOGY
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Inverter Technology
POWER ELECTRONICS TECHNOLOGY
Inverter-based welding power
sources operate at frequencies
above 20 kHz, whereas
traditional power sources
operate at a line frequency
of 50 or 60 Hz. Some of the
advantages an inverter has
are smaller magnetic
components (chokes and
transformers), higher
efficiency, and a fast
response to the welding arc.
Inverter power sources were
first introduced into the
welding industry in the early
1980s. The initial attraction of
the inverter was its small size
and easy portability. For
example, a rectifier-based
machine, like the Lincoln CV305,
weighs four times more than the
Invertec V350-PRO. Less space
is needed and the inverter unit is
easily moved around the job site.
As the popularity and reliability of
What is
Inverter Technology?
The Power Wave®455M/STT
Inverter Technology
The future of welding is here.
®
The Invertec®V350-PRO
The Power Wave®AC/DC 1000™
The Power Wave®355M
Inverter Technology is
showcased in Lincoln’s
Invertec®V350-PRO, and
Power Wave®welding systems
How
Inverter Works
Incoming 50 to 60 Hz alternating
current (AC) is converted
to direct current (DC) by a full
wave rectifier.
The DC power is inverted into high-frequency AC power,
using semiconductor switches above 20 kHz. High-speed
switching improves welding. Switching above 20 kHz
improves efficiency, reduces weight, and is above the
maximum frequency people can hear. Digital controls
dictate the switching rate of the transistors.
The high-frequency AC voltage
requires a step-down
transformer. The transformer
takes high voltage, high
frequency AC and converts it to
low voltage, high frequency AC.
The current is “smoothed”
by a rectifying and
filtering circuit to make it
suitable for welding.
the inverter increased, the capabilities
were expanded. Inverters are now
designed for many different
processes: SMAW, GTAW, FCAW,
SAW, and are capable of operating in
extreme environments. Over the last
decade, Lincoln Electric has invested
heavily in developing inverter
technology, producing highly reliable
inverter machines.

TECHNOLOGY
3/8
Inverter Technology
POWER ELECTRONICS TECHNOLOGY
Using
Inverter Technology
For Multi-Process Welding
Inverters are capable of multiple process welding, providing
optimum arc characteristics for each process.
For Reduced Electrical Power Consumption
Copper conductors, compact transformers, and smaller coils
translate to energy savings.
For Waveform Control Technology*
Inverter machines are software programmable, which means
that they are equipped to use Waveform Control Technology®
to manipulate output weld characteristics.
For Networking Capability*
Multiple inverter machines can be networked together over a
Local Area Network (LAN) or Wide Area Network (WAN) with
an Ethernet/DeviceNet Gateway board.
The Power Wave®455M uses Inverter
technology to produce consistent
welds with a variety of weld processes.
The future of welding is here.
®
Advantages
Of Inverter Technology
Reliable
Every inverter undergoes rigorous testing to ensure
product reliability.
Compact and Portable
Smaller chokes, transformers, and rectifiers, give the inverter
equivalent power to older SCR machines, without the added
size and weight.
Fast Response to Welding Arc
Digital controls regulate the output very accurately so the
welding performance is consistent from machine to machine.
Universal Input Voltage**
The inverter can run on any power supply that supplies
between 208 to 575 volts.
Efficient
The smaller chokes and transformers of the inverter yield an
efficiency rating of 87% to 90%, which means the inverter
consumes less energy to convert the same amount of energy
as SCR-based machines.
* Applies only to Power Wave Welding Systems F355i, 355M, 455M, 455M/STT, 655
Robotic, and Power Wave AC/DC 1000.
**Power Wave 655 Robotic and Power Wave AC/DC 1000 operate from 460 to 575 volts.

TECHNOLOGY
4/8
Chopper Technology®
POWER ELECTRONICS TECHNOLOGY
Lincoln Electric’s Chopper
Technology is the simplest form
of high frequency power
conversion. A chopper is
composed of a transistor
switch and a diode. DC input
power is “chopped” to a lower
output voltage, and a choke is
placed in the path of the output
to smooth current variation.
Choppers were developed for
engine driven welders to offer
the same control over the
welding arc as the inverter
machines. This allows more
consistent arc performance
across product lines. Choppers
are ideal for the customer
searching for an inexpensive
option for low cost, high quality
arc performance.
What
Is Chopper Technology?
How
Chopper Technology Works
Chopper Technology®
The future of welding is here.
®
Incoming AC
power is
converted to
direct current (DC)
by a full wave
rectifier.
DC voltage is applied through a
solid state switch, which
controls the welding arc by
opening and closing, regulating
the amount of current that is
applied to the arc.
When the switch is
closed, current is
applied through the
inductor to the arc.
When the transistor switch
is open, current stored in
the inductor sustains
current in the arc.
The repetition of this
cycle of switch
closure is at least
20 kHz, which allows
fast control of the arc.
Vantage®Series
Ranger®250 & 305D
Chopper Board
Power MIG®350MP
Multi-Weld®
Chopper Technology is
showcased in Lincoln’s
Vantage, Ranger, Multi-Weld
and Power MIG 350MP
Inductor

TECHNOLOGY
5/8
Chopper Technology®
POWER ELECTRONICS TECHNOLOGY
Using
Chopper Technology®
For the "On-The-Go" Welder
Chopper Technology is the field welder’s answer to
superior arc performance. Engine drives allow for the
flexibility of operating in conditions where “plugging in”
is not an option. Lincoln engine drives provide excellent
arc characteristics through Chopper Technology, while
providing high-capacity AC generator power.
Chopper Technology also allows multiple welding arcs
to operate from a single power supply using Multi-Weld
350 units.
The future of welding is here.
®
Advantages
Of Chopper Technology®
Flexible
• Engine-driven Chopper Technology®power sources are not
limited by the weld environment or access to a power line.
• Chopper Technology®is also available in an electric
powered welder, the Power MIG 350MP.
Fast Control over Welding Arc
• Fast response time of the Chopper Technology®circuit
allows greater operator control over the welding arc.
Lincoln engine-driven welders such as
the Vantage®500 can be used in
virtually any work environment.
Chopper Technology®enables fast and
consistent arc control, while providing
high-capacity AC generator power.
Chopper Technology®allows up to four Multi-Weld 350 machines
to draw power from a single SAE®400 power supply.

TECHNOLOGY
6/8
Design
POWER ELECTRONICS TECHNOLOGY
The Electronics Lab
is equipped to support the design and analysis
of analog and digital control systems.
The EMC Lab
is equipped to conduct electro-magnetic
interference testing.
The Power Lab
is equipped to build and test full-scale
prototype machines rapidly to support the
development of new power conversion
techniques. As new power electronic
components emerge they are evaluated
and implemented.
The future of welding is here.
®
Power Electronics Design
The reliability of a welding power source is critical. Electronics improvements are the foremost
method of continually improving the reliability, efficiency, and performance of our power sources.
Lincoln invested in improving the dependability, durability, and efficiency of its inverters. Lincoln engineers
developed innovative solutions for power conversion. Extensive research is conducted in the electronics,
EMC, and power laboratories.
Reliability Testing
During Product Design
Environmental Stress
Screening (ESS) subjects the
machine to extreme conditions
of temperature and humidity.
Mechanical tests such as vibration and drop
testing provide evidence to the machine’s
durability and resistance to breaking.
Infrared thermal analysis is done
on power electronic assemblies in
the power electronics lab. This is
done at both the PC board level
and the machine level.

TECHNOLOGY
7/8
Reliability
POWER ELECTRONICS TECHNOLOGY
Power Section designed around high
speed switching modules
• Lincoln manufactures its own integrated modules,
which allows us to optimize each module for
reliability
and performance.
Designed to withstand extreme
environmental conditions
• All PC boards are trayed
and potted.
• The transformers and
chokes go through a
double dipped varnish
impregnation process.
• Harness connectors
are made with locking
pins and sealed with
electrical grease.
Designed with
Fan As Needed (FANTM) Circuitry
• This reduces the amount of debris that gets drawn
into the machine by turning the fan off when it is
not needed.
• The fan turns on before components get too hot,
thus increasing life expectancy of the electronics.
• Reduces the power used during machine idle.
The future of welding is here.
®
All electrical components are derated
for added reliability
• All electrical components are designed to operate at
voltages lower than their rated voltages and
temperatures below their rated temperatures.
Designed for stable operation
• Patented dual current transformers prevent
current imbalance.
• Active balancing technology is utilized for keeping
the voltages balanced under all conditions.
Control system utilizes common PC
boards and software
• Able to accommodate feature enhancements and
optimizations from other products for longer life of
the inverter.
Designed for protection if a fault occurs
• Thermal protection, misconnection protection,
secondary over-current protection, and primary
over-current protection are all standard in
inverter machines.
Reliability Testing
During Product Build
From initial design to product build, we ensure that every power source we release to a customer meets
our standards for reliability and efficiency.
The burn-in cycle is conducted to
ensure machine performance matches
Lincoln Electric requirements.
Dielectric tests provide evidence that
electrical insulation will withstand the
rigors of the welding environment.
Each Power Wave
machine is weld-tested.

TECHNOLOGY
8/8
Power Electronics Products
POWER ELECTRONICS TECHNOLOGY
Chopper Products
Lincoln Electric power sources equipped with Chopper Technology®include
the Ranger®and Vantage®engine driven welders, as well as the Power MIG®
350MP and Multi-Weld®.
Lincoln Welding Systems
Power Electronics
Customer Assistance Policy
The business of The Lincoln Electric Company is manufacturing and selling high quality welding
equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our
customer and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric
for advice or information about their use of our products. We respond to our customers based
on the best information in our possession at that time. Lincoln Electric is not in a position to
warrant or guarantee such advice, and assumes no liability, with respect to such information or
advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any
customer’s particular purpose, with respect to such information or advice. As a matter of
practical consideration, we also cannot assume any responsibility for updating or correcting any
such information or advice once it has been given, nor does the provision of information or
advice create, expand or alter any warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold
by Lincoln Electric is solely within the control of, and remains the sole responsibility of the
customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirement.
Subject to change - This information is accurate to the best of our knowledge
at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
The future of welding is here.
®
Inverter Products
Lincoln products equipped with Inverter
Technology include the Power Wave®
AC/DC 1000™, Invertec®V350-PRO,
Power Wave®355M, and the Power
Wave®455M.
WHAT IS NEXTWELD?
The challenges facing industrial
fabricators today are growing in number
and complexity. Rising labor, material
and energy costs, intense domestic and
global competition,
a dwindling pool of
skilled workers,
more stringent and
specific quality
demands all
contribute to a
more difficult
welding
environment today.
Through our
commitment to
extensive research and investments in
product development, Lincoln Electric
has established an industry benchmark
for applying technology to improve the
quality, lower the cost and enhance the
performance of arc welding processes.
Advancements in power electronics,
digital communications and Waveform
Control Technology® are the foundation
for many of the improvements.
NEXTWELD brings you a series of
Process, Technology, Application and
Success Story documents like this one.
NEXTWELD explains how technologies,
products, processes and applications are
linked together to answer the important
questions that all businesses face:
• How can we work faster, smarter,
more efficiently?
• How can we get equipment and
people to perform in ways they’ve
never had to before?
• How do we stay competitive?
NEXTWELD is the future of welding but
its benefits are available to you today.
Ask your Lincoln Electric representative
how to improve the flexibility, efficiency
and quality of your welding operations to
reduce your cost of fabrication.
THE LINCOLN ELECTRIC COMPANY
www.lincolnelectric.com
1.216.481.8100