Lincoln Electric SVM103-A Electrical Output Connections, Welding Cable Connections, Power ARC

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A-4

INSTALLATION

FIGURE A.1 - POWER-ARC 4000 OUTPUT CONNECTIONS

1

POWER ARC 4000

80

70AMPS

AMPS

125	90
AMPS	90
GENERATOR	AMPS

100

AMPS

WARNING

6

ELECTRODE SELECTION GUIDE

5

	3
2	4
2

1.	CURRENT CONTROL DIAL	4.	CIRCUIT BREAKERS (2) - 20 AMP
2.	WELD OUTPUT TERMINALS (2)	5.	RECEPTACLE - 240 VOLT, 20 AMP
3.	GROUND STUD	6.	DUPLEX RECEPTACLE - 120 VOLT, 20 AMP

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ELECTRICAL OUTPUT

CONNECTIONS

See Figure A.1 for the location of the current control dial, weld output terminals, ground stud, circuit break- ers, 240 and 120 volt receptacles.

WELDING CABLE CONNECTIONS

Cable Size and Length

Be sure to use welding cables that are large enough. The correct size and length becomes especially important when you are welding at a distance from the welder.

Table A.1 lists recommended cable sizes and lengths for rated current and duty cycle. Length refers to the distance from the welder to the work and back to the welder. Cable diameters are increased for long cable lengths to reduce voltage drops.

TABLE A.1

RECOMMENDED WELDING CABLE

SIZE AND LENGTH

TOTAL COMBINED LENGTH OF ELECTRODE

AND WORK CABLES

	Cable Size for
	125 amp/
Cable Length	30% Duty Cycle
0-50 feet (0-15 meters)	6 AWG
50-100 feet (15-39 meters)	4 AWG
100-150 feet (30-46 meters)	3 AWG
150-200 feet (46061 meters)	2 AWG
200-250 feet (61-76 meters)	1 AWG

POWER-ARC 4000

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Contents POWER-ARC TM4000 POWER-ARC SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications POWER-ARC InstallationStoring Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service Cable Size and Length Power ARCElectrical Output Connections Welding Cable ConnectionsPlugs and HAND-HELD Equipment Auxiliary Power ReceptaclesCable Installation Machine GroundingCircuit Breakers Premises WiringType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the POWER-ARCTable of Contents Operation Section General Description Safety InstructionsOperation Operating InstructionsWelding Capability Operational Features and ControlsDesign Features Advantages Recommended ApplicationsGENERATOR/WELDER Controls Controls and SettingsGasoline Engine Controls Figure B.2 Gasoline Engine ControlsStarting the Engine Engine OperationBefore Starting the Engine BREAK-IN Period Stopping the EngineRunning the Engine General Information To USE the Generator AS AN Auxiliary Power SupplyGenerator Operation Table B.3 Generator Power Applications After YOU Finish the Weld To USE the POWER-ARC 4000 for WeldingWelding Operation Stick Welding Material Thickness Electrode Type Size SettingWelding Guidelines ARC Welding CircuitCorrect WAY to Strike AN ARC 12/95 POWER-ARCFour Factors of Successful Welding ElectrodeCorrect Welding Speed Correct ARC LengthTable of Contents Accessories Briggs and Stratton Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Engine Maintenance Routine and Periodic MaintenanceFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Figure D.4 SET Spark Plug GAP Part Part Number Table D.2 Engine Maintenance PartsGENERATOR/WELDER Maintenance Figure D.6. Major Component Locations Table of Contents Theory of Operation Section ENGINE, EXCITATION, Rotor and Stator Theory of OperationFigure E.3 Field Excitation and Auxiliary Power Rotor Field Feedback and Auxiliary PowerWeld Winding and Reactor Auxiliary Power Overcurrent ProtectionTable of Contents Trouble Shooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairOutput Problems Troubleshooting GuideOr contact your local Lincoln Local Lincoln Electric Authorized Troubleshooting & Repair Troubleshooting & Repair Engine Problems Engine Problems Welding Problems Materials Needed Rotor Voltage TestTest Description Ground Stud Lead 200A Connection Output Panel Test ProcedureRotor Resistance Test Rings SlipCable TIE Brushes Figure F.3 Brushes Retained with Cable TIEEngine Throttle Adjustment Test Oscilloscope Method MarkStrobe-tach Method Frequency Counter MethodNUT Figure F.5 Location of Engine Throttle Adjustment NUTHigh Idle no Load Scope SettingsNormal Open Circuit Weld Voltage Waveform Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded to 125 Amps AT 23 VAC Typical Weld Output WaveformMachine Loaded Description Brush Removal and ReplacementFigure F.6 Brushes Retained with Cable TIE ProcedureProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal Replacement Procedure Capacitor Removal and Replacement Capacitor AND/OR Diode Bridge Removal and ReplacementProcedure Diode Bridge Removal and Replacement Instructions STATOR/ROTOR Removal and ReplacementTerminals Stator Removal ProcedureTIE Wrap OutputFigure F.10 Stator END Bracket Support and THRU-BOLTS Thru Bolts Support Nuts POWER-ARCRotor THRU-BOLT Rotor Removal ProcedureReassembly Procedure Rotor Feeler GaugeWELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine OutputPOWER-ARC Section G Table of ContentsElectrical Diagrams POWER-ARC Electrical DiagramPOWER-ARC POWER-ARC