Lincoln Electric SVM103-A service manual Premises Wiring, Circuit Breakers

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A-6

INSTALLATION

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PREMISES WIRING

The POWER-ARC 4000 three-wire, grounded neutral generator allows it to be connected to premises wiring. However, the wiring procedure needed to meet the National Electric Code (NEC) regulations as well as city ordinances can be confusing. Matters get worse depending on whether you want the machine to be “hardwired” to the premises or only connected temporarily.

WARNING

Only a licensed, certified, trained electrician should install the machine to a premises or residential electri- cal system. Be certain that:

•The premises is isolated and no feedbacking into the utility system can occur. Certain state and local laws require the premises to be isolated before the generator is linked to the premises. Check your state and local requirements.

•A double pole, double throw transfer switch in con- junction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter.

The POWER-ARC 4000 (unlike other Lincoln Electric equipment) does not have a combined 120/240 volt twist-lock receptacle and cannot be connected to a premises as described in other Lincoln literature.

Remember that the POWER-ARC 4000 is intended only for backup, intermittent use. The gasoline engine has a rated life of 500 hours. It cannot withstand long- term use without proper maintenance. See the MAIN- TENANCE section of this manual for more informa- tion.

Certain electrical devices cannot be powered by the POWER-ARC 4000. Refer to Table A.2 for these devices.

CIRCUIT BREAKERS

The POWER-ARC 4000 has its own

20 amp circuit breakers for overload protection. When the machine is

operated in high temperature environments, the breakers may tend to trip at lower loads than normal- ly.

CAUTION

Never bypass the circuit breakers. Without overload protection, the power-arc 4000 could overheat and/or cause damage to the equipment being used.

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 InstallationLocation and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Electrical Output Connections Power ARCWelding Cable Connections Cable Size and LengthCable Installation Auxiliary Power ReceptaclesMachine Grounding Plugs and HAND-HELD EquipmentCircuit Breakers Premises WiringType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the POWER-ARCTable of Contents Operation Section Operation Safety InstructionsOperating Instructions General DescriptionDesign Features Advantages Operational Features and ControlsRecommended Applications Welding CapabilityGENERATOR/WELDER Controls Controls and SettingsGasoline Engine Controls Figure B.2 Gasoline Engine ControlsBefore Starting the Engine Engine OperationStarting the Engine Running the Engine Stopping the EngineBREAK-IN Period Generator Operation To USE the Generator AS AN Auxiliary Power SupplyGeneral Information Table B.3 Generator Power Applications Welding Operation To USE the POWER-ARC 4000 for WeldingAfter YOU Finish the Weld Welding Guidelines Material Thickness Electrode Type Size SettingStick Welding ARC Welding CircuitFour Factors of Successful Welding 12/95 POWER-ARCElectrode Correct WAY to Strike AN ARCCorrect Welding Speed Correct ARC LengthTable of Contents Accessories Lincoln Electric Accessories OPTIONS/ACCESSORIESBriggs and Stratton 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 GENERATOR/WELDER Maintenance Table D.2 Engine Maintenance PartsPart Part Number 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 Test Description Rotor Voltage TestMaterials Needed 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 Strobe-tach Method MarkFrequency Counter Method Oscilloscope MethodNUT Figure F.5 Location of Engine Throttle Adjustment NUTNormal Open Circuit Weld Voltage Waveform Scope SettingsHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded Typical Weld Output WaveformMachine Loaded to 125 Amps AT 23 VAC 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 ReplacementTIE Wrap Stator Removal ProcedureOutput TerminalsFigure F.10 Stator END Bracket Support and THRU-BOLTS Thru Bolts Support Nuts POWER-ARCReassembly Procedure Rotor Removal ProcedureRotor THRU-BOLT Rotor Feeler GaugeRetest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1POWER-ARC Electrical Diagrams Table of ContentsSection G POWER-ARC Electrical DiagramPOWER-ARC POWER-ARC