Lincoln Electric SVM197-A service manual Safety, Electric Shock can kill ARC Rays can burn

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ii

 

 

 

SAFETY

 

ii

 

 

 

 

 

 

 

 

 

 

ELECTRIC SHOCK can kill.

 

 

 

 

ARC RAYS can burn.

 

 

3.a. The electrode and work (or ground) circuits

 

 

 

 

4.a. Use a shield with the proper filter and cover

 

 

are electrically “hot” when the welder is on.

 

 

 

 

 

 

 

 

 

 

plates to protect your eyes from sparks and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Do not touch these “hot” parts with your bare

 

 

 

 

the rays of the arc when welding or observing

 

 

skin or wet clothing. Wear dry, hole-free

 

 

 

 

open arc welding. Headshield and filter lens

 

 

gloves to insulate hands.

 

 

 

 

should conform to ANSI Z87. I standards.

3.b. Insulate yourself from work and ground using dry insulation.

 

4.b. Use suitable clothing made from durable flame-resistant

 

Make certain the insulation is large enough to cover your full

 

 

 

 

material to protect your skin and that of your helpers from

 

area of physical contact with work and ground.

 

 

 

 

the arc rays.

 

 

 

In addition to the normal safety precautions, if welding

 

4.c. Protect other nearby personnel with suitable, non-flammable

 

must

be performed

under

electrically hazardous

 

 

 

 

screening and/or warn them not to watch the arc nor expose

 

conditions (in damp locations or while wearing wet

 

 

 

 

themselves to the arc rays or to hot spatter or metal.

 

 

 

 

 

 

 

 

 

clothing; on metal structures such as floors, gratings or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

scaffolds; when in cramped positions such as sitting,

 

 

 

 

 

 

 

 

 

 

 

FUMES AND GASES

 

kneeling or lying, if there is a high risk of unavoidable or

 

 

 

 

 

accidental contact with the workpiece or ground) use

 

 

 

 

can be dangerous.

 

the following equipment:

 

 

 

 

 

 

• Semiautomatic DC Constant Voltage (Wire) Welder.

 

 

 

 

5.a. Welding may

produce

fumes and gases

 

• DC Manual (Stick) Welder.

 

 

 

 

 

hazardous to health. Avoid breathing these

 

 

 

 

 

 

 

• AC Welder with Reduced Voltage Control.

 

 

 

 

fumes and gases.When welding, keep

 

 

 

 

 

 

 

 

 

your head out of the fume. Use enough

3.c. In semiautomatic or automatic wire welding, the electrode,

 

 

 

 

ventilation and/or exhaust at the arc to keep

 

electrode reel, welding head, nozzle or semiautomatic

 

 

 

 

fumes and gases away from the breathing zone. When

 

welding gun are also electrically “hot”.

 

 

 

 

welding with electrodes which require special

 

 

 

 

 

 

 

 

 

ventilation such as stainless or hard facing (see

3.d. Always

be sure the work cable makes a good electrical

 

 

 

 

instructions on container or MSDS) or on lead or

 

connection with the metal being welded. The connection

 

 

 

 

cadmium plated steel and other metals or coatings

 

should be as close as possible to the area being welded.

 

 

 

 

which produce highly toxic fumes, keep exposure as

 

 

 

 

 

 

 

 

 

low as possible and within applicable OSHA PEL and

3.e. Ground the work or metal to be welded to a good electrical

 

 

 

 

ACGIH TLV limits using local exhaust or mechanical ven-

 

(earth) ground.

 

 

 

 

 

 

tilation. In confined spaces or in some circumstances,

 

 

 

 

 

 

 

 

 

outdoors, a respirator may be required. Additional pre-

3.f.

Maintain the electrode holder, work clamp, welding cable and

 

 

 

 

cautions are also required when welding on galvanized

 

welding machine in good, safe operating condition. Replace

 

 

 

 

steel.

 

 

 

damaged insulation.

 

 

 

5. b. The operation of welding fume control equipment is affected

 

 

 

 

 

 

3.g. Never dip the electrode in water for cooling.

 

 

 

 

by various factors including proper use and positioning of the

 

 

 

 

equipment, maintenance of the equipment and the specific

 

 

 

 

 

 

 

 

 

3.h. Never

simultaneously

touch

electrically “hot” parts of

 

 

 

 

welding procedure and application involved. Worker expo-

 

 

 

 

sure level should be checked upon installation and periodi-

 

electrode holders connected to two welders because voltage

 

 

 

 

 

 

 

 

 

cally thereafter to be certain it is within applicable OSHA PEL

 

between the two can be the total of the open circuit voltage

 

 

 

 

 

 

 

 

 

and ACGIH TLV limits.

 

 

 

of both welders.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.i.

When working above floor level, use a safety belt to protect

 

5.c. Do not weld in locations near chlorinated hydrocarbon vapors

 

 

 

 

coming from degreasing, cleaning or spraying operations.

 

yourself from a fall should you get a shock.

 

 

 

 

 

 

 

 

 

The heat and rays of the arc can react with solvent vapors to

 

 

 

 

 

 

 

 

 

3.j.

Also see Items 6.c. and 8.

 

 

 

 

 

form phosgene, a highly toxic gas, and other irritating prod-

 

 

 

 

 

ucts.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.d. Shielding gases used for arc welding can displace air and

 

 

 

 

 

 

 

 

 

cause injury or death. Always use enough ventilation,

 

 

 

 

 

 

 

 

 

especially in confined areas, to insure breathing air is safe.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.e. Read and understand the manufacturer’s instructions for this

 

 

 

 

 

 

 

 

 

equipment and the consumables to be used, including the

 

 

 

 

 

 

 

 

 

material safety data sheet (MSDS) and follow your

 

 

 

 

 

 

 

 

 

employer’s safety practices. MSDS forms are available from

 

 

 

 

 

 

 

 

 

your welding distributor or

from

the manufacturer.

 

 

 

 

 

 

5.f. Also see item 1.b.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Jan ‘09

POWERARC® 5500

Image 3
Contents Powerarc ISAFETYi Electric Shock can kill ARC Rays can burn SafetyIii For ElectricallyPrécautions DE Sûreté Electromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Powerarc InstallationEngine Exhaust can kill Safety PrecautionsLocation and Ventilation StoringPRE-OPERATION Engine Service Honda 9 HP PowerArc 5500 Typical Fuel ConsumptionMuffler Deflector Spark ArresterCable Size and Length Powerarc 5500 Output ConnectionsElectrical Output Connections Welding Cable ConnectionsMachine Grounding Auxiliary Power ReceptaclesCable Installation Plugs and HAND-HELD EquipmentCircuit Breakers Premises WiringType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the PowerarcPowerarc Table of Contents Operation Section Operation Physical Location of Components may vary by Code No Controls and SettingsLimitations Output Panel ControlsGasoline Engine Controls Engine OperationStarting the Engine Before Starting the EngineRunning the Engine Generator OperationStopping the Engine General InformationTable B.3 Generator Power Applications Control Function / Operation Current Control Dial Welding OperationWelding Guidelines Material Thickness Electrode Type Size SettingWelding circuit for Stick shielded metal arc welding What Happens in the Arc?Correct Welding Speed Correct Welding PositionCorrect Way to Strike An Arc Correct Arc LengthDo the following Common MetalsTypes of Welds Use the followingWelding in the Vertical Position PenetrationVertical-Down Welding Vertical-Up WeldingWelding Sheet Metal How to Hardface the Sharp Edge Metal to Ground WearOverhead Welding Hardfacing To Reduce WearCast Iron Plate Preparation Welding Cast IronOut-of-Position Group AWS E6011 Selecting ElectrodesHigh-Speed Group AWS E6013 Low Hydrogen Group AWS E7018Powerarc Table of Contents Accessories Section Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Section Maintenance Routine and Periodic MaintenanceEngine Maintenance Figure D.3 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Engine AdjustmentsPart Robin / Subaru Honda Table D.1 Engine Maintenance PartsDo not attempt to polish slip rings while engine is running GENERATOR/WELDER MaintenanceFigure D.6. Major Component Locations 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Engine Control and IgnitionENGINE, EXCITATION, Rotor and Stator Return Rotor Field Feedback Auxiliary PowerWeld Winding and Reactor Auxiliary Power Overcurrent Protection1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2Troubleshooting and Repair Output Problems Perform the Rotor and Flashing Voltage Test Troubleshooting and Repair Troubleshooting and Repair Rotor Resistance Test Engine Problems Troubleshooting and Repair Engine Throttle Adjustment Test Powerarc Materials Needed Test DescriptionLead 14TROUBLESHOOTING and REPAIRF-14Rotor Voltage Test Procedure Flashing Voltage Test ProcedureRotor Resistance Test Procedure Rotor Resistance Test Procedure Figure F.3 Brushes Retained with Cable TIE Powerarc Engine Throttle Adjustment Test ROBIN/SUBARU Engine ROBIN/SUBARU Engine Engine Throttle Adjustment TestHigh Speed Stop Screw Scope Settings Normal Open Circuit Weld Voltage WaveformHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Typical Weld Output Waveform Machine LoadedMachine Loaded to 125 Amps AT 23 VAC Brush Removal and Replacement Procedure Brush Removal and Replacement Procedure Powerarc Rheostat Removal and Replacement Procedure Rheostat Removal and Replacement Procedure Troubleshooting and Repair Attachment for 201 201A Jumper Procedure Capacitor Removal and REPLACE- MentCapacitor AND/OR Diode Bridge Attachment for 202A Cable Tie CapacitorFigure F.10 Field Diode Bridge Location Procedure Field Diode Bridge Removal and ReplacementPowerarc STATOR/ROTOR Removal and Replacement Procedure STATOR/ROTOR Stator Removal ProcedureSection TOC Rotor Removal Procedure Procedure Reactor Bolts Lead WELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine OutputPowerarc Table of Contents Diagram Section Wiring Diagram Codes 11182, 11187, 11329 S25984 Electrical DiagramsSwitch Wiring Diagram Codes 11403, 11405 S26829Wiring Diagram Code 11404 S26830 Wiring Diagram Power ARCWiring Diagram Code 11215 S26023 S26008 Schematic -CODES 11182, 11187, 11329 S26008S26881 Schematic Codes 11403, 11405 S26881S26882 Schematic Code 11404 S26882