Lincoln Electric SVM197-A service manual For Electrically, Iii

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iii

 

 

 

 

 

SAFETY

iii

 

WELDING and CUTTING

CYLINDER may explode

 

SPARKS can

 

 

 

if damaged.

 

 

cause fire or explosion.

7.a. Use only compressed gas

cylinders

 

6.a. Remove fire hazards from the welding area.

containing the correct shielding gas for the

 

 

If this is not possible, cover them to prevent

process used and properly operating

 

 

the welding sparks from starting a fire.

regulators designed for the gas and

 

Remember

that

welding

sparks

and

hot

pressure used. All hoses, fittings, etc. should be suitable for

 

materials from welding can easily go through small cracks

the application and maintained in good condition.

 

 

and openings to adjacent areas. Avoid welding near

 

 

 

hydraulic lines. Have a

fire extinguisher readily available.

7.b. Always keep cylinders in an upright position securely

6.b. Where compressed gases are to be used at the job site,

chained to an undercarriage or fixed support.

 

 

 

 

special precautions should be used to prevent hazardous

7.c. Cylinders should be located:

 

 

situations. Refer to “Safety in Welding and Cutting” (ANSI

• Away from areas where they may be struck or subjected to

 

Standard Z49.1) and the operating information for the

physical damage.

 

 

equipment being used.

 

 

 

 

 

 

6.c. When not welding, make certain no part of the electrode

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

 

 

circuit is touching the work or ground. Accidental contact can

 

 

 

cause overheating and create a fire hazard.

 

 

7.d. Never allow the electrode, electrode holder or any other

6.d. Do not heat, cut or weld tanks, drums or containers until the

electrically “hot” parts to touch a cylinder.

 

 

 

 

proper steps have been taken to insure that such procedures

7.e. Keep your head and face away from the cylinder valve outlet

 

will not cause flammable or toxic vapors from substances

when opening the cylinder valve.

 

 

inside. They can cause an explosion even though they have

 

 

 

been “cleaned”. For information, purchase “Recommended

7.f. Valve protection caps should always be in place and hand

 

Safe Practices for the Preparation for Welding and Cutting of

tight except when the cylinder is in use or connected for

 

Containers and Piping That Have Held Hazardous

use.

 

 

Substances”, AWS F4.1 from the American Welding Society

 

 

 

(see address above).

 

 

 

 

7.g. Read and follow the instructions on compressed gas

6.e. Vent hollow castings or containers before heating, cutting or

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

 

welding. They may explode.

 

 

 

Cylinders,” available from the Compressed Gas Association

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil

1235 Jefferson Davis Highway, Arlington, VA 22202.

 

 

 

free protective garments such as leather gloves, heavy shirt,

FOR ELECTRICALLY

 

cuffless trousers, high shoes and a cap over your hair. Wear

 

ear plugs when welding out of position or in confined places.

 

powered equipment.

 

Always wear safety glasses with side shields when in a

 

welding area.

 

 

 

 

 

 

 

6.g. Connect the work cable to the work as close to the welding

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

 

area as practical. Work cables connected to the building

the equipment.

 

 

framework or other locations away from the welding area

 

 

 

increase the possibility of the welding current passing

8.b. Install equipment in accordance with the U.S. National

 

through lifting chains, crane cables or other alternate circuits.

Electrical Code, all local codes and the manufacturer’s

 

This can create fire hazards or overheat lifting chains or

recommendations.

 

 

cables until they fail.

 

 

 

 

8.c. Ground the equipment in accordance with the U.S. National

 

 

 

 

 

 

 

6.h. Also see item 1.c.

 

 

 

 

Electrical Code and the manufacturer’s recommendations.

6.I.

Read and follow NFPA 51B “ Standard for Fire Prevention

 

 

 

During Welding, Cutting and Other Hot Work”, available from

 

 

 

NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma

 

 

 

022690-9101.

 

 

 

 

 

 

 

6.j.

Do not use a welding power source for pipe thawing.

 

 

 

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ‘09

POWERARC® 5500

Image 4
Contents Powerarc ISAFETYi Safety Electric Shock can kill ARC Rays can burnFor Electrically IiiPrécautions DE Sûreté Electromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications PowerarcSafety Precautions Location and VentilationStoring Engine Exhaust can killPRE-OPERATION Engine Service PowerArc 5500 Typical Fuel Consumption Muffler DeflectorSpark Arrester Honda 9 HPPowerarc 5500 Output Connections Electrical Output ConnectionsWelding Cable Connections Cable Size and LengthAuxiliary Power Receptacles Cable InstallationPlugs and HAND-HELD Equipment Machine GroundingPremises Wiring Circuit BreakersTable A.2 Electrical Device USE with the Powerarc Type Common Electrical Devices Possible ConcernsPowerarc Table of Contents Operation Section Operation Controls and Settings LimitationsOutput Panel Controls Physical Location of Components may vary by Code NoEngine Operation Gasoline Engine ControlsBefore Starting the Engine Starting the EngineGenerator Operation Stopping the EngineGeneral Information Running the EngineTable B.3 Generator Power Applications Welding Operation Control Function / Operation Current Control DialMaterial Thickness Electrode Type Size Setting Welding GuidelinesWhat Happens in the Arc? Welding circuit for Stick shielded metal arc weldingCorrect Welding Position Correct Way to Strike An ArcCorrect Arc Length Correct Welding SpeedCommon Metals Types of WeldsUse the following Do the followingPenetration Welding in the Vertical PositionVertical-Up Welding Vertical-Down WeldingHow to Hardface the Sharp Edge Metal to Ground Wear Overhead WeldingHardfacing To Reduce Wear Welding Sheet MetalWelding Cast Iron Cast Iron Plate PreparationSelecting Electrodes High-Speed Group AWS E6013Low Hydrogen Group AWS E7018 Out-of-Position Group AWS E6011Powerarc Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesLincoln Electric Accessories Table of Contents Maintenance Section Routine and Periodic Maintenance MaintenanceEngine Maintenance Engine Adjustments Figure D.3 Clean Rotating SCREEN/FINGER GUARD/DEBRIS GuardTable D.1 Engine Maintenance Parts Part Robin / Subaru HondaGENERATOR/WELDER Maintenance Do not attempt to polish slip rings while engine is runningFigure D.6. Major Component Locations 1TABLE of CONTENTS-THEORY of Operation Section E-1 Engine Control and Ignition Theory of OperationENGINE, EXCITATION, Rotor and Stator Rotor Field Feedback Auxiliary Power ReturnAuxiliary Power Overcurrent Protection Weld Winding and Reactor1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting GuideTroubleshooting 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 Test Description Materials Needed14TROUBLESHOOTING and REPAIRF-14 Rotor Voltage Test ProcedureFlashing Voltage Test Procedure LeadRotor Resistance Test Procedure Rotor Resistance Test Procedure Figure F.3 Brushes Retained with Cable TIE Powerarc Engine Throttle Adjustment Test ROBIN/SUBARU Engine Engine Throttle Adjustment Test ROBIN/SUBARU EngineHigh Speed Stop Screw Normal 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 Brush Removal and Replacement Procedure Brush Removal and Replacement Procedure Powerarc Rheostat Removal and Replacement Procedure Rheostat Removal and Replacement Procedure Troubleshooting and Repair Procedure Capacitor Removal and REPLACE- Ment Capacitor AND/OR Diode BridgeAttachment for 202A Cable Tie Capacitor Attachment for 201 201A JumperProcedure Field Diode Bridge Removal and Replacement Figure F.10 Field Diode Bridge LocationPowerarc STATOR/ROTOR Removal and Replacement Procedure Stator Removal Procedure STATOR/ROTORSection TOC Rotor Removal Procedure Procedure Reactor Bolts Lead Auxiliary Power Receptacle OUTPUT1 Retest After RepairEngine Output WELDER/GENERATOR OUTPUT1Powerarc Table of Contents Diagram Section Electrical Diagrams Wiring Diagram Codes 11182, 11187, 11329 S25984Wiring Diagram Codes 11403, 11405 S26829 SwitchWiring Diagram Power ARC Wiring Diagram Code 11404 S26830Wiring Diagram Code 11215 S26023 Schematic -CODES 11182, 11187, 11329 S26008 S26008Schematic Codes 11403, 11405 S26881 S26881Schematic Code 11404 S26882 S26882