Lincoln Electric SVM197-A Weld Winding and Reactor, Auxiliary Power Overcurrent Protection

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E-4

THEORY OF OPERATION

E-4

 

FIGURE E.4 – WELDING OUTPUT

 

 

 

REACTOR

 

 

 

 

OUTPUT

 

 

 

TERMINALS

 

 

STATOR

 

ENGINE

MECHANICAL

 

 

 

ROTATION

 

 

 

ROTOR

ROTOR

 

 

SLIP

 

 

MAGNETO

RINGS

 

 

 

 

 

CIRCUIT

 

STATOR

 

 

 

 

 

CAPACITOR

 

 

LOW OIL

 

 

 

SWITCH

 

CIRCUIT

CIRCUIT

 

 

 

 

BREAKER

BREAKER

RUN/STOP

 

 

 

SWITCH

 

 

 

RHEOSTAT

BRIDGE

 

 

 

 

 

 

230VAC

115VAC

 

 

RECEPTACLES

RECEPTACLES

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WELD WINDING AND REACTOR

The AC voltage developed in the stator weld winding is delivered, through the reactor, to the machine out- put terminals. The POWERARC® 5500 provides the user up to 125 amps of constant current AC welding for stick electrodes. The reactor stores energy, and this energy is released into the welding arc when the AC voltage passes through the zero point. In this manner the reactor enhances and stabilizes the AC welding arc. The reactor is designed to provide opti- mum welding characteristics when used with the rec- ommended electrodes.

AUXILIARY POWER OVERCURRENT PROTECTION

The POWERARC® 5500 watt auxiliary power winding and circuitry is protected from an overload condition by two 20 amp circuit breakers. The circuit breakers are located below the output receptacles. They can be manually reset.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion

POWERARC® 5500

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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 Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Section Maintenance Routine and Periodic 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 Theory of Operation Engine Control and IgnitionENGINE, 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 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 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