Lincoln Electric SVM103-C service manual Vertical-Up Welding, Vertical-Down Welding

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B-17

OPERATION

B-17

 

 

 

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Vertical-Up Welding

The problem, when welding vertical-up, is to put the molten metal where it is wanted and make it stay there. If too much molten metal is deposited, gravity will pull it downwards and make it “drip”. Therefore, a certain technique has to be followed:

Long arc

Short arc

NOTE: Holder end of electrode is lower than arc.

1.Use 1/8” (3.2mm) 90-115 amps or 3/32” (2.5mm) 70 amps AWS 6011.

2.When welding, the electrode should be kept hori- zontal or pointing slightly upwards. (See drawing above).

3.The arc is struck and metal deposited at the bot- tom of the two pieces to be welded together.

4.Before too much molten metal is deposited, the arc is SLOWLY moved 1/2-3/4” (12-20mm) upwards. This takes the heat away from the molten puddle, which solidifies. (If the arc is not taken away soon enough, too much metal will be deposited, and it will “drip”.)

5.The upward motion of the arc is caused by a very slight wrist motion. Most definitely, the arm must not move in and out, as this makes the entire process very complicated and difficult to learn.

6.If the upward motion of the arc is done correctly with a wrist motion, the arc will automatically become a long arc that deposits little or no metal. (See drawing above.)

7.During this entire process, the ONLY thing to watch is the molten metal. As soon as it has solid- ified, the arc is SLOWLY brought back, and anoth- er few drops of metal are deposited. DO NOT FOLLOW THE UP AND DOWN MOVEMENT OF THE ARC WITH YOUR EYES. KEEP THEM ON THE MOLTEN METAL.

8.When the arc is brought back to the now solidified puddle, IT MUST BE SHORT, otherwise no metal will be deposited, the puddle will melt again, and it will “drip”.

9.It is important to realize that the process consists of SLOW, DELIBERATE movements. There are no fast motions.

Vertical-Down Welding

Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow, and are excellent for sheet metal. Do not use the vertical- down technique on heavy metal. The welds will not be strong enough.

1.Use 1/8” (3.2m) or 3/32” (2.5mm) AWS 6011.

2.On thin metal use 70-75 amps.

(14 ga. 75 A - 16 ga. 60 A.)

3.Hold the electrode in a 30-45° angle with the tip of the electrode pointing upwards.

4.Hold a VERY SHORT arc, but do not let the elec- trode touch the metal.

5. An up and down whipping

Very

short

motion will help prevent

arc

burn-through on very thin plate.

 

30°-40°

6. Watch the molten metal carefully.

The important thing is to continue lowering the entire arm as the weld is made so the angle of the electrode does not change. Move the electrode fast enough so that the slag does not catch up with the arc.

POWER-ARC 4000

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Contents Safety Depends on You POWER-ARCCalifornia Proposition 65 Warnings SafetyElectric Shock can kill Welding Sparks can cause fire or explosion Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications POWER-ARC InstallationSafety Precautions Location and VentilationStoring PRE-OPERATION Engine Service Cert. Kool Bore Spark ArresterWelding Cable Connections Electrical Output ConnectionsCable Size for 125 ampAuxiliary Power Receptacles Machine GroundingPlugs and HAND-HELD Equipment Circuit Breakers Premises WiringThese Devices Without POWER-ARC Table of Contents Operation Section Operation Safety InstructionsOperating Instructions General DescriptionDesign Features Advantages Operational Features and ControlsRecommended Applications Welding CapabilityGENERATOR/WELDER Controls Controls and Settings20 AMP, 120 Volt Duplex Receptacle Gasoline Engine ControlsEngine Operation Before Starting the EngineStarting the Engine For a HOT Engine To USE the Generator AS AN Auxiliary Power Supply Generator OperationGeneral Information Suggested Power Applications Running Watts Start-up Watts Table B.1 Generator Power ApplicationsWelding Operation Table B.2 Welding APPLICATIONS/ELECTRODE Selection Guide Welding GuidelinesOperation What Happens in the Arc? Correct Welding Position Correct Arc Length Use the following PracticeDo the following Butt WeldsPenetration Fillet WeldsVertical-Down Welding Vertical-Up WeldingOverhead Welding Hardfacing To Reduce WearWelding Sheet Metal Cast Iron Plate Preparation Welding Cast IronHigh-Speed Group AWS E6013 Out-of-Position Group AWS E6011Low Hydrogen Group Stable-Arc E7018 Table of Contents Accessories Section Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Section Routine and Periodic Maintenance MaintenanceEngine Maintenance Engine AdjustmentsFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Table D.1 Engine Maintenance Schedule Do not attempt to polish slip rings while engine is running GENERATOR/WELDER MaintenanceFigure 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 Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairOutput Problems TroubleshootingOr contact your local Lincoln Electric Authorized Field SerVice Facility Local Lincoln Electric Authorized Field Service FacilityTroubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment Rotor Voltage Test This procedure takes approximately 15 minutes to performTest Description Materials NeededRotor Voltage Test Test ProcedureRotor Resistance Test This procedure takes approximately 25 minutes to performRotor Resistance Test Figure F.3 Brushes Retained with Cable TIE This procedure takes approximately 20 minutes to perform Engine Throttle Adjustment TestStrobe-tach Method Frequency Counter MethodOscilloscope Method Wing NUT High 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 Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal This procedure takes approximately 35 minutes to perform Capacitor AND/OR Diode Bridge Removal and ReplacementFigure F.8 Location and Discharging the Field Capacitor Procedure Capacitor Removal and REPLACE- MentFigure F.8A Field Diode Bridge Location Procedure Field Diode Bridge Removal and ReplacementSTATOR/ROTOR Removal and Replacement This procedure takes approximately 3 hours to performInstructions STATOR/ROTOR Removal and Replacement Troubleshooting & Repair Rotor Removal Procedure Figure F.12 Checking ROTOR-STATOR AIR GAP Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1Return to Section TOC Table of Contents Diagrams Section Wiring Diagram Power ARC DiagramsDIAGRAMSG-3 DIAGRAMSG-4 Dimension Print Power ARC Return to Section TOC SVM Error Reporting Form
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