Theory of Operation | Lincoln Electric SVM103-C instruction

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E-2E-2

THEORY OF OPERATION

FIGURE E.2 – ENGINE, ROTOR AND STATOR

REACTOR

OUTPUT

TERMINALS

		STATOR
ENGINE	MECHANICAL
	ROTATION
	ROTOR	ROTOR
	SLIP
	RINGS
MAGNETO		STATOR
		STATOR
	CAPACITOR

RHEOSTAT

115 AND 230VAC

RECEPTACLES

BRIDGE

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ENGINE, EXCITATION, ROTOR AND STATOR

A small voltage developed by the engine magneto is fed through a diode to the rotating field coil in the rotor via a brush and slip ring configuration. This excitation (“flashing”) voltage magnetizes the rotor lamination. The rotor is mechanically coupled to the engine. The rotating magnet induces a voltage in the stationary windings of the main alternator (stator).

Three separate and isolated windings are incor- porated in the stator lamination assembly. Each winding set has a different number of turns, produc- ing different magnitudes of AC output voltages. The three windings are the weld winding, the auxiliary power winding and the field feedback winding. The field feedback winding provides rotor current during machine operation. The output of the PowerArc 4000 is dependent on two criteria: the engine RPM and the amount of current in the rotor winding.

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

POWER-ARC 4000

Image 46

Lincoln Electric SVM103-C service manual Theory of Operation, ENGINE, EXCITATION, Rotor and Stator

Contents

POWER-ARC Safety Depends on You Safety California Proposition 65 Warnings Electric 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 Installation Technical Specifications POWER-ARC Location and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Spark Arrester Cert. Kool Bore Cable Size for Electrical Output ConnectionsWelding Cable Connections 125 amp Machine Grounding Auxiliary Power ReceptaclesPlugs and HAND-HELD Equipment Premises Wiring Circuit Breakers These Devices Without POWER-ARC Table of Contents Operation Section Operating Instructions Safety InstructionsOperation General Description Recommended Applications Operational Features and ControlsDesign Features Advantages Welding Capability Controls and Settings GENERATOR/WELDER Controls Gasoline Engine Controls 20 AMP, 120 Volt Duplex Receptacle Before Starting the Engine Engine OperationStarting the Engine For a HOT Engine Generator Operation To USE the Generator AS AN Auxiliary Power SupplyGeneral Information Table B.1 Generator Power Applications Suggested Power Applications Running Watts Start-up Watts Welding Operation Welding Guidelines Table B.2 Welding APPLICATIONS/ELECTRODE Selection Guide Operation What Happens in the Arc? Correct Welding Position Correct Arc Length Do the following PracticeUse the following Butt Welds Fillet Welds Penetration Vertical-Up Welding Vertical-Down Welding Hardfacing To Reduce Wear Overhead WeldingWelding Sheet Metal Welding Cast Iron Cast Iron Plate Preparation Out-of-Position Group AWS E6011 High-Speed Group AWS E6013Low Hydrogen Group Stable-Arc E7018 Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesLincoln Electric Accessories Table of Contents Maintenance Section Engine Maintenance MaintenanceRoutine and Periodic Maintenance Engine Adjustments Figure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Table D.1 Engine Maintenance Schedule GENERATOR/WELDER Maintenance Do not attempt to polish slip rings while engine is running Figure D.6. Major Component Locations Table of Contents Theory of Operation Section Theory of Operation ENGINE, EXCITATION, Rotor and Stator Rotor Field Feedback and Auxiliary Power Figure E.3 Field Excitation and Auxiliary Power Auxiliary Power Overcurrent Protection Weld Winding and Reactor Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting Guide Troubleshooting Output Problems Electric Authorized Field Ser Or contact your local LincolnVice Facility Field Service Facility Local Lincoln Electric Authorized Troubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment Test Description This procedure takes approximately 15 minutes to performRotor Voltage Test Materials Needed Test Procedure Rotor Voltage Test This procedure takes approximately 25 minutes to perform Rotor Resistance Test Rotor Resistance Test Figure F.3 Brushes Retained with Cable TIE Engine Throttle Adjustment Test This procedure takes approximately 20 minutes to perform Frequency Counter Method Strobe-tach MethodOscilloscope Method Wing NUT High 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 Description Brush Removal and Replacement Procedure Procedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal and Replacement This procedure takes approximately 35 minutes to perform Procedure Capacitor Removal and REPLACE- Ment Figure F.8 Location and Discharging the Field Capacitor Procedure Field Diode Bridge Removal and Replacement Figure F.8A Field Diode Bridge Location This procedure takes approximately 3 hours to perform STATOR/ROTOR Removal and ReplacementInstructions STATOR/ROTOR Removal and Replacement Troubleshooting & Repair Rotor Removal Procedure Figure F.12 Checking ROTOR-STATOR AIR GAP Engine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair WELDER/GENERATOR OUTPUT1 Return to Section TOC Table of Contents Diagrams Section Diagrams Wiring Diagram Power ARC DIAGRAMSG-3 DIAGRAMSG-4 Dimension Print Power ARC Return to Section TOC SVM Error Reporting Form