Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM103-C Weld Winding and Reactor, Auxiliary Power Overcurrent Protection

Models: SVM103-C

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E-4E-4

THEORY OF OPERATION

FIGURE E.4 – WELDING OUTPUT

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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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 4000 provides the user with 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 optimum welding characteristics when used with the recom- mended electrodes.

AUXILIARY POWER OVERCURRENT PROTECTION

The 4000 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

POWER-ARC 4000

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Lincoln Electric SVM103-C service manual Weld Winding and Reactor, Auxiliary Power Overcurrent Protection

Contents

POWER-ARC Safety Depends on YouSafety California Proposition 65 WarningsElectric 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-ARCSafety Precautions Location and VentilationStoring PRE-OPERATION Engine Service Spark Arrester Cert. Kool BoreElectrical Output Connections Welding Cable ConnectionsCable Size for 125 ampAuxiliary Power Receptacles Machine GroundingPlugs and HAND-HELD Equipment Premises Wiring Circuit BreakersThese Devices Without POWER-ARC Table of Contents Operation Section Safety Instructions OperationOperating Instructions General DescriptionOperational Features and Controls Design Features AdvantagesRecommended Applications Welding CapabilityControls and Settings GENERATOR/WELDER ControlsGasoline Engine Controls 20 AMP, 120 Volt Duplex ReceptacleEngine Operation Before Starting the EngineStarting the Engine For a HOT Engine To USE the Generator AS AN Auxiliary Power Supply Generator OperationGeneral Information Table B.1 Generator Power Applications Suggested Power Applications Running Watts Start-up WattsWelding Operation Welding Guidelines Table B.2 Welding APPLICATIONS/ELECTRODE Selection GuideOperation What Happens in the Arc? Correct Welding Position Correct Arc Length Practice Use the followingDo the following Butt WeldsFillet Welds PenetrationVertical-Up Welding Vertical-Down WeldingOverhead Welding Hardfacing To Reduce WearWelding Sheet Metal Welding Cast Iron Cast Iron Plate PreparationHigh-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 Maintenance Routine and Periodic MaintenanceEngine Maintenance Engine AdjustmentsFigure 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 runningFigure D.6. Major Component Locations Table of Contents Theory of Operation Section Theory of Operation ENGINE, EXCITATION, Rotor and StatorRotor Field Feedback and Auxiliary Power Figure E.3 Field Excitation and Auxiliary PowerAuxiliary Power Overcurrent Protection Weld Winding and ReactorTable of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuideTroubleshooting Output ProblemsOr contact your local Lincoln Electric Authorized Field SerVice Facility Field Service Facility Local Lincoln Electric AuthorizedTroubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment This procedure takes approximately 15 minutes to perform Rotor Voltage TestTest Description Materials NeededTest Procedure Rotor Voltage TestThis procedure takes approximately 25 minutes to perform Rotor Resistance TestRotor Resistance Test Figure F.3 Brushes Retained with Cable TIE Engine Throttle Adjustment Test This procedure takes approximately 20 minutes to performStrobe-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 Brush Removal and Replacement DescriptionBrush Removal and Replacement ProcedureProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal and Replacement This procedure takes approximately 35 minutes to performProcedure Capacitor Removal and REPLACE- Ment Figure F.8 Location and Discharging the Field CapacitorProcedure Field Diode Bridge Removal and Replacement Figure F.8A Field Diode Bridge LocationSTATOR/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 Auxiliary Power Receptacle OUTPUT1 Retest After RepairEngine Output WELDER/GENERATOR OUTPUT1Return to Section TOC Table of Contents Diagrams Section Diagrams Wiring Diagram Power ARCDIAGRAMSG-3 DIAGRAMSG-4 Dimension Print Power ARC Return to Section TOC SVM Error Reporting Form