Electrical Output Connections | Lincoln Electric SVM197-A guide

Section TOC

Master TOC

A-6

INSTALLATION

A-6

POWERARC® 5500 OUTPUT CONNECTIONS

Physical Location of Items and Components may vary by Code No.

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FIGURE A.1 (For Codes 11182, 11187, 11215)

7

1

9

POWER ARC 5500

80

70AMPS

AMPS

125	90
AMPS	90
GENERATOR	AMPS

100

AMPS

WARNING

6

ELECTRODE SELECTION GUIDE

2

5

	3
2	4
2

1.CURRENT CONTROL DIAL

2.WELD OUTPUT TERMINALS (2)

3.GROUND STUD

4.CIRCUIT BREAKERS (2) - 20 AMP

5.RECEPTACLE - 240 VOLT, 20 AMP

6.DUPLEX RECEPTACLE - 120 VOLT, 20 AMP

7.TACHOMETER / HOUR METER (CODE 11215 ONLY)

FIGURE A.2 (For Codes 11403, 11404)

1

POWER ARC 5500

80

70AMPS

AMPS

125	90
AMPS	90
GENERATOR	AMPS

100

AMPS

WARNING

8

ELECTRODE SELECTION GUIDE

7

	4	5
3	4	6
3

1.CURRENT CONTROL DIAL

2.WELD OUTPUT TERMINALS (2)

3.GROUND STUD

4.CIRCUIT BREAKER- 20 AMP

5.RECEPTACLE - 240 VOLT, 20 AMP

6.DUPLEX RECEPTACLE - 120 VOLT, 20 AMP

7.TACHOMETER / HOUR METER (CODE 11404 ONLY)

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ELECTRICAL OUTPUT

CONNECTIONS

See Figure A.1 for the location of the current control dial, weld output terminals, ground stud, circuit break- ers, 240 and 120 volt receptacles.

WELDING CABLE CONNECTIONS

Cable Size and Length

Be sure to use welding cables that are large enough. The correct size and length becomes especially important when you are welding at a distance from the welder.

Table A.1 lists recommended cable sizes and lengths for rated current and duty cycle. Length refers to the distance from the welder to the work and back to the welder. Cable diameters are increased for long cable lengths to reduce voltage drops.

TABLE A.1

RECOMMENDED WELDING CABLE

SIZE AND LENGTH

TOTAL COMBINED LENGTH OF ELECTRODE AND

WORK CABLES


	Cable Size for
	125 amp/
Cable Length	30% Duty Cycle
0-50 feet (0-15 meters)	6 AWG
50-100 feet (15-39 meters)	4 AWG
100-150 feet (30-46 meters)	3 AWG
150-200 feet (46-61 meters)	2 AWG
200-250 feet (61-76 meters)	1 AWG

POWERARC® 5500

Image 14

Lincoln Electric SVM197-A Electrical Output Connections, Powerarc 5500 Output Connections, Welding Cable Connections

Contents

Powerarc ISAFETYi Safety Electric Shock can kill ARC Rays can burn For Electrically Iii Précautions DE Sûreté Electromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Powerarc Storing Safety PrecautionsLocation and Ventilation Engine Exhaust can kill PRE-OPERATION Engine Service Spark Arrester PowerArc 5500 Typical Fuel ConsumptionMuffler Deflector Honda 9 HP Welding Cable Connections Powerarc 5500 Output ConnectionsElectrical Output Connections Cable Size and Length Plugs and HAND-HELD Equipment Auxiliary Power ReceptaclesCable Installation Machine Grounding Premises Wiring Circuit Breakers Table A.2 Electrical Device USE with the Powerarc Type Common Electrical Devices Possible Concerns Powerarc Table of Contents Operation Section Operation Output Panel Controls Controls and SettingsLimitations Physical Location of Components may vary by Code No Engine Operation Gasoline Engine Controls Before Starting the Engine Starting the Engine General Information Generator OperationStopping the Engine Running the Engine Table B.3 Generator Power Applications Welding Operation Control Function / Operation Current Control Dial Material Thickness Electrode Type Size Setting Welding Guidelines What Happens in the Arc? Welding circuit for Stick shielded metal arc welding Correct Arc Length Correct Welding PositionCorrect Way to Strike An Arc Correct Welding Speed Use the following Common MetalsTypes of Welds Do the following Penetration Welding in the Vertical Position Vertical-Up Welding Vertical-Down Welding Hardfacing To Reduce Wear How to Hardface the Sharp Edge Metal to Ground WearOverhead Welding Welding Sheet Metal Welding Cast Iron Cast Iron Plate Preparation Low Hydrogen Group AWS E7018 Selecting ElectrodesHigh-Speed Group AWS E6013 Out-of-Position Group AWS E6011 Powerarc Table of Contents Accessories Section Lincoln Electric Accessories AccessoriesOPTIONS/ACCESSORIES Table of Contents Maintenance Section Engine Maintenance MaintenanceRoutine and Periodic Maintenance Engine Adjustments Figure D.3 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Table D.1 Engine Maintenance Parts Part Robin / Subaru Honda GENERATOR/WELDER Maintenance Do not attempt to polish slip rings while engine is running Figure D.6. Major Component Locations 1TABLE of CONTENTS-THEORY of Operation Section E-1 ENGINE, EXCITATION, Rotor and Stator Theory of OperationEngine Control and Ignition Rotor Field Feedback Auxiliary Power Return Auxiliary Power Overcurrent Protection Weld Winding and Reactor 1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting Guide Troubleshooting 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 Needed Flashing Voltage Test Procedure 14TROUBLESHOOTING and REPAIRF-14Rotor Voltage Test Procedure Lead Rotor 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 Engine High Speed Stop Screw High Idle no Load Scope SettingsNormal Open Circuit Weld Voltage Waveform Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded to 125 Amps AT 23 VAC Typical Weld Output WaveformMachine Loaded Brush Removal and Replacement Procedure Brush Removal and Replacement Procedure Powerarc Rheostat Removal and Replacement Procedure Rheostat Removal and Replacement Procedure Troubleshooting and Repair Attachment for 202A Cable Tie Capacitor Procedure Capacitor Removal and REPLACE- MentCapacitor AND/OR Diode Bridge Attachment for 201 201A Jumper Procedure Field Diode Bridge Removal and Replacement Figure F.10 Field Diode Bridge Location Powerarc STATOR/ROTOR Removal and Replacement Procedure Stator Removal Procedure STATOR/ROTOR Section TOC Rotor Removal Procedure Procedure Reactor Bolts Lead Engine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair WELDER/GENERATOR OUTPUT1 Powerarc Table of Contents Diagram Section Electrical Diagrams Wiring Diagram Codes 11182, 11187, 11329 S25984 Wiring Diagram Codes 11403, 11405 S26829 Switch Wiring Diagram Power ARC Wiring Diagram Code 11404 S26830 Wiring Diagram Code 11215 S26023 Schematic -CODES 11182, 11187, 11329 S26008 S26008 Schematic Codes 11403, 11405 S26881 S26881 Schematic Code 11404 S26882 S26882