Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM197-A Electrical Output Connections, POWERARC 5500 OUTPUT CONNECTIONS

Models: SVM197-A

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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

SERVICE MANUAL Safety Depends on YouPOWERARC View Safety Info View Safety Info View Safety Info View Safety InfoELECTRIC AND MAGNETIC FIELDS may be dangerous iSAFETYiFOR ENGINE powered equipment POWERARCARC RAYS can burn SAFETYELECTRIC SHOCK can kill FUMES AND GASESCYLINDER may explode powered equipmentWELDING and CUTTING SPARKS canPOWERARC PRÉCAUTIONS DE SÛRETÉSAFETY Return to Master TOC Return to Master TOC Return to Master TOCPOWERARC Electromagnetic Compatibility EMCSAFETY Return to Master TOC Return to Master TOC Return to Master TOCElectromagnetic Compatibility EMC SAFETYPOWERARC Return to Master TOC Return to Master TOC Return to Master TOCPOWERARC I - MASTER TABLE OF CONTENTS FOR ALL SECTIONSSafety PageReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - INSTALLATION SECTIONPOWERARC Return to Master TOCDisplacement INSTALLATIONTECHNICAL SPECIFICATIONS - POWERARC AC Auxiliary PowerSTORING SAFETY PRECAUTIONSLOCATION AND VENTILATION INSTALLATIONTILTING PRE-OPERATION ENGINE SERVICESTACKING FUELSPARK ARRESTER PowerArc 5500 Typical Fuel ConsumptionMUFFLER DEFLECTOR INSTALLATIONPhysical Location of Items and Components may vary by Code No POWERARC 5500 OUTPUT CONNECTIONSELECTRICAL OUTPUT CONNECTIONS WELDING CABLE CONNECTIONSMACHINE GROUNDING AUXILIARY POWER RECEPTACLESPLUGS AND HAND-HELD EQUIPMENT INSTALLATIONINSTALLATION PREMISES WIRINGCIRCUIT BREAKERS POWERARCReturn to Section TOC Return to Section TOC Return to Section TOC INSTALLATIONPOWERARC Return to Section TOCReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - OPERATION SECTIONPOWERARC Return to Master TOCOPERATION SAFETY INSTRUCTIONSOPERATIONAL FEATURES AND CONTROLS GENERAL DESCRIPTIONOUTPUT PANEL CONTROLS CONTROLS AND SETTINGSLIMITATIONS Physical Location of Components may vary by Code NoSee SPARK ARRESTER in the INSTALLATION section of this manual ENGINE OPERATIONGASOLINE ENGINE CONTROLS POWERARCPOWERARC BEFORE STARTING THE ENGINESTARTING THE ENGINE OPERATIONGENERAL INFORMATION GENERATOR OPERATIONSTOPPING THE ENGINE RUNNING THE ENGINEReturn to Section TOC Return to Section TOC Return to Section TOC POWERARCOPERATION Return to Section TOCTO USE THE POWERARC 5500 FOR WELDING WELDING OPERATIONCONTROL FUNCTION / OPERATION “Current Control Dial” POWERARCStick Welding Semi-automatic, Wire Welding With a Lincoln Wire Feeder / WelderWELDING GUIDELINES Learning To Stick WeldOPERATION What Happens in the Arc?POWERARC B-103. The Correct Arc Length 1. The Correct Welding Position2. The Correct Way to Strike An Arc 4. The Correct Welding SpeedTypes of Welds PRACTICECommon Metals POWERARCGood POWERARCOPERATION 1/8 3.2mmB-14 POWERARCOPERATION B-14OPERATION How to Hardface the Sharp Edge Metal to Ground WearPOWERARC Side Viewhot coldcold POWERARCOPERATION White brittle cast ironOPERATION Selecting ElectrodesPOWERARC MotionsReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - ACCESSORIES SECTIONPOWERARC Return to Master TOCLINCOLN ELECTRIC ACCESSORIES ACCESSORIESOPTIONS/ACCESSORIES POWERARCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - MAINTENANCE SECTIONPOWERARC Return to Master TOCENGINE MAINTENANCE MAINTENANCEROUTINE AND PERIODIC MAINTENANCE FIGURE D.2 - OIL DRAIN AND REFILLFIGURE D.4 - CLEAN COOLING SYSTEM ENGINE ADJUSTMENTSFIGURE D.3 - CLEAN ROTATING SCREEN/FINGER GUARD/DEBRIS GUARD MAINTENANCEMAINTENANCE TABLE D.1 ENGINE MAINTENANCE PARTSFIGURE D.5 - SET SPARK PLUG GAP POWERARCPOWERARC GENERATOR/WELDER MAINTENANCEMAINTENANCE Return to Master TOC Return to Master TOCFIGURE D.6. - MAJOR COMPONENT LOCATIONS MAINTENANCEPOWERARC E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1FIGURE E.1 - POWERARC 5500 BLOCK LOGIC DIAGRAM Block Logic DiagramENGINE, EXCITATION, ROTOR AND STATOR THEORY OF OPERATIONENGINE CONTROL AND IGNITION POWERARCPOWERARC ROTOR FIELD FEEDBACK AND AUXILIARY POWERFIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER THEORY OF OPERATIONPOWERARC AUXILIARY POWER OVERCURRENT PROTECTIONWELD WINDING AND REACTOR THEORY OF OPERATIONReturn to Master TOC Return to Master TOC Return to Master TOC F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1POWERARC Return to Master TOCStep 1. LOCATE PROBLEM SYMPTOM F-2TROUBLESHOOTING AND REPAIRF-2HOW TO USE TROUBLESHOOTING GUIDE POWERARCPOWERARC TROUBLESHOOTING AND REPAIRPC BOARD TROUBLESHOOTING PROCEDURES Return to Section Return to Section TOCSYMPTOMS TROUBLESHOOTING AND REPAIRPROBLEMS MISADJUSTMENTSSSYMPTOMS TROUBLESHOOTING AND REPAIRPROBLEMS MISADJUSTMENTSSSYMPTOMS TROUBLESHOOTING AND REPAIRPROBLEMS MISADJUSTMENTSSSYMPTOMS TROUBLESHOOTING AND REPAIRPROBLEMS MISADJUSTMENTSSSYMPTOMS TROUBLESHOOTING AND REPAIRPROBLEMS MISADJUSTMENTSSSYMPTOMS TROUBLESHOOTING AND REPAIRPROBLEMS MISADJUSTMENTSSSYMPTOMS TROUBLESHOOTING AND REPAIRPROBLEMS MISADJUSTMENTSSSYMPTOMS TROUBLESHOOTING AND REPAIRPROBLEMS MISADJUSTMENTSSReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCMATERIALS NEEDED ROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURETEST DESCRIPTION TROUBLESHOOTING AND REPAIRROTOR VOLTAGE TEST PROCEDURE F-14TROUBLESHOOTING AND REPAIRF-14ROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURE continued FLASHING VOLTAGE TEST PROCEDUREPOWERARC ROTOR RESISTANCE TEST PROCEDURETROUBLESHOOTING AND REPAIR TEST DESCRIPTIONTROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TEST PROCEDURE continuedROTOR RESISTANCE TEST continued PROCEDUREPOWERARC TROUBLESHOOTING AND REPAIRROTOR RESISTANCE TEST PROCEDURE continued ROTOR RESISTANCE TEST continuedReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCPOWERARC ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINETROUBLESHOOTING AND REPAIR TEST DESCRIPTIONTROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continuedTEST PROCEDURE POWERARCPOWERARC TROUBLESHOOTING AND REPAIRENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continued HIGH SPEED STOP SCREWHIGH IDLE - NO LOAD SCOPE SETTINGSNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM TROUBLESHOOTING AND REPAIRSCOPE SETTINGS NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115 VAC SUPPLYTROUBLESHOOTING AND REPAIR POWERARCMACHINE LOADED TO 125 AMPS AT 23 VAC TYPICAL WELD OUTPUT WAVEFORMMACHINE LOADED TROUBLESHOOTING AND REPAIRPOWERARC BRUSH REMOVAL AND REPLACEMENT PROCEDURETROUBLESHOOTING AND REPAIR TEST DESCRIPTIONTROUBLESHOOTING AND REPAIR BRUSH REMOVAL AND REPLACEMENT continuedPROCEDURE POWERARCPROCEDURE continued TROUBLESHOOTING AND REPAIRBRUSH REMOVAL AND REPLACEMENT continued POWERARCReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCPOWERARC RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURETROUBLESHOOTING AND REPAIR TEST DESCRIPTIONPROCEDURE RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE continuedTROUBLESHOOTING AND REPAIR POWERARCPOWERARC CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT PROCEDURETROUBLESHOOTING AND REPAIR TEST DESCRIPTIONCAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT PROCEDURE continuedPROCEDURE - CAPACITOR REMOVAL AND REPLACE- MENT TROUBLESHOOTING AND REPAIRREMOVAL AND REPLACEMENT PROCEDURE continued PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR POWERARCReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCPOWERARC STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURETROUBLESHOOTING AND REPAIR TEST DESCRIPTIONTROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continuedSTATOR REMOVAL PROCEDURE POWERARCPOWERARC TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continued Section TOCTROUBLESHOOTING AND REPAIR ROTOR REMOVAL PROCEDUREREASSEMBLY PROCEDURE STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continuedProcedure TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continued 23. Conduct the Retest After Repair ProcedurePOWERARC TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continued REACTOR BOLTSENGINE OUTPUT AUXILIARY POWER RECEPTACLE OUTPUT1RETEST AFTER REPAIR WELDER/GENERATOR OUTPUT1Return to Section TOC POWERARCReturn to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - DIAGRAM SECTIONPOWERARC Return to Master TOCWIRING DIAGRAM - CODES 11182, 11187, 11329 S25984 WIRING DIAGRAM - POWER ARCELECTRICAL DIAGRAMS ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODES 11403, 11405 S26829WIRING DIAGRAM - POWER ARC S26829ELECTRICAL DIAGRAMS WIRING DIAGRAM - POWER ARCWIRING DIAGRAM - CODE 11404 S26830 ELECTRICAL SYMBOLS PER E1537ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODE 11215 S26023WIRING DIAGRAM - POWER ARC CONNECTOR POWER ARCMACHINE SCHEMATIC TEMPERATURES26881 POWER ARC 5500 SUBARU ROBINSCHEMATIC - CODES 11403, 11405 S26881 MACHINE SCHEMATICS26882 POWER ARC 5500 HONDASCHEMATIC - CODE 11404 S26882 MACHINE SCHEMATIC