Lincoln Electric SVM197-A manual

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E-1TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1

Theory of Operation	Section E
Block Logic Diagram	E-1
Engine Control & Ignition, Rotor and Stator	E-2
Rotor Field Feedback and Auxiliary Power	E-3
Welding Output	E-4

FIGURE E.1 – POWERARC® 5500 BLOCK LOGIC DIAGRAM

		REACTOR
			OUTPUT
			TERMINALS
		STATOR
ENGINE	MECHANICAL
	ROTATION
	ROTOR	ROTOR
	SLIP
MAGNETO	RINGS
MAGNETO
CIRCUIT		STATOR
		STATOR
	CAPACITOR
LOW OIL
SWITCH		CIRCUIT	CIRCUIT
		CIRCUIT	CIRCUIT
		BREAKER	BREAKER
RUN/STOP
	SWITCH
	RHEOSTAT	BRIDGE
	RHEOSTAT
		230VAC	115VAC
		RECEPTACLES	RECEPTACLES

POWERARC® 5500

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Lincoln Electric SVM197-A service manual 1TABLE of CONTENTS-THEORY of Operation Section E-1

Contents

Powerarc ISAFETYi Electric Shock can kill ARC Rays can burn Safety Iii For Electrically Précautions DE Sûreté Electromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Powerarc Installation Location and Ventilation Safety PrecautionsStoring Engine Exhaust can kill PRE-OPERATION Engine Service Muffler Deflector PowerArc 5500 Typical Fuel ConsumptionSpark Arrester Honda 9 HP Electrical Output Connections Powerarc 5500 Output ConnectionsWelding Cable Connections Cable Size and Length Cable Installation Auxiliary Power ReceptaclesPlugs and HAND-HELD Equipment Machine Grounding Circuit Breakers Premises Wiring Type Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the Powerarc Powerarc Table of Contents Operation Section Operation Limitations Controls and SettingsOutput Panel Controls Physical Location of Components may vary by Code No Gasoline Engine Controls Engine Operation Starting the Engine Before Starting the Engine Stopping the Engine Generator OperationGeneral Information Running the Engine Table B.3 Generator Power Applications Control Function / Operation Current Control Dial Welding Operation Welding Guidelines Material Thickness Electrode Type Size Setting Welding circuit for Stick shielded metal arc welding What Happens in the Arc? Correct Way to Strike An Arc Correct Welding PositionCorrect Arc Length Correct Welding Speed Types of Welds Common MetalsUse the following Do the following Welding in the Vertical Position Penetration Vertical-Down Welding Vertical-Up Welding Overhead Welding How to Hardface the Sharp Edge Metal to Ground WearHardfacing To Reduce Wear Welding Sheet Metal Cast Iron Plate Preparation Welding Cast Iron High-Speed Group AWS E6013 Selecting ElectrodesLow Hydrogen Group AWS E7018 Out-of-Position Group AWS E6011 Powerarc Table of Contents Accessories Section Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Section Maintenance Routine and Periodic MaintenanceEngine Maintenance Figure D.3 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Engine Adjustments Part Robin / Subaru Honda Table D.1 Engine Maintenance Parts Do not attempt to polish slip rings while engine is running GENERATOR/WELDER Maintenance Figure D.6. Major Component Locations 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Engine Control and IgnitionENGINE, EXCITATION, Rotor and Stator Return Rotor Field Feedback Auxiliary Power Weld Winding and Reactor Auxiliary Power Overcurrent Protection 1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2 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 Materials Needed Test Description Rotor Voltage Test Procedure 14TROUBLESHOOTING and REPAIRF-14Flashing 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 ROBIN/SUBARU Engine Engine Throttle Adjustment Test 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 Procedure Brush Removal and Replacement Procedure Powerarc Rheostat Removal and Replacement Procedure Rheostat Removal and Replacement Procedure Troubleshooting and Repair Capacitor AND/OR Diode Bridge Procedure Capacitor Removal and REPLACE- MentAttachment for 202A Cable Tie Capacitor Attachment for 201 201A Jumper Figure F.10 Field Diode Bridge Location Procedure Field Diode Bridge Removal and Replacement Powerarc STATOR/ROTOR Removal and Replacement Procedure STATOR/ROTOR Stator Removal Procedure Section TOC Rotor Removal Procedure Procedure Reactor Bolts Lead Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1 Powerarc Table of Contents Diagram Section Wiring Diagram Codes 11182, 11187, 11329 S25984 Electrical Diagrams Switch Wiring Diagram Codes 11403, 11405 S26829 Wiring Diagram Code 11404 S26830 Wiring Diagram Power ARC Wiring Diagram Code 11215 S26023 S26008 Schematic -CODES 11182, 11187, 11329 S26008 S26881 Schematic Codes 11403, 11405 S26881 S26882 Schematic Code 11404 S26882