Manuals / Lincoln Electric / Lawn and Garden / Portable Generator

Lincoln Electric SVM208-A Weld Winding And Reactor, Theory Of Operation, Return, Bulldog

Models: SVM208-A

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WELD WINDING AND REACTOR

E-4	THEORY OF OPERATION	E-4

FIGURE E.4 - WELD WINDING, REACTOR AND AUXILIARY POWER OVERCURRENT PROTECTION

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ENGINE

MAGNETO

MECHANICAL ROTATION

ROTOR

SLIP

RINGS

CAPACITOR

REACTOR

OUTPUT

TERMINALS

STATOR

ROTOR

STATOR

Return

115 AND 230VAC

RECEPTACLES

RHEOSTATBRIDGE

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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 output terminals. The BULLDOG 140 provides the user up to 125 amps of constant current AC welding for stick elec- trodes. 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 recommended elec- trodes.

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

BULLDOG® 140

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Lincoln Electric SVM208-A Weld Winding And Reactor, Theory Of Operation, Return to Master TOC to Master TOC, Bulldog

Contents

Safety Depends on You JanuarySERVICE MANUAL View Safety Info View Safety Info View Safety Info View Safety InfoSAFETY FOR ENGINE powered equipmentELECTRIC AND MAGNETIC FIELDS may be dangerous CALIFORNIA PROPOSITION 65 WARNINGSELECTRIC SHOCK can kill ARC RAYS can burncan be dangerous FUMES AND GASESFOR ELECTRICALLY powered equipment WELDING and CUTTING SPARKS can cause fire or explosionCYLINDER may explode if damaged SAFETYPRÉCAUTIONS DE SÛRETÉ SAFETYReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSAFETY Electromagnetic Compatibility EMCInstallation and Use Return to Master TOC Return to Master TOC Return to Master TOCSAFETY Maintenance of the Welding EquipmentElectromagnetic Compatibility EMC Return to Master TOC Return to Master TOC Return to Master TOCI - MASTER TABLE OF CONTENTS FOR ALL SECTIONS SafetyPage BULLDOGTABLE OF CONTENTS - INSTALLATION SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC BULLDOGINSTALLATION TECHNICAL SPECIFICATIONS - Bulldog 140 K2708-1Displacement AC Auxiliary PowerSAFETY PRECAUTIONS LOCATION AND VENTILATIONSTORING INSTALLATIONPRE-OPERATION ENGINE SERVICE STACKINGTILTING FUELELECTRICAL OUTPUT CONNEC- TIONS WELDING CABLE CONNECTIONSTABLE A.1 RECOMMENDED WELDING CABLE SIZE AND LENGTH Bulldog 140 OUTPUT CONNECTIONSAUXILIARY POWER RECEPTACLES ELECTRICAL CONNECTIONSPLUGS AND HAND-HELD EQUIPMENT INSTALLATIONPREMISES WIRING CIRCUIT BREAKERSINSTALLATION Return to Section TOC Return to Section TOC Return to Section TOCINSTALLATION Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCTABLE OF CONTENTS - OPERATION SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC BULLDOGSAFETY INSTRUCTIONS OPERATIONAL FEATURES AND CONTROLSOPERATION GENERAL DESCRIPTIONCONTROLS AND SETTINGS LIMITATIONSWELDER/GENERATOR CONTROLS OUTPUT PANEL CONTROLSENGINE OPERATION GASOLINE ENGINE CONTROLSOPERATION Return to Section TOC Return to Section TOC Return to Section TOCBEFORE STARTING THE ENGINE STARTING THE ENGINEOPERATION Return to Section TOC Return to Section TOC Return to Section TOCGENERATOR OPERATION STOPPING THE ENGINERUNNING THE ENGINE BREAK-IN PERIODGENERATOR POWER APPLICATIONS Suggested Power ApplicationsOPERATION Return to Section TOC Return to Section TOC Return to Section TOCWELDING OPERATION CONTROL FUNCTION / OPERATION“Current Control Dial” OPERATIONSemi-automatic, Wire Welding With a Lincoln Wire Feeder / Welder WELDING GUIDELINESStick Welding Learning To Stick WeldWhat Happens in the Arc? OPERATIONB-10 B-101. The Correct Welding Position 2. The Correct Way to Strike An Arc3. The Correct Arc Length 4. The Correct Welding SpeedPRACTICE Types of WeldsCommon Metals OPERATIONGood 1/2 Poor 12mm1/4 6mm 1/4 6mm1/8 3.2mm OPERATIONVery short30-40 OPERATIONSide View End View3030 How to Hardface the Sharp Edge Metal to Ground WearWhite brittle coldcast iron When breaking the weld stays on one pieceMotions Selecting ElectrodesOPERATION B-17Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTABLE OF CONTENTS - ACCESSORIES SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC BULLDOGACCESSORIES OPTIONS/ACCESSORIESLINCOLN ELECTRIC ACCESSORIES Return to Section TOC Return to Section TOC Return to Section TOCTABLE OF CONTENTS - MAINTENANCE SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC BULLDOGMAINTENANCE Return to Section TOCReturn to Section TOC Return to Section TOCROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCEFIGURE D.1 - OIL DRAIN AND REFILL LOCATIONENGINE ADJUSTMENTS MAINTENANCEFIGURE D.2 - CLEAN AREA FIGURE D.3 - CLEAN COOLING SYSTEMTABLE D.1 ENGINE MAINTENANCE PARTS SPARK PLUG SERVICEOPERATIONAL CLEARANCE MAINTENANCEGENERATOR/WELDER MAINTENANCE FIGURE D.6. - BRUSH REMOVAL AND REPLACEMENTMAINTENANCE 1. BRUSH, BRUSH HOLDER ASSEMBLY 2. BEARING BRACKET END COVERFIGURE D.7. - MAJOR COMPONENT LOCATIONS MAINTENANCE1. CRADLE ASSEMBLY 2. ROTOR, BLOWER, AND BEARING ASSEMBLY 3. STATOR ASSEMBLYReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCE-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 ENGINEREACTOR OUTPUT TERMINALS STATOR ROTOR STATOR FIGURE E.1 BLOCK LOGIC DIAGRAMTHEORY OF OPERATION ENGINE, EXCITATION, ROTOR AND STATORFIGURE E.2 - ENGINE, EXCITATION, ROTOR AND STATOR Return to Master TOC to Master TOCROTOR FIELD FEEDBACK AND AUXILIARY POWER FIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWERTHEORY OF OPERATION Return to Master TOC to Master TOCWELD WINDING AND REACTOR THEORY OF OPERATIONReturn to Master TOC to Master TOC ReturnF-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1 Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC BULLDOGTROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDEStep 1. LOCATE PROBLEM SYMPTOM Return to Section TOCPC BOARD TROUBLESHOOTING PROCEDURES TROUBLESHOOTING AND REPAIRReturn to Section Return to Section TOC Return to Master TOCTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSTROUBLESHOOTING AND REPAIR PROBLEMS SYMPTOMSPOSSIBLE AREAS OF MISADJUSTMENTS OUTPUT PROBLEMSTROUBLESHOOTING AND REPAIR PROBLEMS SYMPTOMSPOSSIBLE AREAS OF MISADJUSTMENTS OUTPUT PROBLEMSTROUBLESHOOTING AND REPAIR PROBLEMS SYMPTOMSPOSSIBLE AREAS OF MISADJUSTMENTS OUTPUT PROBLEMSTROUBLESHOOTING AND REPAIR PROBLEMS SYMPTOMSPOSSIBLE AREAS OF MISADJUSTMENTS ENGINE PROBLEMSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSTROUBLESHOOTING AND REPAIR PROBLEMS SYMPTOMSPOSSIBLE AREAS OF MISADJUSTMENTS WELDING PROBLEMSReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCROTOR VOLTAGE TEST TEST DESCRIPTIONMATERIALS NEEDED TROUBLESHOOTING AND REPAIRPROCEDURE ROTOR VOLTAGE TEST continuedLEAD 200A CONNECTION GROUND STUDFIELD DIODE BRIDGE TEST TROUBLESHOOTING AND REPAIRTEST DESCRIPTION MATERIALS NEEDEDFIELD DIODE BRIDGE TEST continued + ~TROUBLESHOOTING AND REPAIR PROCEDUREROTOR “FLASHING” CIRCUIT TEST TROUBLESHOOTING AND REPAIRTEST DESCRIPTION MATERIALS NEEDEDROTOR “FLASHING” CIRCUIT TEST continued 201A202A+ TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR ROTOR “FLASHING” CIRCUIT TEST continuedReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCROTOR RESISTANCE TEST TROUBLESHOOTING AND REPAIRTEST DESCRIPTION MATERIALS NEEDEDROTOR RESISTANCE TEST continued SLIP RINGSTROUBLESHOOTING AND REPAIR PROCEDURECABLE TIE BRUSHES TROUBLESHOOTING AND REPAIRROTOR RESISTANCE TEST continued Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE TROUBLESHOOTING AND REPAIRTEST DESCRIPTION MATERIALS NEEDEDENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continued TROUBLESHOOTING AND REPAIRPROCEDURE Return to Section TOCTROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continuedHIGH SPEED STOP SCREW THROTTLE LOCKING NUTSCOPE SETTINGS TROUBLESHOOTING AND REPAIRReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY HIGH IDLE - NO LOADTROUBLESHOOTING AND REPAIR SCOPE SETTINGSTYPICAL WELD OUTPUT WAVEFORM MACHINE LOADEDMACHINE LOADED TO 125 AMPS AT 23 VAC TROUBLESHOOTING AND REPAIRBRUSH REMOVAL AND REPLACEMENT TROUBLESHOOTING AND REPAIRTEST DESCRIPTION MATERIALS NEEDEDBRUSH REMOVAL AND REPLACEMENT continued CABLE TIE BRUSHESTROUBLESHOOTING AND REPAIR PROCEDURETROUBLESHOOTING AND REPAIR BRUSH REMOVAL AND REPLACEMENT continuedF-33 F-33Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCRHEOSTAT REMOVAL AND REPLACEMENT TROUBLESHOOTING AND REPAIRTEST DESCRIPTION MATERIALS NEEDEDRHEOSTAT REMOVAL AND REPLACEMENT continued TROUBLESHOOTING AND REPAIRPROCEDURE Return to Section TOC Return to Section TOCCAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT TROUBLESHOOTING AND REPAIRTEST DESCRIPTION MATERIALS NEEDEDCAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT continued PROCEDURE - CAPACITOR REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR Attachment for 202 202A +PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT TROUBLESHOOTING AND REPAIRCAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT continued Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCSTATOR/ROTOR REMOVAL AND REPLACEMENT INSTRUCTIONSTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONSTATOR/ROTOR REMOVAL AND REPLACEMENT continued TROUBLESHOOTING AND REPAIRPROCEDURE GENERATORENGINETROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT continuedReturn to Section TOC Return to Section TOC Section TOC Return to Master TOC Return to Master TOC Master TOCTROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT continuedReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCSTATOR REMOVAL PROCEDURE TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT continued Return to Section TOC Return to Section TOCTHRU BOLTS THRU BOLTS SUPPORTNUTS TROUBLESHOOTING AND REPAIRROTOR REMOVAL PROCEDURE REASSEMBLY PROCEDURETROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT continuedto Section TOC to Master TOCAUXILIARY POWER RECEPTACLE OUTPUT1 RETEST AFTER REPAIRENGINE OUTPUT WELDER/GENERATOR OUTPUT1Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTABLE OF CONTENTS - DIAGRAM SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC BULLDOGElEcTrical DiaGramS WiriNG DiaGram - cOmplETE machiNE - l15064L15064 WIRING DIAGRAM - BULLDOGSchEmaTic - cOmplETE machiNE - S28101 SUBJECTENGINEERING CONTROLLED MANUFACTURER