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SVM197-A
January, 2010
®
POWERARC 5500
For use with machine code number: 11182, 11187, 11215, 11329, 11403, 11404, 11405
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 3.b. In
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté specifiques qui parraissent dans ce la masse. Un court-circuit accidental peut provoquer un manuel aussi bien que les précautions de sûreté générales suiv- échauffement et un risque d’inc
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v v SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln El
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vi vi SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommen- dations. If interference occurs, it may be necessary to take additional precautions such as filter
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I I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A-1 A-1 TABLE OF CONTENTS - INSTALLATION SECTION Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - POWERARC® 5500 INPUT - GASOLINE ENGINE Manufacturer Description Speed Displacement Ignition Capacities Robin / Subaru 1 cyl., 3700 RPM 16.17 cu. in. Manual, Fuel: 1.6 gal. (6.1 l) EX 27 4 cycle ± 50 RPM (265 cc) Recoil start; Codes air-cooled at no load Manual choke Oil: 1.1 qts.(1.0 l) (11182, 11187) OHC gasoline (11329, 11403) 9 HP @ (11405) 3600 RPM INPUT - HONDA GASOLINE ENGINE INPUT - HONDA GASOLINE ENGINE Honda 1 cyl., 3700 RPM 16.5 cu. in. M
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A-3 A-3 INSTALLATION SAFETY PRECAUTIONS LOCATION AND VENTILATION Read this entire installation section before you Whenever you use the POWERARC® 5500, be sure that clean cooling air can flow through the machine’s start installation. gasoline engine and the generator. Avoid dusty, dirty areas. Also, keep the machine away from heat WARNING sources. Do not place the back end of the generator anywhere near hot engine exhaust from another Do not attempt to use this equipment until you machine. And of
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A-4 A-4 INSTALLATION STACKING POWERARC® 5500 machines CANNOT be stacked. FUEL TILTING Fill the fuel tank with clean, fresh, regular grade lead- Place the machine on a secure, level surface whenev- free gasoline. DO NOT MIX OIL WITH THE GASO- er you use it or store it. Any surfaces you place it on LINE. Remove the fuel cap slowly to release pres- other than the ground must be firm, non-skid, and sure. Keep hands away from the engine muffler or structurally sound. HOT engine parts. The gasoline en
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A-5 A-5 INSTALLATION PowerArc 5500 Typical Fuel Consumption Robin / Subaru 9 HP Carb. Certified Honda 9 HP EX 27 Carb. Certified No Load 0.31 Gallons/Hour .30 Gallons/Hour 3700 RPM ±50 R.P.M. (1.17 Liters/Hour) (1.14 Liters/Hour) AC CC Weld Output .70 Gallons/Hour .58 Gallons/Hour 125 Amps @ 20 Volts (2.66 Liters/Hour) (2.18 Liters/Hour) AC CC Weld Output .66 Gallons/Hour .55 Gallons/Hour 100 Amps @ 25 Volts (2.48 Liters/Hour) (2.1 Liters/Hour) Auxiliary Power 4000 .68 Gallons/Hour .67 Gallons/H
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A-6 A-6 INSTALLATION POWERARC® 5500 OUTPUT CONNECTIONS Physical Location of Items and Components may vary by Code No. FIGURE A.1 (For Codes 11182, 11187, 11215) FIGURE A.2 (For Codes 11403, 11404) 1 7 9 1 POWER POWER A ARC RC 55 550 00 0 P POWER OWER A ARC RC 55 550 00 0 880 0 80 80 70 70 AAMPS MPS AMPS AMPS 70 70 AMPS AMPS AMPS AMPS 1125 25 AAMPS MPS 990 0 1125 25 9900 AAMPS MPS AMPS AMPS GGENERATOR ENERATOR GENERATOR GENERATOR AMPS AMPS 11000 0 1100 00 AMPS AMPS AAMMPS PS WARNING WARNING W WAR
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A-7 A-7 INSTALLATION Cable Installation WARNING Install the welding cables to your POWERARC® 5500 Do not ground the machine to a pipe that carries as follows. See Figure A.1 for the location of parts. explosive or combustible material. 1. The gasoline engine must be OFF to install weld- ing cables. When the POWERARC® 5500 is mounted on a truck 2. Remove the 1/2 - 13 flanged nuts from the output or a trailer, the machine generator ground terminals. stud MUST be securely connected to the 3. Connec
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A-8 A-8 INSTALLATION PREMISES WIRING CIRCUIT BREAKERS The POWERARC® 5500 three-wire, grounded neutral generator allows it to be connected to premises Auxiliary power is protected by circuit breaker. When wiring. However, the wiring procedure needed to meet the machine is operated in high temperature environ- the National Electrical Code (NEC) regulations as well ments, the breakers may tend to trip at lower loads as city ordinances and can be confusing. The connec- than normally. tions could var
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A-9 A-9 INSTALLATION CAUTION Certain Electrical devices cannot be powered by the POWERARC® 5500. See Table A.2. TABLE A.2 ELECTRICAL DEVICE USE WITH THE POWERARC® 5500. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker. Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage appliances with electrical control. regulation can cause the capac- itative elements to fail. Surge
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A-10 A-10 NOTES POWERARC® 5500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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B-1 B-1 TABLE OF CONTENTS - OPERATION SECTION Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 Output Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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B-2 B-2 OPERATION SAFETY INSTRUCTIONS GENERAL DESCRIPTION The POWERARC® 5500 is a generator/welder designed Read and understand this entire section before oper- for home use and other non-commercial applications. As ating your POWERARC® 5500. a generator it can supply up to 4,000 continuous watts WARNING (or 5,500 surge watts) of 120/240 volt, single-phase AC power. As a welder it provides 125 amps of AC constant Do not attempt to use this equipment until you have current for welding with AC sti
