Lincoln Electric IM900 User Manual
POWER-ARC
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For Machines with Code Number 11329, 11405
™
5500
IM900-A
December, 2008
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 READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
5500
Various engine configurations are available and machine appearance will vary
accordingly.
ISO 9001
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
ANSI RAB
QMS
OPERATOR’S MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
i
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
____________________________________________________
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.b. Operate engines in open, well-ventilated
areas
or vent the engine exhaust fumes
outdoors.
1.c. Do not add the fuel near an open flame
welding
arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
and in good repair.Keep hands, hair, clothing and
to perform required maintenance. Remove
1.f. Do not put your hands near the engine fan.
Do
not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning
the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ʻ95
ii
SAFETY
ii
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
vapors
AUG 06
to
iii
SAFETY
iii
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
6.I. Read and folllow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Jan, 07
iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
iv
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de nʼimporte quelle
partie du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du
rayonnement de lʼarc et des projections quand on soude
ou quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection
libres de lʼhuile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la
debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ʻ93
Thank You
vv
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
vi vi
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Safety.................................................................................................................................................i-iv
Installation .............................................................................................................................Section A
Technical Specifications .............................................................................................................A-1
Safety Precautions......................................................................................................................A-2
Location and Ventilation .............................................................................................................A-2
Pre-operation Engine Service .............................................................................................A-3, A-4
Electrical Output Connections ............................................................................................A-5, A-6
Premises Wiring and Circuit Breakers ........................................................................................A-7
Electrical Devises used with the Power -Arc 5500 .....................................................................A-8
Operation...............................................................................................................................Section B
Safety Instructions ......................................................................................................................B-1
General Description ....................................................................................................................B-1
Recommended Applications.......................................................................................................B-1
Operational Features and Controls.............................................................................................B-1
Welding Capability......................................................................................................................B-1
Limitations .................................................................................................................................B-2
Controls and Settings .................................................................................................................B-2
Engine Operation .........................................................................................................B-3 Thru B-6
Welding Operation.....................................................................................................B-7 Thru B-16
Accessories...........................................................................................................................Section C
Maintenance..........................................................................................................................Section D
Safety Precautions ............................................................................................................................D-1
Routine and Periodic Maintenance ...................................................................................................D-1
General Assembly Exploded View ....................................................................................................D-5
Troubleshooting and Repair ................................................................................................Section E
Electrical Diagrams and Dimension Print ...........................................................................Section F
Parts Manual (Robin / Subaru) ......................................................................................P-510 Series
POWER-ARC 5500
A-1
INSTALLATION
A-1
TECHNICAL SPECIFICATIONS - POWER-ARC 5500 K1429-11
(1)
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)
(11329) OHC gasoline
(11405)
(1)
9 HP @
3600 RPM
INPUT - HONDA GASOLINE ENGINEINPUT - GASOLINE ENGINE
RATED OUTPUT - WELDER
Duty Cycle Amps AC Volts at Rated Amperes
30% Duty Cycle 125 Amps AC Constant Current 20 VAC
60% Duty Cycle 100 Amps AC Constant Current 25 VAC
OUTPUT - WELDER AND GENERATOR
Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power
70 - 125 Amps AC 62 VAC Max. 4000 Continuous Watts
5500 Surge Watts
PHYSICAL DIMENSIONS
Height Width Depth Weight
20.9 in. 20 in. 30 in. 160 lb.
530 mm 508 mm 762 mm 72.5 kg
(1)
This product includes 20Ft.(6.1m) #6 welding cable with lug, 15Ft.(4.6) #6 work cable with lugs, 200 amp electrode holder, light duty work clamp, sample electrode pack, welding gloves, helmet, chipping hammer and
brush.
POWER-ARC 5500
A-2
INSTALLATION
A-2
SAFETY PRECAUTIONS
Read this entire installation section before you
start installation.
WARNING
Do not attempt to use this equipment until you
have thoroughly read all the operation and maintenance manuals supplied with your machine.
They include important safety precautions;
detailed engine starting, operating, and maintenance instructions; and parts lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.
• Insulate yourself from the
work and ground.
•Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
• Use in open, well ventilated
areas or vent exhaust to the
outside.
• Do not stack anything on or
near the engine.
LOCATION AND VENTILATION
Whenever you use the POWER-ARC 5500, be sure
that clean cooling air can flow through the machine’s
gasoline engine and the generator. Avoid dusty, dirty
areas. Also, keep the machine away from heat
sources. Do not place the back end of the generator
anywhere near hot engine exhaust from another
machine. And of course, make sure that engine
exhaust is ventilated to an open, outside area.
The POWER-ARC 5500 must be used outdoors. Do
not set the machine in puddles or otherwise submerge it in water. Such practices pose safety hazards and cause improper operation and corrosion of
parts.
Always operate the POWER-ARC 5500 with the case
roof on and all machine components completely
assembled. This will protect you from the dangers of
moving parts, hot metal surfaces, and live electrical
devices.
STORING
1. Store the machine in a cool, dry place when it’s
not in use. Protect it from dust and dirt. Keep it
where it can’t be accidentally damaged from construction activities, moving vehicles, and other
hazards.
2. If you will be storing the machine for over 30
days, you should drain the fuel to protect fuel
system and carburetor parts from gum deposits.
Empty all fuel from the tank and run the engine
until it stops from lack of fuel.
MOVING PARTS can injure.
• Do not operate this equipment with any of its doors
open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
Only qualified personnel should install, use, or service
this equipment.
POWER-ARC 5500
3. You can store the machine for up to 24 months if
you use a gasoline stabilizing additive in the fuel
system. Mix the additive with the fuel in the tank
and run the engine for a short time to circulate
the additive through the carburetor.
4. While the engine is still warm, drain the oil and
refill with fresh oil per the engine manual.
5. Remove the spark plug and pour approximately
1/2 ounce (15 ml) of engine oil into the cylinder.
Replace the spark plug and crank the engine
slowly to distribute the oil.
6. Clean any dirt and debris from the cylinder and
cylinder head fins and housing, rotating screen,
and muffler areas.
7. Store in a clean, dry area.
A-3
INSTALLATION
STACKING
POWER-ARC 5500 machines CANNOT be stacked.
TILTING
Place the machine on a secure, level surface whenever you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
structurally sound.
A-3
FUEL
Fill the fuel tank with
clean, fresh, regular
grade lead-free gasoline. DO NOT MIX OIL WITH
THE GASOLINE. Remove the fuel cap slowly to
release pressure. Keep hands away from the
engine muffler or HOT engine parts.
The gasoline engine is designed to run in a level position for best performance. It can operate at an angle,
but this should never be more than 15 degrees in any
direction. If you do operate it at a slight angle, be sure
to check the oil regularly and keep the oil level full.
Also, fuel capacity will be a little less at an angle.
LIFTING
The POWER-ARC 5500 should be lifted by two people. (It weighs 160 lbs/72.5 kg.) Its welded tube roll
cage is designed to make lifting easy.
ANGLE OF OPERATION
Internal combustion engines are designed to run in a
level condition to achieve optimum performance. The
maximum angle of operation for the engine is 15
degrees from horizontal in any direction. Be certain to
place the machine on a firm, non-skid, structural supporting surface. Anchor unit if necessary.
If you are operating the engine at a slight angle, be
certain to check the oil regularly and maintain a level,
full oil condition. The effective fuel capacity will also
be slightly less than the specified 1.6 gallon (6.1 liters).
PRE-OPERATION ENGINE SERVICE
WARNING
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
GASOLINE
can cause fire
or explosion.
fumes to clear before starting
engine.
• Do not overfill tank, fuel expansion may cause overflow.
GASOLINE FUEL ONLY
------------------------------------------------------------------------
The POWER-ARC 5500 has a fuel tank mounted on
the engine. See the engine owner’s manual for more
details about fuel.
Read and understand the information about the gasoline engine in the OPERATION and MAINTENANCE
sections of this manual and the engine owner’s manual before you operate the POWER-ARC 5500.
OIL
The Power-Arc 5500 with the Robin / Subaru 9HP
engine is supplied with low oil protection. The engine
is equipped with protection that will shut down the
engine in the event of a low oil condition. The engine
cannot be restarted until sufficient oil is added.
The POWER-ARC 5500 is shipped with the engine
filled with SAE 10W-30 oil. CHECK THE OIL LEVEL
BEFORE YOU START THE ENGINE. This is an added
precaution. When full, the oil level should be at the top
of the fill plug hole. If it is not full, add enough oil to fill
it. Be sure the fill plug is tight. Change oil after the first
20 hours of operation. For more oil fill and service
information, see the Engine owner’s manual.
POWER-ARC 5500
A-4
INSTALLATION
Power-Arc 5500 Typical Fuel Consumption
Robin / Subaru 9 HP Carb. Certified
EX 27
A-4
No Load
3700 RPM ±50 R.P.M.
AC CC Weld Output
125 Amps @ 20 Volts
AC CC Weld Output
100 Amps @ 25 Volts
Auxiliary Power 4000
Watts (120/240 Volts)
0.31 Gallons/Hour
(1.17 Liters/Hour)
.70 Gallons/Hour
(2.66 Liters/Hour)
.66 Gallons/Hour
(2.48 Liters/Hour)
.68 Gallons/Hour
(2.59 Liters/Hour)
SPARK ARRESTER
Gasoline engine mufflers may emit sparks when the
engine is running. Some federal, state, or local laws
require spark arresters in locations where unarrested
sparks could present a fire hazard.
The Power-Arc 5500 is supplied with a spark arrester
as standard equipment. Refer to the engine owner’s
manual for proper maintenance.
CAUTION
An incorrect additional spark arrester may lead to
damage to the engine or reduce performance.
-----------------------------------------------------------
POWER-ARC 5500
A-5
POWER ARC 5500
ELECTRODE SELECTION GUIDE
80
90
100
70
AMPS
AMPS
AMPS
AMPS
WARNING
AMPS
125
GENERATOR
80
90
100
70
AMPS
AMPS
AMPS
AMPS
WARNING
AMPS
125
GENERATOR
ELECTRODE SELECTION GUIDE
POWER ARC 5500
INSTALLATION
POWER-ARC 5500 OUTPUT CONNECTIONS
A-5
FIGURE A.1 FOR CODE 11329
1
80
AMPS
AMPS
125
AMPS
GENERATOR
WARNING
ELECTRODE SELECTION GUIDE
90
AMPS
100
AMPS
POWER ARC 5500
3
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
FIGURE A.1a FOR CODE 11405
1
POWER ARC 5500
GENERATOR
100
AMPS
WARNING
6
ELECTRODE SELECTION GUIDE
6
4
5
5
4
2
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
3
ELECTRICAL OUTPUT
CONNECTIONS
See Figure A.1 for the location of the current control
dial, weld output terminals, ground stud, circuit
breakers, 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
POWER-ARC 5500
A-6
Cable Installation
Install the welding cables to your POWER-ARC 5500
as follows. See Figure A.1 for the location of parts.
1. The gasoline engine must be OFF to install welding cables.
2. Remove the 1/2 - 13 flanged nuts from the output
terminals.
3. Connect the electrode holder and work cables to
the weld output terminals. You can connect either
cable to either terminal, since the POWER-ARC
5500 provides AC weld current.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding
(the “work”) is securely connected to the work
clamp and cable.
6. Check and tighten the connections periodically.
INSTALLATION
CAUTION
• Loose connections will cause the output termi-
nals to overheat. The terminals may eventually
melt.
A-6
WARNING
Do not ground the machine to a pipe that carries
explosive or combustible material.
When the POWER-ARC 5500 is mounted on a truck
or a trailer, the machine generator
ground stud MUST be securely connected to the metal frame of the vehicle. See
Figure A.1. The ground stud is marked
with the symbol.
PLUGS AND HAND-HELD EQUIPMENT
For further protection against electric shock, any
electrical equipment connected to the generator
receptacles must use a three-blade, grounded type
plug or an Underwriter’s Laboratories (UL) approved
double insulation system with a two-blade plug.
Ground fault protection is needed for hand held
equipment.
• Do not cross the welding cables at the output
terminal connection. Keep the cables isolated
and separate from one another.
Lincoln Electric offers a welding accessory kit with
the properly specified welding cables. See the
ACCESSORIES section of this manual for more information.
MACHINE GROUNDING
Because the POWER-ARC 5500 creates
its own power from its gasoline-engine
driven generator, you do not need to
connect the machine frame to an earth
ground. However, for best protection
against electrical shock, connect a heavy gauge wire
from the ground stud located on the bottom center of
the output panel (see Figure A.1) to a suitable earth
ground such as a metal pipe driven into the ground.
WARNING
Never operate this machine with damaged or
defective cords. All electrical equipment must be
in safe condition.
-----------------------------------------------------------
AUXILIARY POWER RECEPTACLES
The control panel of the POWER-ARC 5500 features
two auxiliary power receptacles:
• A 20 amp, 120 volt duplex (double outlet) receptacle
• A 20 amp 240 volt simplex (single outlet) receptacle.
See Figure A.1.
Through these receptacles the machine can supply
up to 4,000 rated continuous watts and 5,500 surge
watts of single-phase AC power.
POWER-ARC 5500
A-7
INSTALLATION
A-7
PREMISES WIRING
The POWER-ARC 5500 three-wire, grounded neutral
generator allows it to be connected to premises
wiring. However, the wiring procedure needed to
meet the National Electrical Code (NEC) regulations
as well as city ordinances and can be confusing. The
connections could vary from a "commonly grounded"
to a "separately derived" system depending on
whether you want the unit to be "hard wired" or temporary to the premises.
WARNING
Only a licensed, certified, trained electrician
should install the machine to a premises or residential electrical system. Be certain that:
• The premises is isolated and no feedbacking
into the utility system can occur. Certain state
and local laws require the premises to be isolated before the generator is linked to the premises. Check your state and local requirements.
• A double pole, double throw transfer switch in
conjunction with the properly rated double
throw circuit breaker is connected between the
generator power and the utility meter.
CIRCUIT BREAKERS
Auxiliary power is protected by circuit breakers.
When the machine is operated in high temperature
environments, the breakers may tend to trip at lower
loads than normally.
CAUTION
Never bypass the circuit breakers. Without overload protection, the power-arc 5500 could overheat and/or cause damage to the equipment being
used.
-----------------------------------------------------------
The POWER-ARC 5500 does not have a combined
120/240 volt twist-lock receptacle and cannot be
connected to a premises as described in other
Lincoln literature.
Remember that the POWER-ARC 5500 is intended
only for backup, intermittent use power. Oil level must
be checked after every 5 hours of use. It cannot withstand long-term use without proper maintenance.
See the MAINTENANCE section of this manual and
the engine owner’s manual for more information.
Certain electrical devices cannot be powered by the
POWER-ARC 5500. Refer to Table A.2 for these
devices.
POWER-ARC 5500
A-8
INSTALLATION
CAUTION
Certain Electrical devices cannot be powered by the POWER-ARC 5500. See Table A.2.
TABLE A.2
ELECTRICAL DEVICE USE WITH THE POWER-ARC 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 capaci-
tative elements to fail. Surge
protection, transient protection,
and additional loading is recommended for 100% fail-safe
operation. DO NOT RUN
THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.
A-8
Inductive Single-phase induction motors, These devices require large
drills, well pumps, grinders, small current inrush for starting. (See
refrigerators, weed and hedge Table B.3, GENERATOR POWER
trimmers APPLICATIONS, in the OPERA-
TION section of this manual for
required starting wattages.)
Some synchronous motors may
be frequency sensitive to attain
maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.
Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-
complicated electrical equipment. er along with transient and
surge protection is required, and
liabilities still exist. DO NOT
USE THESE DEVICES WITH A
POWER-ARC 5500.
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the POWER-ARC 5500.
POWER-ARC 5500
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