Lincoln Electric SVM192-A service manual Instructions, Connection of Lincoln Electric Wire Feeders

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A-6

INSTALLATION

A-6

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CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

NOTE: A constant voltage (CV) power source is rec- ommended for wire feeder applications. The LN-15 and LN-25 may be used with a constant current (CC) power source, such as the EAGLE 10,000, for non-critical applications where weld quality and deposition properties

are not critical.

WARNING

Shut off welder before making any electrical connections.

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WIRE FEED (CONSTANT VOLTAGE) CONNECTION OF LN-15 ACROSS-THE-ARC WIRE FEEDER

The LN-15 has an internal contactor and the electrode is not energized until the gun trigger is closed. When the gun trigger is closed the wire will begin to feed and the welding process is started.

a.Shut the welder off.

b.For electrode Positive, connect the electrode cable to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable "-" terminal of the welder and work cable to the "+" terminal of the welder.

c.Attach the single lead from the front of the LN-15 to work using the spring clip at the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current.

d.Set the “RANGE” switch to a suitable position.

e.Place the Engine switch in the “Auto Idle” position.

f.Set the Welding Mode on the LN-15 to the “CC” mode.

g.Adjust the wire feed speed at the LN-15 and adjust the welding current with the output “CONTROL” at the welder. Output “CONTROL” must be set above 3.

Note: LN-15 Control Cable model will not work with the EAGLE 10,000.

CONNECTION OF THE LN-25 TO THE EAGLE 10,000

a.Shut the welder off.

b.For electrode Positive, connect the electrode cable from the LN-25 to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable from the LN-25 to the "-" terminal of the welder and work cable to the "+" terminal of the welder.

c.Position the “RANGE” switch to a suitable position.

d.Attach the single lead from the LN-25 control box to the work using the spring clip on the end of the lead - it carries no welding current.

e.Place the engine switch in the “AUTO IDLE” posi- tion.

f.Set the Wire Feed Mode switch on the LN-25 to the “CC” mode.

g.Adjust wire feed speed at the LN-25 and adjust the welding current with the output “CONTROL” at the welder.

NOTE: The welding electrode is energized at all times, unless an LN-25 with built-in contactor is used. If the output “CONTROL” is set below “3”, the LN-25 contactor may not pull in.

CONNECTION OF K930-2 TIG MODULE TO THE EAGLE 10,000.

The TIG Module is an accessory that provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding. See IM528 supplied with the TIG Module for installation instructions.

NOTE: The TIG Module does not require the use of a high frequency bypass capacitor. However, if the EAGLE 10,000 is used with any other high frequency equipment, the bypass capacitor must be installed, order kit T12246.

INSTRUCTIONS

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the roof and case sides in place as this provides maximum protection from moving parts and assures proper cooling air flow.

Read and understand all Safety Precautions before operating this machine. Always follow these and any other safety procedures included in this manual and in the Engine Owner’s Manual.

WELDER OPERATION

WELDER OUTPUT

•Maximum Open Circuit Voltage at 3700 RPM is 80 Volts RMS.

•Duty Cycle is the percentage of time the load is being applied in a 10 minute period. For example, a 60% duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period. Duty Cycle for the EAGLE 10,000 is 100%.

EAGLE 10,000

Constant Current

210 Amps DC @ 25 Volts

 

 

 

 

EAGLE™ 10,000

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Contents Eagle 10,000 ISAFETYi Eagle 10,000Safety Electric Shock can kill ARC Rays can burnFumes and Gases Can be dangerousPowered equipment Welding CuttingCylinder may explode Sparks can cause fire or If damaged ExplosionPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Eagle 10,000 K2343-1,K2343-2Height Width Depth Weight Safety Precautions Machine GroundingSpark Arrester TowingVehicle Mounting Fuel Gasoline Fuel onlyFollow vehicle manufacturer’s instructions Do not overfill tank, fuel expansion may cause overflowAdditional Safety Precautions High Altitude Operation Angle of OperationLifting Location / VentilationConnection of Lincoln Electric Wire Feeders Additional Safety PrecautionsInstructions Welder OperationAuxiliary Power 120/240 Volt Dual Voltage ReceptacleDuplex Receptacles Motor StartingElectrical Device USE with the Eagle 10,000 These Devices WithoutAdditional Resistive Type LoadsAuxiliary Power While Welding Simultaneous Welding and PowerStandby Power Connections Connection diagram shown Eagle 10,000Connection of Eagle 10,000 to Premises Wiring Figure A.1Table of Contents Operation Section Engine Switch OperationGeneral Description Welder Controls Function and OperationRange Switch OPERATIONB-3Eagle 10,000 Approximate Fuel Consumption Control DialSTARTING/SHUTDOWN Instructions BREAK-IN PeriodStarting the Engine Stopping the EngineWire Feed Welding Processes Welding ProcessTIG Constant Current Welding ARC GougingTypical Current Ranges 1 for Tungsten ELECTRODES2 Summary of Welding ProcessesTable of Contents Accessories Section Accessories Optional Equipment Field InstalledK1745-1 GAS Cylinder Holder Wire Feed Recommended EquipmentPlasma Cutting Stick TIG WeldingEagle 10,000 Table of Contents Maintenance Section Maintenance Safety PrecautionsEngine OIL Change Engine OIL Refill CapacitiesAIR Cleaner and Other Maintenance OIL Filter ChangeEngine Adjustments Figure D.1 Major Component Locations Eagle 10,000 1TABLE of CONTENTS-THEORY of Operation Section E-1 BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler Solenoid Theory of OperationRotor Field Feedback Auxiliary Power Figure E.3 Rotor Field Feedback and Auxiliary PowerWeld WINDING, REACTOR, and Range Switch Output BRIDGE, CHOKE, and Output Terminals1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting GuideTroubleshooting and Repair PC Board Troubleshooting ProceduresPerform the Rotor Voltage Test Problems Possible Areas Symptoms Misadjustments Recommended Course of ActionProblems Symptoms Possible Areas MisadjustmentsRotor Voltage2. PTestrform Engine Problems Wiring Charging Circuit Test BridgePerformTestthe. Output Rectifier Eagle 10,000 Rotor Voltage Test Test DescriptionMaterials Needed Test Procedure Remove the case top, then reinstall the fuel capRotor Voltage Test Rotor Resistance Test Rotor Resistance Test Remove the case top, then replace the fuel capTroubleshooting and Repair Eagle 10,000 Auxiliary and Field Winding Test Auxiliary and Field Winding Test To test the 115 VAC windingTo test the 230 VAC winding To test the field winding Eagle 10,000 Output Rectifier Bridge Test Output Rectifier Bridge Test Figure F.4 Location of Output Rectifier LeadsCharging Circuit Test Charging Circuit Test Figure F.5 Location of Voltage RegulatorEngine Throttle Adjustment Test Engine Throttle Adjustment Test Strobe-tach MethodFigure F.7 Frequency Counter MethodEngine Throttle Adjustment Test Oscilloscope Method Vibratach MethodScope Settings Normal Open Circuit Voltage Waveform 115VAC SupplyHigh Idle no Load Output Control AT Maximum Typical DC Weld Output Waveform CC Mode Machine LoadedMachine Loaded to 200 Amps AT 26 VDC Abnormal Open Circuit DC Weld Voltage Waveform Normal Open Circuit DC Weld Voltage Waveform CC Mode Brush Removal and Replacement Brush Removal and Replacement ProcedureSlip Rings Figure F.9 Brush LEADS/BRUSHES Retained with Cable TIEEagle 10,000 Printed Circuit Board Removal Replacement Replacement Printed Circuit Board RemovalTroubleshooting and Repair Eagle 10,000 43TROUBLESHOOTING and REPAIRF-43 Output Rectifier Bridge Removal Replacement44TROUBLESHOOTING and REPAIRF-44 Output Rectifier Bridge Removal45TROUBLESHOOTING and REPAIRF-45 Eagle 10,000 ENGINE/ROTOR Removal and Replacement InstructionsENGINE/ROTOR Removal and Replacement Figure F.12 Component LOCATIONS, ENGINE/ROTOR RemovalEngine and Rotor Removal Procedure Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from Stator THRU-BOLTReplacement KIT S20788 Reassembly ProcedureENGINE/ROTOR Removal Auxiliary Power Receptacle OUTPUT1 Retest After RepairEngine Output Welder DC OUTPUT1Table of Contents Diagram Section Electrical Diagrams Eagle 10,000 KohlerWiring Diagram Code 11397 M21271 Schematic Complete Machine Code 11096 L12259 TerminalSchematic Complete Machine Code 11397 L13104 Torroid Core located onSchematic IDLER/FIELD Control P.C. Board L12197

SVM192-A specifications

Lincoln Electric's SVM192-A is a standout model in the sphere of welding machines, renowned for its advanced technology and versatility, making it a preferred choice among welding professionals and industrial applications. This single-phase inverter-based machine balances performance and portability, providing users with a reliable solution for a variety of welding tasks.

One of the key features of the SVM192-A is its capacity to perform multiple welding processes. It supports MIG, TIG, and stick welding, which allows users to switch between different techniques depending on the project requirements. This multi-functionality enhances the machine's utility, making it viable for various applications ranging from home projects to professional fabrication works.

The SVM192-A is equipped with Lincoln Electric’s proprietary technologies, including the advanced inverter technology, which ensures high efficiency and power output while maintaining a compact size. This inverter technology not only improves arc stability but also reduces power consumption and heat generation, making it a more eco-friendly option.

Key characteristics of the SVM192-A include a user-friendly digital display that provides clear settings for amperage, voltage, and other parameters, enabling precise control during welding. The machine also features a robust construction, designed to withstand tough working environments, ensuring longevity and minimal downtime.

Moreover, the SVM192-A incorporates safety features designed to protect the user and the machine, including overcurrent and thermal overload protection. This prioritization of safety ensures a worry-free operation, allowing welders to focus on their craft without the distraction of potential hazards.

Portability is another significant advantage of the SVM192-A. Weighing in at a lightweight design, it is easy to transport, making it ideal for mobile operations or jobs that require moving the equipment frequently.

In summary, the Lincoln Electric SVM192-A embodies versatility, efficiency, and durability, making it an exceptional choice for both novice and experienced welders. Its ability to handle multiple welding processes, combined with advanced technologies and user-friendly features, positions it as a top contender in the welding equipment market, suitable for a wide range of applications in various sectors.
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