Lincoln Electric SVM192-A service manual Theory of Operation

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E-2

THEORY OF OPERATION

E-2

 

FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND IDLER SOLENOID

 

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MECHANICAL

ROTATION

STARTER ENGINE

FLYWHEEL

ALTERNATOR

IDLER

SOLENOID

BATTERY

OUTPUT

CONTROL

RANGE

SWITCH

 

AC

 

 

 

OUTPUT

CHOKE

POSITIVE

REACTOR

AC BRIDGE

 

TERMINAL

 

 

 

 

 

 

NEGATIVE

 

 

 

TERMINAL

STATOR

ROTOR

SLIPROTOR

RINGS

STATOR

TOROID

FIELD

CAPACITOR

115 & 230VAC

RECEPTACLES

TOC

TOC

PRINTED CIRCUIT

BOARD

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BATTERY, STARTER, ENGINE, ROTOR, STATOR, AND IDLER SOLENOID

The 12VDC battery powers the starter motor. When the engine is started and running, the battery circuit voltage is fed, through the printed circuit board, to the rotating field coil in the rotor via a brush and slip ring configuration. This excitation (“flashing”) voltage mag- netizes the rotor lamination. The rotor is mechanically coupled to the engine. This rotating magnet induces a voltage in the stationary windings of the main alterna- tor (stator). Three separate and isolated windings are incorporated in the stator lamination assembly. Each winding set has a different number of turns producing different magnitudes of AC output voltages. The three windings are the weld winding, the auxiliary power

winding and the field feedback winding. The field feed- back winding provides rotor current during machine operation. The output of the EAGLE 10,000 is depen- dent on two criteria: the engine RPM and the amount of current in the rotor winding.

The flywheel alternator, located on the engine, supplies “charging” current for the battery circuit. The battery circuit provides power for the printed circuit board and also for the idler solenoid. The idler solenoid is mechanically connected to the engine throttle linkage. If no current is drawn from the EAGLE 10,000, the printed circuit board activates the idler solenoid, which then brings the engine to a low idle state. When either weld or auxiliary output current is sensed by the toroid the printed circuit board deactivates the idler solenoid, and the engine goes to high RPM. After 12 to 15 sec- onds of no load, the solenoid is reactivated to reduce the speed.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion

EAGLE™ 10,000

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Contents Eagle 10,000 ISAFETYi Eagle 10,000Fumes and Gases SafetyElectric Shock can kill ARC Rays can burn Can be dangerousCylinder may explode Powered equipmentWelding Cutting 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 Technical Specifications Eagle 10,000 K2343-1,K2343-2 InstallationHeight Width Depth Weight Spark Arrester Safety PrecautionsMachine Grounding TowingFollow vehicle manufacturer’s instructions Vehicle MountingFuel Gasoline Fuel only Do not overfill tank, fuel expansion may cause overflowLifting Additional Safety Precautions High Altitude OperationAngle of Operation Location / VentilationInstructions Connection of Lincoln Electric Wire FeedersAdditional Safety Precautions Welder OperationDuplex Receptacles Auxiliary Power120/240 Volt Dual Voltage Receptacle Motor StartingAdditional Resistive Electrical Device USE with the Eagle 10,000These Devices Without Type LoadsStandby Power Connections Auxiliary Power While WeldingSimultaneous Welding and Power Connection diagram shown Eagle 10,000Connection of Eagle 10,000 to Premises Wiring Figure A.1Table of Contents Operation Section General Description Engine SwitchOperation Welder Controls Function and OperationEagle 10,000 Approximate Fuel Consumption Range SwitchOPERATIONB-3 Control DialStarting the Engine STARTING/SHUTDOWN InstructionsBREAK-IN Period Stopping the EngineTIG Constant Current Welding Wire Feed Welding ProcessesWelding Process ARC GougingTypical Current Ranges 1 for Tungsten ELECTRODES2 Summary of Welding ProcessesTable of Contents Accessories Section Optional Equipment Field Installed AccessoriesK1745-1 GAS Cylinder Holder Plasma Cutting Stick Wire FeedRecommended Equipment TIG WeldingEagle 10,000 Table of Contents Maintenance Section Engine OIL Change MaintenanceSafety Precautions 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 Test Description Rotor Voltage TestMaterials Needed Remove the case top, then reinstall the fuel cap Test ProcedureRotor 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 To test the 115 VAC winding Auxiliary and Field Winding TestTo 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 MethodNormal Open Circuit Voltage Waveform 115VAC Supply Scope SettingsHigh Idle no Load Output Control AT Maximum Machine Loaded Typical DC Weld Output Waveform CC ModeMachine 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-BOLTReassembly Procedure Replacement KIT S20788ENGINE/ROTOR Removal Engine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair 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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