Lincoln Electric SVM192-A Troubleshooting and Repair, PC Board Troubleshooting Procedures

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TROUBLESHOOTING AND REPAIR

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PC BOARD TROUBLESHOOTING PROCEDURES

 

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WARNING

ELECTRIC SHOCK can kill.

•Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.

CAUTION

Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure:

1.Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2.Check for loose connections at the PC board to assure that the PC board is properly connected.

3.If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

-Remove the PC board from the static-shielding bag and place it directly into the equipment. Don’t set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can’t be installed immediately, put it back in the static-shield- ing bag.

-If the PC board uses protective shorting jumpers, don’t remove them until installation is complete.

-If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- er failure analysis.

4.Test the machine to determine if the failure symptom has been corrected by the replacement PC board.

NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

5.Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.

a.If the original problem does not reappear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.

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PC board can be damaged by static electricity.

b. If the original problem is recreated by the

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ATTENTION

Static-Sensitive

Devices

Handle only at

Static-Safe

Workstations

-Remove your body’s static charge before opening the static- shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.

-If you don’t have a wrist strap, touch an un-painted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.

substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.

6.Always indicate that this procedure was followed when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

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-Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.

EAGLE™ 10,000

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Contents Eagle 10,000 Eagle 10,000 ISAFETYiCan be dangerous SafetyElectric Shock can kill ARC Rays can burn Fumes and GasesSparks can cause fire or If damaged Explosion Powered equipmentWelding Cutting Cylinder may explodeSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Eagle 10,000 K2343-1,K2343-2Height Width Depth Weight Towing Safety PrecautionsMachine Grounding Spark ArresterDo not overfill tank, fuel expansion may cause overflow Vehicle MountingFuel Gasoline Fuel only Follow vehicle manufacturer’s instructionsLocation / Ventilation Additional Safety Precautions High Altitude OperationAngle of Operation LiftingWelder Operation Connection of Lincoln Electric Wire FeedersAdditional Safety Precautions InstructionsMotor Starting Auxiliary Power120/240 Volt Dual Voltage Receptacle Duplex ReceptaclesType Loads Electrical Device USE with the Eagle 10,000These Devices Without Additional ResistiveConnection diagram shown Eagle 10,000 Auxiliary Power While WeldingSimultaneous Welding and Power Standby Power ConnectionsFigure A.1 Connection of Eagle 10,000 to Premises WiringTable of Contents Operation Section Welder Controls Function and Operation Engine SwitchOperation General DescriptionControl Dial Range SwitchOPERATIONB-3 Eagle 10,000 Approximate Fuel ConsumptionStopping the Engine STARTING/SHUTDOWN InstructionsBREAK-IN Period Starting the EngineARC Gouging Wire Feed Welding ProcessesWelding Process TIG Constant Current WeldingSummary of Welding Processes Typical Current Ranges 1 for Tungsten ELECTRODES2Table of Contents Accessories Section Accessories Optional Equipment Field InstalledK1745-1 GAS Cylinder Holder TIG Welding Wire FeedRecommended Equipment Plasma Cutting StickEagle 10,000 Table of Contents Maintenance Section Engine OIL Refill Capacities MaintenanceSafety Precautions Engine OIL ChangeOIL Filter Change AIR Cleaner and Other MaintenanceEngine Adjustments Figure D.1 Major Component Locations Eagle 10,000 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler SolenoidFigure E.3 Rotor Field Feedback and Auxiliary Power Rotor Field Feedback Auxiliary PowerOutput BRIDGE, CHOKE, and Output Terminals Weld WINDING, REACTOR, and Range Switch1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Troubleshooting and RepairPerform the Rotor Voltage Test Recommended Course of Action Problems Possible Areas Symptoms MisadjustmentsPossible Areas Misadjustments Problems SymptomsRotor 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 Remove the case top, then replace the fuel cap Rotor Resistance TestTroubleshooting 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 Figure F.4 Location of Output Rectifier Leads Output Rectifier Bridge TestCharging Circuit Test Figure F.5 Location of Voltage Regulator Charging Circuit TestEngine Throttle Adjustment Test Strobe-tach Method Engine Throttle Adjustment TestFrequency Counter Method Figure F.7Oscilloscope Method Vibratach Method Engine Throttle Adjustment TestScope 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 Procedure Brush Removal and ReplacementFigure F.9 Brush LEADS/BRUSHES Retained with Cable TIE Slip RingsEagle 10,000 Printed Circuit Board Removal Replacement Printed Circuit Board Removal ReplacementTroubleshooting and Repair Eagle 10,000 Output Rectifier Bridge Removal Replacement 43TROUBLESHOOTING and REPAIRF-43Output Rectifier Bridge Removal 44TROUBLESHOOTING and REPAIRF-4445TROUBLESHOOTING and REPAIRF-45 Eagle 10,000 Instructions ENGINE/ROTOR Removal and ReplacementFigure F.12 Component LOCATIONS, ENGINE/ROTOR Removal ENGINE/ROTOR Removal and ReplacementEngine and Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from Stator THRU-BOLT Rotor Removal ProcedureReplacement KIT S20788 Reassembly ProcedureENGINE/ROTOR Removal Welder DC OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine OutputTable of Contents Diagram Section Eagle 10,000 Kohler Electrical DiagramsWiring Diagram Code 11397 M21271 Terminal Schematic Complete Machine Code 11096 L12259Torroid Core located on Schematic Complete Machine Code 11397 L13104Schematic 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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