Lincoln Electric SVM192-A service manual Wiring

Page 45

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F-9

TROUBLESHOOTING AND REPAIR

 

F-9

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

 

RECOMMENDED

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

ENGINE PROBLEMS

 

 

 

 

Engine will not go to high idle when

1. Make sure the welding cables

1.

Check for broken or faulty con-

attempting to weld. Welding output

and connections are tight.

 

nections in the sensing lead

is normal when Idler Switch is in

 

 

(#254). Make sure the connec-

“HIGH”

position. Automatic

idle

 

 

tions are tight at the Electrode

auxiliary power is loaded.

the

 

 

Switch See

Wiring Diagram.

function

works properly when

 

 

Output Terminal and the Range

 

 

 

 

2. Make sure the lead is routed

 

 

 

 

 

through the toroid.

 

 

 

 

 

Engine will not go to high idle when

1. Make sure the welding cables

1.

Check for broken or faulty con-

attempting to weld or when the aux-

and connections are tight.

 

nections in the Toroid leads.

iliary power is loaded. Welding out-

2. Automatic idler may not function

 

(#260 and

#261).

Make sure

put and auxiliary power output is

 

their connections are tight at the

normal when Idler Switch is in the

less than 150 Watts.

 

PC Board.

See

Wiring

 

 

 

if the auxiliary power is loaded to

 

Diagram.

 

 

“HIGH” position.

 

 

 

 

 

 

 

 

 

2. The Toroid may be faulty.

 

 

 

 

3. The Printed Circuit Board may

 

 

 

 

 

be faulty. Replace.

 

 

 

 

Engine will not go to high idle when

1. Automatic idler may not function if

1. If the machine works OK when

the Auxiliary Power is loaded. The

the auxiliary power is loaded to

 

set to High Idle,mMake sure that

Idle Circuit works OK with a weld-

less than 150 Watts.

 

leads #3 and #6 are wrapped

ing load.

 

 

 

 

correctly through the Toroid.

 

 

 

 

2. If the machine does not function

 

 

 

 

 

properly at High Idle check that

 

 

 

 

 

the connections are good at the

 

 

 

 

 

circuit breakers and that the cir-

 

 

 

 

 

cuit breakers are functional.

 

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

EAGLE™ 10,000

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Contents Eagle 10,000 Eagle 10,000 ISAFETYiElectric Shock can kill ARC Rays can burn SafetyFumes and Gases Can be dangerousWelding Cutting Powered equipmentCylinder may explode Sparks can cause fire or If damaged ExplosionSûreté 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 Machine Grounding Safety PrecautionsSpark Arrester TowingFuel Gasoline Fuel only Vehicle MountingFollow vehicle manufacturer’s instructions Do not overfill tank, fuel expansion may cause overflowAngle of Operation Additional Safety Precautions High Altitude OperationLifting Location / VentilationAdditional Safety Precautions Connection of Lincoln Electric Wire FeedersInstructions Welder Operation120/240 Volt Dual Voltage Receptacle Auxiliary PowerDuplex Receptacles Motor StartingThese Devices Without Electrical Device USE with the Eagle 10,000Additional Resistive Type LoadsSimultaneous Welding and Power Auxiliary Power While WeldingStandby Power Connections Connection diagram shown Eagle 10,000Figure A.1 Connection of Eagle 10,000 to Premises WiringTable of Contents Operation Section Operation Engine SwitchGeneral Description Welder Controls Function and OperationOPERATIONB-3 Range SwitchEagle 10,000 Approximate Fuel Consumption Control DialBREAK-IN Period STARTING/SHUTDOWN InstructionsStarting the Engine Stopping the EngineWelding Process Wire Feed Welding ProcessesTIG Constant Current Welding ARC GougingSummary of Welding Processes Typical Current Ranges 1 for Tungsten ELECTRODES2Table of Contents Accessories Section Accessories Optional Equipment Field InstalledK1745-1 GAS Cylinder Holder Recommended Equipment Wire FeedPlasma Cutting Stick TIG WeldingEagle 10,000 Table of Contents Maintenance Section Safety Precautions MaintenanceEngine OIL Change Engine OIL Refill CapacitiesOIL 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 Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output Welder DC OUTPUT1Table 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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