Lincoln Electric SVM149-A service manual Operation, Safety Precautions, Description

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OPERATION

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Read and understand this entire section before operat- ing the machine.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

Do not touch electrically live parts or electrode with skin or wet clothing.

Insulate yourself from work and ground.

Always wear dry insulating gloves.

FUMES AND GASES

can be dangerous.

• Keep your head out of fumes.

Use ventilation or exhaust to remove fumes from breathing zone.

WELDING, CUTTING and

GOUGING SPARKS

can cause fire or explosion

Keep flammable material away.

Do not weld, cut or gouge on containers that have held combustibles.

ARC RAYS can burn.

Wear eye, ear and body protection.

PLASMA ARC can injure

• Keep your body away from nozzle and plasma arc.

Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others or even piercing safety clothing.

Observe additional Safety Guidelines detailed in the beginning of this manual.

DESCRIPTION

The PRO-CUT 25 is a constant current, continuous control plasma cutting power source. It provides supe- rior and reliable starting characteristics, cutting visibili- ty and arc stability. The control system has a safety mechanism to insure that the nozzle and electrode are in place before cutting or gouging. This is extremely important due to the high voltages involved.

The PRO-CUT 25 comes standard with an air regula- tor and pressure gauge. The machine also comes with an input power cord. Hand-held torches are available in 15' or 25' cable. Consumables are included with each Pro-Cut purchase so that cutting can begin right out of the box. Consumables can also be ordered as individual packages.

The PRO-CUT 25 initiates the plasma arc with a sim- ple, yet reliable, touch start mechanism. This system eliminates many of the failure problems associated with hi-frequency start systems.

PREHEAT TEMPERATURE FOR PLASMA CUTTING

Preheat temperature control is not necessary in most applications when plasma arc cutting or gouging. Preheat temperature control may be necessary on high carbon alloy steels and heat treated aluminum for crack resistance and hardness control. Job conditions, pre- vailing codes, alloy level, and other considerations may also require preheat temperature control. The following minimum preheat temperature is recommended as a starting point. Higher temperatures may be used as required by the job conditions and/or prevailing codes. If cracking or excessive hardness occurs on the cut face, higher preheat temperature may be required. The rec- ommended minimum preheat temperature for plate thickness up to 1/2" (12.7mm) is 70°F (21.1°C).

PRO-CUT 25

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Contents PRO-CUT Safety Cylinder may explode if damaged Safety Précautions DE SûretéMaster Table of Contents for ALL Sections PRO-CUT Table of Contents Installation SectionInstallation Technical Specifications PRO-CUT 25 K1756-1High Frequency Interference Protection Safety Precautions Electric Shock can KillSelect Proper Location Input Electrical ConnectionsGAS Input Connections Output Connections TorchPRO-CUT Table of Contents Operation Section Operation Safety PrecautionsPreheat Temperature for Plasma Cutting DescriptionUser Responsibility Operational Features and ControlsDesign Features Advantages Cutting Capability Consumable LifeControls and Settings LimitationsApparently wrong, reset the machine by turning Pilot ARC DiscussionProcedure Recommendations General In All CasesPRO-CUT Accessories General Options Accessories Maintenance Routine Maintenance Electric Shock can killPRO CUT PRO-CUT Table of Contents Theory of Operation Section Input Line VOLTAGE, and Auxiliary Transformer Theory of OperationGeneral Description Precharge and Protection Figure E.3 Precharge and ProtectionMain Transformer Return Return to Section TOCFigure E.5 Plasma Output Section and Torch Control Board Figure E.6 Control BoardAccidental Operation Protection Safety PARTS-IN-PLACE ProtectionProtection Circuits Insulated Gate Bipolar Transistor Igbt Operation Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Output Problems Function Problems See the Operation section Troubleshooting & Repair LED Function Problems Input Filter Capacitor Discharge Procedure DescriptionDischarge Procedure Right Side of MachineMain Inverter Board Resistance Test Right Side of Machine IGBT’s D2 D1 D11 D10 PRO-CUT Input Board Voltage Test Test Points Fan PRO-CUT Main Inverter Board Voltage Test P2 P1 P2 P1 PRO-CUT Torch Continuity and Solenoid Test Torch Continuity and Solenoid Test Torch Continuity and Solenoid Test PRO-CUT AIR/GAS Solenoid Test AIR/GAS Solenoid Test Control Board Removal and Replacement Small Red Cap Screws Over tighten Input Board Removal and Replacement Input Board Input Board Removal & Replacement PRO-CUT Main Inverter Board Removal and Replacement Main Board Main Inverter Board Removal & Replacement PRO-CUT Switch Removal and Replacement PRO FAN Removal and Replacement Fan Do Not Over tighten Retest After Repair Machine Input and OutputElectrical Diagrams Table of Contents Electrical Diagrams SectionInput Voltage Board Pressure SCHEMATIC- Control Printed Circuit Board Sheet Electrical Diagrams Electrical Diagrams PC Board Assembly Main Inverter Board PC Board Assembly Input Board Cutting Current Path SVM Error Reporting Form