Lincoln Electric SVM149-A service manual Theory of Operation, General Description

Page 28

Section TOC

Master TOC

E-2E-2

THEORY OF OPERATION

FIGURE E.2 – INPUT LINE VOLTAGE

VAC

 

 

INPUT 115/230/1/50/60

L1

SW1

A

 

300uH

 

 

B

 

 

RL3

 

RL2

R1

 

RL2

10/10W

 

F1

 

1A/250V

RL2

C26

AC

AC

 

CP

CP

CP

CP

CP

 

AC

AC

 

R1

CP

R2

15K/3W 15K/3W

1500uF/250V

+

C1a,b

+

C2a,b

Q1a,b,c

D10

Lout

BS1

 

IRG4BC30W

WRK

 

 

240uH

8A

 

 

 

 

 

T2

SEC

 

+12VDC TRANSFER

 

PRI

 

 

 

C12

D11

 

RL1

NZL (2)

 

 

 

 

 

 

 

C14

 

WORK CLAMP

V1

RL2

RL1

 

R24

Q2a,b,c

6.8k/5W

IRG4BC30W

 

FN1

230VAC

V2

 

 

115VAC

L1

T1

230V

RL1

1500uF/250V

 

SHUNT

EL (3)

C13

SH-

SH+

 

 

 

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NO

COM

NC

Purge Switch

115V

L1

Input

Voltage Board

12VDC

Air

Solenoid

1

CN1

15VAC

 

CN2

 

 

 

 

 

 

 

 

 

 

 

 

CN3

1

 

9

 

 

 

 

 

 

 

 

 

 

 

 

1

2

15VAC

 

10

 

 

 

 

 

 

 

 

 

 

 

 

2

3

SAFETY

 

5

 

 

 

 

 

 

 

 

 

 

 

 

3

4

+28VDC

 

6

 

 

 

 

 

 

 

 

 

 

 

 

4

5

SEC GND

 

3

 

 

 

 

 

 

 

 

 

 

 

 

Main Inverter Board

6

OVLOAD

 

22

 

 

 

 

 

 

 

 

 

 

 

 

7

115/230

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

8

+12VDC

 

20

 

 

 

 

 

 

 

 

 

CN1

 

 

 

 

 

 

 

 

15 16 12 18 14 1

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

11 4

13 7

19 24 21 23 8

17

1

2

3

 

PS2

PS1

SEC GND OVLOAD

SAFETY

V+ EV1 +15Vrms

+12VDC

+8V SW +12VDC SW

SEC GND

OVLOAD

TRANSFER SW

TRANSFER

SOL 1 DRIVER

V OUT OUTPUT TRIGGER SOL 2 DRIVER

 

POT WIPER

POT CW

POT CCW

 

CN1

8

6

17 9

3

1

2

18 14 7

15 4

11 5

16 10 12 13

 

23 22 24

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Display LED's

Output Control

Control Board

PT

12VDC Solenoid 2

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GENERAL DESCRIPTION

The PRO-CUT 25 is an inverter based constant current, continuous control plasma cutting power source. The control system has a safety mechanism to insure that the nozzle and electrode are in place before cutting or gouging. The PRO-CUT 25 initiates the plasma arc with a simple, yet reliable, touch start mechanism. This system eliminates many of the prob- lems associated with hi-frequency type start systems.

INPUT LINE VOLTAGE, AND AUXILIARY TRANSFORMER

The single-phase input power of 115 230 Volts AC is connected to the machine, via an input cord, to a switch located on the front panel.

The PRO-CUT 25 Input voltage board automatically reconnects the auxiliary and inverter connections to configure the machine for either a low 115V AC or high 230V AC input voltage. The auxiliary transformer develops the appropriate AC voltages to operate the cooling fan, the control board, and the inverter board.

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

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 K1756-1Safety Precautions Electric Shock can Kill Select Proper LocationHigh Frequency Interference Protection Input Electrical ConnectionsGAS Input Connections Output Connections TorchPRO-CUT Table of Contents Operation Section Safety Precautions Preheat Temperature for Plasma CuttingOperation DescriptionDesign Features Advantages Operational Features and ControlsUser Responsibility 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 kill PRO CUT PRO-CUT Table of Contents Theory of Operation Section General Description Theory of OperationInput Line VOLTAGE, and Auxiliary Transformer 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 BoardProtection Circuits Safety PARTS-IN-PLACE ProtectionAccidental Operation Protection 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
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