Lincoln Electric SVM149-A service manual Function Problems

Page 39

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F-5

TROUBLESHOOTING & REPAIR

F-5

 

TROUBLESHOOTING GUIDE

 

 

 

 

Observe Safety Guidelines

 

 

 

 

 

detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

 

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FUNCTION PROBLEMS

 

 

 

 

 

 

 

 

 

 

 

 

The machine powers up properly,

1.

Make sure the torch handle or

1.

Check all connectors and wires

 

but there is no response (no air flow

 

cable is not damaged or pulled

 

for loose or faulty connections.

 

or pilot arc) when the torch trigger

 

from the machine. Replace if

 

See Wiring Diagram.

 

 

 

 

 

 

 

 

 

is pulled. Only the power LED is lit.

 

necessary.

 

2.

Perform the Air/Gas

 

 

 

 

 

2.

Make sure

the air supply is

 

Solenoid Test.

 

 

 

 

 

3.

The control board may be

 

 

 

 

 

 

converted and operating

 

 

 

 

 

 

 

faulty. Replace.

 

 

 

 

 

 

properly.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The machine powers up properly,

1.

Make sure the torch consum-

1.

Check all connectors and wires

 

but only air flows when the torch

 

ables are in place and in good

 

for loose or faulty connections.

 

trigger is pulled; no pilot arc is

 

condition.

Replace if neces-

 

See Wiring Diagram.

 

 

 

established.

 

 

sary.

 

2

Perform the Torch Continuity

 

 

 

 

 

 

 

 

 

2.

Set air pressure at 65psi.

 

and Solenoid Test.

 

 

 

 

 

3.

Make sure there are no kinks or

3.

Perform the Main Inverter

 

 

 

 

 

 

restrictions for air flow in the

 

Board Voltage and

 

 

 

 

 

 

torch cable.

 

 

Resistance Tests.

 

 

 

 

 

4.

Make sure that the correct size

4.

The control board may be

 

 

 

 

 

 

nozzle is being used. Must be a

 

faulty. Replace.

 

 

 

 

 

 

.028 orifice. Pro-Cut 55 size

 

 

 

 

 

 

 

 

nozzles will not work with the

 

 

 

 

 

 

 

 

Pro-Cut 25 system.

 

 

 

 

 

 

 

 

 

 

 

 

The machine powers up properly,

1.

CP leads to its terminal from the

1.

Reconnect the leads to its cor-

 

and cuts OK with 230 input

 

input to the inverter board are

 

rect terminal per the wiring dia-

 

applied. With 115 applied the pilot

 

loose or disconnected.

 

gram.

 

 

 

arc ignites but goes out when cut-

 

 

 

2.

Perform the Input Board Test.

 

ting commences.

Or, no pilot or

 

 

 

3. The input board may be faulty.

 

cutting when 115 input is supplied.

 

 

 

 

 

 

 

 

Replace.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The air begins to flow when the

1.

Check the input voltage at the

1.

Check all connectors and wires

 

 

torch trigger is pulled. There is a

 

machine. Input voltage must

 

for loose or faulty connections.

 

very brief pilot arc. (Normal is 3

 

match the rating plate.

 

See Wiring Diagram.

 

 

 

Seconds.) The sequence is repeat-

2.

Make sure the torch

2.

Perform the Main Inverter

 

 

 

ed with subsequent trigger pulls.

 

 

 

 

consumable parts are in place

 

Board Voltage and

 

 

 

 

 

 

 

 

 

 

 

 

 

and in good condition.

 

Resistance Tests.

 

 

 

 

 

 

Replace if necessary.

3.

The control board may be

 

 

 

 

 

 

 

 

 

 

 

 

 

3. Make sure there are no kinks or

 

faulty. Replace.

 

 

 

 

 

 

restrictions for air flow in the

 

 

 

 

 

 

 

 

torch cable.

 

 

 

 

 

 

 

 

4. Make sure the air pressure is

 

 

 

 

 

 

 

 

set at 65psi.

 

 

 

 

 

 

 

5. Make sure that the correct size

 

 

 

 

 

 

 

 

nozzle is being used. Must be a

 

 

 

 

 

 

 

 

.028 orifice. Pro-Cut 55 size

 

 

 

 

 

 

 

 

nozzles will not work with the

 

 

 

 

 

 

 

 

PC 25 system.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PRO-CUT 25

 

 

 

 

Page 38 Page 40
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Page 38 Page 40
Contents PRO-CUT Safety Cylinder may explode if damaged Précautions DE Sûreté SafetyMaster Table of Contents for ALL Sections PRO-CUT Installation Section Table of ContentsTechnical Specifications PRO-CUT 25 K1756-1 InstallationInput Electrical Connections Safety Precautions Electric Shock can KillSelect Proper Location High Frequency Interference ProtectionGAS Input Connections Torch Output ConnectionsPRO-CUT Table of Contents Operation Section Description Safety PrecautionsPreheat Temperature for Plasma Cutting OperationOperational Features and Controls Design Features AdvantagesUser Responsibility Consumable Life Cutting CapabilityLimitations Controls and SettingsPilot ARC Discussion Apparently wrong, reset the machine by turningGeneral In All Cases Procedure RecommendationsPRO-CUT Accessories General Options Accessories Maintenance Electric Shock can kill Routine MaintenancePRO CUT PRO-CUT Table of Contents Theory of Operation Section Theory of Operation General DescriptionInput Line VOLTAGE, and Auxiliary Transformer Figure E.3 Precharge and Protection Precharge and ProtectionReturn Return to Section TOC Main TransformerFigure E.5 Plasma Output Section and Torch Figure E.6 Control Board Control BoardSafety PARTS-IN-PLACE Protection Protection CircuitsAccidental Operation Protection Insulated Gate Bipolar Transistor Igbt Operation Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board Troubleshooting Procedures Output Problems Function Problems See the Operation section Troubleshooting & Repair LED Function Problems Description Input Filter Capacitor Discharge ProcedureRight Side of Machine Discharge ProcedureMain 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 Machine Input and Output Retest After RepairTable of Contents Electrical Diagrams Section Electrical DiagramsInput 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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