Lincoln Electric SVM149-A service manual See the Operation section

Page 40

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F-6

TROUBLESHOOTING & REPAIR

 

 

F-6

 

Observe Safety Guidelines

 

 

 

 

 

 

 

TROUBLESHOOTING GUIDE

 

detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

 

RECOMMENDED

 

 

 

 

 

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FUNCTION PROBLEMS

 

 

 

 

 

 

 

 

The cutting arc starts but sputters

1. Make sure the operating proce-

 

1.

Check all connectors and

 

badly.

 

dure is correct for the process.

 

 

 

wires for loose or faulty con-

 

 

 

See the Operation section of

 

 

 

nections. See Wiring Diagram.

 

 

 

the manual.

 

 

 

2.

Perform the Torch Continuity

 

 

 

 

 

 

 

 

 

 

 

 

2. Make sure the work clamp is

 

 

 

and Solenoid Test.

 

 

 

 

connected

tightly

to the work

 

3.

 

Perform

the

Main

Inverter

 

 

 

piece.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Board Voltage and Resistance

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3. Make sure the torch consum-

 

 

 

Tests.

 

 

 

 

 

 

able parts are in place and in

 

4.

 

The control

board

may be

 

 

 

good condition. Replace if

 

 

 

 

 

 

 

 

faulty. Replace.

 

 

 

 

necessary.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4. Make sure the air pressure is

 

5. Use the correct extension cord.

 

 

 

 

 

 

See the instruction manual.

 

 

 

set at 65psi.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5. Make sure the air supply is not

 

 

 

 

 

 

 

 

 

 

contaminated with oil or

 

 

 

 

 

 

 

 

 

 

excessive water.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The pilot arc is normal, but the arc

1. Make

sure

the

operating

 

1.

Check all connectors and

 

will not transfer to the work piece.

procedure is correct for the

 

 

 

wires for loose or faulty con-

 

 

 

process.

See

the Operation

 

 

 

nections. See Wiring Diagram.

 

 

 

section of the manual.

 

2.

 

Perform

the

Main

Inverter

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Make sure the work clamp is

 

 

 

Board Voltage and Resistance

 

 

 

connected tightly to the work

 

 

 

Tests.

 

 

 

 

 

 

piece.

 

 

 

 

3.

The control

board

may be

 

 

 

 

 

 

 

 

 

 

 

 

3. The work piece must be electri-

 

 

 

faulty. Replace.

 

 

 

 

cally

conductive material, and

 

 

 

 

 

 

 

 

 

 

the work clamp must make a

 

 

 

 

 

 

 

 

 

 

good electrical connection with

 

 

 

 

 

 

 

 

 

 

the work piece.

 

 

 

 

 

 

 

 

 

 

 

 

4. Do not use a drag cup. Not

 

 

 

 

 

 

 

 

 

 

recommended for Pro-Cut 25

 

 

 

 

 

 

 

 

 

 

use.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Trigger or purge is activated brief

 

 

 

 

 

 

1.

 

The Control Board is defective.

 

air flow then the safety light illumi-

 

 

 

 

 

 

 

 

Replace.

 

 

 

 

nates.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Poor performance of pilot arc or

1. Check pressure switch to be

 

1.

Try increasing or decreasing the

 

cutting. Poor consumable life.

functioning

 

correctly

 

 

 

air pressure to see if conditions

 

 

 

(opening/closing)

at its correct

 

 

 

improve.

 

 

 

 

 

 

pressure.

 

 

 

 

2. Replace

regulator or

pressure

 

 

 

 

 

 

 

 

 

 

 

 

2. Check pressure gauge to be

 

 

 

switch may be required.

 

 

 

correct in its reading.

 

3. Screen in air line at inlet to air

 

 

 

 

 

 

 

 

 

 

 

 

3. Check for recommended flow

 

 

 

solenoid

may be

clogged.

 

 

 

rate coming from the torch end

 

 

 

Clean. (no screen before 7/1/02)

 

 

 

with a flow meter.

 

 

4. Ensure that air is clean and dry

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

External filters may be used.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PRO-CUT 25

 

 

 

 

 

 

 

Page 39 Page 41
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Page 39 Page 41
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 killPRO 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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