Lincoln Electric SVM149-A Safety Precautions Electric Shock can Kill, Select Proper Location

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INSTALLATION

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Read entire Installation Section before installing the PRO-CUT 25.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK CAN KILL.

Only qualified personnel

should install this machine.

Turn the input power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equipment.

Do not touch electrically hot parts.

Turn the PRO-CUT Power Switch OFF when connecting power cord to input power.

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SELECT PROPER LOCATION

Place the PRO-CUT 25 where clean cool air can freely circulate in and out the side louvers. Dirt, dust or any foreign material that can be drawn into the machine should be kept at a minimum. Failure to observe these precautions can result in excessive operating temper- atures and nuisance shutdown of the machine.

A source of clean, dry air or nitrogen must be supplied to the PRO-CUT 25. Oil in the air is a severe problem and must be avoided. The supply pressure must be between 80 and 150 psi. The flow rate is approximate- ly 4.0 cfm (113 l/min.). Failure to observe these pre- cautions could result in excessive operating tempera- tures or damage to the torch.

STACKING

The PRO-CUT 25 cannot be stacked.

TILTING

The PRO-CUT 25 must be placed on a stable, level surface so it will not topple over.

HIGH FREQUENCY INTERFERENCE PROTECTION

The PRO-CUT 25 employs a touch start mechanism for arc initiation which eliminates high frequency emis- sions from the machine as compared with spark gap and solid state type high frequency generators. Keep in mind, though, that these machines may be used in an environment where other high frequency generating machines are operating. By taking the following steps, high frequency interference into the Pro-Cut can be minimized

(1)Make sure the power supply chassis is connected to a good earth ground. The work terminal ground does NOT ground the machine frame.

(2)Keep the work clamp isolated from other work clamps that have high frequency.

(3)If the work clamp cannot be isolated, then keep the clamp as far as possible from other work clamp connections.

(4)When the machine is enclosed in a metal building, several good earth driven electrical grounds around the periphery of the building are recom- mended.

Failure to observe these recommended installation procedures may cause improper function of the Pro- Cut or possibly even damage to the control system or power supply components.

INPUT ELECTRICAL CONNECTIONS

The PRO-CUT 25 is rated for 115VAC or 230VAC inputs and will automatically reconnect for the supplied voltage. The machine is shipped from the factory for operation on 115VAC 15 amp circuits. Use on 15 amp branch circuits will limit cutting output as indicated by the graphics around the output knob. If the output is set at 20 amps or greater, the input fuse or circuit breaker may “blow” in roughly 30 seconds or less (depending on fuse or circuit breaker type).

To achieve 20 amp output with 115VAC input, replace the 15 amp plug on the input cord with the supplied 20 amp plug, and connect the unit to a 20 amp branch cir- cuit with super lag fuses (or equivalent breaker). To install the supplied 20 amp plug: Connect the white (neutral) wire under terminal clamp with silver screw, and black (hot) wire under terminal clamp with brass screw. Connect green wire under terminal clamp with green screw. Tighten terminal wire clamp screws securely.

PRO-CUT 25

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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 InstallationSelect Proper Location Safety Precautions Electric Shock can KillHigh Frequency Interference Protection Input Electrical ConnectionsGAS Input Connections Torch Output ConnectionsPRO-CUT Table of Contents Operation Section Preheat Temperature for Plasma Cutting Safety PrecautionsOperation DescriptionOperational 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