Lincoln Electric SVM104-A service manual Control Board, Identification

Page 101

ELECTRICAL DIAGRAMS

G-7

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Item

Identification

X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .IC,NMOS,MCU,68705R3CS X5 . . . . . . . . . . . . . . .IC-CMOS,GATE,NAND,2-INPUT,QUAD,4011 X6 . . . . . . . . . . . . . . . . .IC-CMOS,INVERTER,SCHMITT,HEX,4584 C14 . . . . . . . . . . . . . . . . . . . . . . .CAPACITOR-CEMO,22P,100V,5% C36,C45 . . . . . . . . . . . . . . . . . .CAPACITOR-CEMO,100P,100V,5%

C5,C8,C12,C13,C27,C30,C31 . .CAPACITOR-CEMO,.022,50V,20% C38,C52,C56

J4,J7 . . . . . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,4-PIN J2,J10 . . . . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,6-PIN J5 . . . . . . . . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,8-PIN C11 . . . . . . . . . . . . . . . . . . .CAPACITOR 150uF, 50V, +150% -10% D1,D2,D3,D4,D5,D6,D7,D8,D9 . . . . . . . . . .DIODE-AXLDS,1A,400V

D10,D11,D12,D13,D14,D24

D25,D35,D36,D46,D47,D48

D49,D50,D58,D59,D69,D70

D71 *

D26,D27,D29,D30 . . . . . . . . . . . . . . . . . .DIODE-AXLDS,1A,1000V L6 . . . . . . . . . . . . . . . . . . . . . .CHOKE-5.6MH,10%,28MA,MOLDED L1,L2,L3,L4 . . . . . . .CHOKE-5.0MH,5%,160MA,CONFORMAL,SLV PT3 . . . . . . . . . . . . . . .TRANSFORMER-PULSE,3-WINDING,1:1:1 C2,C4,C26,C43,C44 . . . . . . . . . . .CAPACITOR-TAEL,4.7,35V,10% C42 . . . . . . . . . . . . . . . . . . . . . . . .CAPACITOR-TAEL,2.7,50V,10% C6,C50,C53,C54,C55,C58,C60 . .CAPACITOR,PCF, 0.027,50V,20%

C64,C65,C66,C67

C1,C3 . . . . . . . . . . . . . . . . .CAPACITOR-ALEL,3300,50V,+30/-10% C10,C16,C39,C40,C41 . . . . . . .CAPACITOR,PEMF, 0.33,200V,10% OCI1,OCI2,OCI3 . . . . .OPTOCOUPLER-TRIAC DRIVER,ZVC,3043 TRI1,TRI2,TRI3 . . . . . . . . . . . . . . . . . . . . . .TRIAC, T220, 6A, 400V J3 . . . . . . . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,10-PIN J6 . . . . . . . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,12-PIN J8 . . . . . . . . . . . . . . . . . . .CONNECTOR,MOLEX,MINI,PCB,16-PIN C46 . . . . . . . . . . . . . . . . . . . . . . . .CAPACITOR-PEF,0.1,100V,10% C48 . . . . . . . . . . . . . . . . . . . . . . .CAPACITOR-PEF,0.22,100V,10% C29 . . . . . . . . . . . . . . . . . . . . . . .CAPACITOR-PEF,.047,200V,10% C25 . . . . . . . . . . . . . . . . . . . . .CAPACITOR-CD,.02,600V,+80/-20% C63 . . . . . . . . . . . . . . . . . . . . .CAPACITOR-CD,.05,600V,+80/-20% C21,C22,C23 . . . . . . . . . . . . . . . . .CAPACITOR-PEF,0.1,400V,10% DZ8 . . . . . . . . . . . . . . . . . . . .ZENER DIODE-5W,15V,5%,1N5352B DZ3,DZ9,DZ10 . . . . . . . . . . . .ZENER DIODE-1W,15V,5%,1N4744A DZ7 . . . . . . . . . . . . . . . . . . . .ZENER DIODE-5W,17V,5%,1N5354B

Q1,Q3,Q4,Q5,Q6,Q8,Q9,Q13 . . . . . . . . . . . . . . . . . .TRANSISTOR N,T226,0.5A,40V,2N4401

Q14,Q16

Q2,Q15 . . . . . . . . . . . . . . .TRANSISTOR-P,T226,0.5A,40V,2N4403 D55,D56,D61,D64 . . . . . . . . . .DIODE-AXLDS,1A,400V,FR,1N4936 R119,R120 . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-CC,1W,3.3,5% R114 . . . . . . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-CC,2W,15,5% R160,R161 . . . . . . . . . . . . . . . . . . . . .RESISTOR-CC,1/2W,100,5% R23,R24 . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-CC,1/2W,150,5% R25,R26,R75 . . . . . . . . . . . . . . . . . . .RESISTOR-CC,1/2W,330,5% C49 . . . . . . . . . . . . . . . . . . . . . .CAPACITOR-PEMF,.047,100V,10% Q12 . . . . . . . . . . . . . . . . .TRANSISTOR-ND,T220,5A,100V,TIP122 R27,R31,R33,R85,R102,R127 . . . . . .RESISTOR-MF,1/4W,100,1%

R128,R164

R12,R18,R19,R38,R48,R53 . . . . . . .RESISTOR-MF,1/4W,1.00K,1% R56,R60,R63,R65,R68,R72 R73,R74,R80,R121,R159,R169

R175,R176

CONTROL BOARD

Item

Identification

R3,R8,R14,R20,R21,R35,R36 . . . . .RESISTOR-MF,1/4W,10.0K,1% R40,R41,R43,R44,R81,R82

R94,R95,R96,R97,R98,R103

R104,R111,R123,R130,R150

R151,R152,R165,R170,R171

R172,R173

R140,R142,R143 . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,100K,1% R144 . . . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,1.00M,% R76 . . . . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,10.0,1% R46,R90,R93 . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,1.50K,1% R55,R62,R66 . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,200,1% R30,R45,R57,R59,R69,R83 . . . . . . .RESISTOR-MF,1/4W,2.21K,1%

R157,R158,R174

R101,R137 . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,22.1K,1% R70,R89,R91,R100,R139,R156 . . . .RESISTOR-MF,1/4W,221K,1% R2 . . . . . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,267,1% R1,R54,R64,R67 . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,26.7,1% R71,R148,R149 . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,3.01K,1% R32 . . . . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,332,1% R47,R129,R168,R177,R178 . . . . . . .RESISTOR-MF,1/4W,3.32K,1% R86,R87,R145,R179,R180 . . . . . . . .RESISTOR-MF,1/4W,33.2K,1% R28,R29,R34,R84,R99,R108 . . . . . . .RESISTOR-MF,1/4W,475,1%

R153,R154,R155

R16 . . . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,4.75K,1% R22,R58,R138,R146,R147 . . . . . . . .RESISTOR-MF,1/4W,5.11K,1% R15 . . . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,5.62K,1% R9 . . . . . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,681,1% R5,R6,R10,R61,R141 . . . . . . . . . . .RESISTOR-MF,1/4W,6.81K,1% R4,R7,R11 . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,68.1K,1% R166 . . . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,68.1,1% X3,X7 . . . . . . . . . . . . . . .IC-OP-AMP,QUAD,GEN-PURPOSE,224N OCI6,OCI7,OCI9 . . . . . .OPTOCOUPLER-PHOTO-Q,70V,CNY17-3 DZ1 . . . . . . . . . . . . . . . . . . . .ZENER DIODE-1W,10V,5%,1N4740A DZ6 . . . . . . . . . . . . . . . . . . .ZENER DIODE-1W,6.2V,5%,1N4735A

DZ2,DZ4,DZ5,DZ13,DZ14,DZ15

. . . . . . . . . . . . . . . . . . . . . . .ZENER DIODE-1W,5.1V,5%,1N4733A

DZ17,DZ18,DZ19,DZ20,DZ21

Q7 . . . . . . . . . . . . . . . .TRANSISTOR-NMF,4PDIP,1A,100V,RFD110 C9,C15,C17,C18,C19,C28,C51 . . .CAPACITOR-TAEL,1.0,50V,10%

C62 *

C24 . . . . . . . . . . . . . . . . . . . . .CAPACITOR-CEMO,4700P,50V,10% L7,L8,L9 . . . . . . . . . . . . . . . .CHOKE-330UH,10%,110MA,MOLDED C68 . . . . . . . . . . . . . . . . . . . . . .CAPACITOR-CD,.0047,3000V,20% DZ16 . . . . . . . . . . . . . . . . . . .ZENER DIODE-1W,12V,5%,1N4742A R13 . . . . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,243,1% R88 . . . . . . . . . . . . . . . . . . . . . . . . .RESISTOR-MF,1/4W,8.25K,1% Y1 . . . . . . . . . . . . . . . . . . . . . . .CRYSTAL-QUARTZ,3.579545MHZ OCI4 . . . . . . . . . . . . . . . . . .OPTOCOUPLER-TRIAC DRIVER,3023 C20 . . . . . . . . . . . . . . . . . . . . . . .CAPACITOR-PEF,0.22,400V,10% D72 . . . . . . . . . . . . . . . . . . . . . . . .DIODE-AXLDS,3A,600V,1N5406 R49,R184 . . . . . . . . . . . . . . . . . . . .RESISTOR, WW, 5W, 390, 5% R78,R181,R182 . . . . . . . . . . . . . .RESISTOR, MF, 1/4W, 90.0K, 1% SCR1 . . . . . . . . . . . . . . . . . . . . . . . . .SCR-T220,25A,600V,2N6508 C7 . . . . . . . . . . . . . . . . . . . . . . . .CAPACITOR,CEMO,0.1,50V,10% X1 . . . . . . . . . . . . . . . . . . . . . .IC-VOLT REG, FIXED,3-T,(+),1A,5V X2 . . . . . . . . . . . . . . . . . . . . .IC-VOLT REG, FIXED,3-T,(+),1A,15V

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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

PRO-CUT 60

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Contents SVM104-A Electric Shock can kill SafetyWelding or Cutting Sparks can cause fire or explosion Electric and Magnetic Fields IiiSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Technical Specifications PRO-CUT InstallationSelect Proper Location Safety Precautions Electric Shock can KillHigh Frequency Interference Protection TiltingInput Electrical Connections ➁ ➂ ➀ ➃Ground Connection Fuse and Wire SizesInput Power Supply Connections AIR Input Connections 208/230/460 VAC machines Reconnect ProcedureWork Output ConnectionsOperation Section Table of ContentsElectric Shock can kill OperationDesign Features Advantages Operational Features and ControlsGeneral Description Recommended Processes and EquipmentLimitations Controls and SettingsCutting and Gouging Capability ON/OFF Operating StepsUse Pilot Arc Properly Cutting Procedure RecommendationsCutting Thin Gauge Sheet Metal Cutting Expanded Metal Figure B.3 -- Gouging Metal Return to Section TOC Accessories Section OPTIONS/ACCESSORIES AccessoriesSection D Maintenance SectionSafety Precautions MaintenanceCapacitor Discharge Procedure Procedure DescriptionFigure D.1 Capacitor Discharge Procedure ProcedurePerform the following daily Routine and Periodic MaintenanceMaintenance PRO-CUT Theory of Operation Section Theory of Operation SectionInput Line Voltage and Main Transformer Theory of OperationFigure E.3 Output Rectification, Control and Feedback Output Rectification Control and FeedbackHigh Voltage / High Pilot ARC Theory of OperationFigure E.7 Transistor Switching Operation Transistor Switching OperationThermal Protection Pulse Width ModulationThermostat Thermal SensorPRO-CUT Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairBoard can be dam- aged by static electricity Troubleshooting PC Board Troubleshooting ProceduresTroubleshooting Guide PRO-CUT Troubleshooting GuideConnect ALL Input Disconnect ALL Input Machine Troubleshooting & Repair Function Problems AIR Flow Problems Cutting Problems Power Board Connector Location Control Board Connector LocationCapacitor Discharge Procedure Insulated Pliers Gloves Figure F.19-Capacitor Discharge ProcedureTest Description Work Torch and Cable Resistance Test ProcedureFigure F.4 Torch and Cable Resistance Test Points Internal Trigger Safety Circuit TestReturn to Return to Section TOC Figure F.6-Control Board and 4-pin Locations Test Description Transistor Module TestTest Procedure J21 Main Transformer Test Test a Main Secondary Voltage Test Test ProcedureCR2 Power Board Test Figure F.11-Power Board Test Points Transistor Module Test Troubleshooting & Repair High Voltage Transformer and Circuit Test Figure F.12-High Voltage Test Component Locations Test C Test Resistance of High Voltage Transformer Secondary REMOVAL/REPLACEMENT Description ON/OFF Power Switch Removal➂ ➃ ➄ REMOVAL/REPLACEMENT ProcedureControl Board Removal To Section TOC Power Board Removal Figure F.14-Power Board Removal/Replacement Return to Return to Section TOC Transistor Module Removal 41TROUBLESHOOTING & RepairRemoval Procedure SCR Module Removal Socket Head CAP Screws Torque to Power Board REMOVAL/ Replacement Procedure FAN Blade and FAN Motor REMOVAL/REPLACEMENT Figure F.17-Fan Blade & Fan Motor To Section TOC Torch Head REMOVAL/REPLACEMENT Figure F.18-Torch Head Removal/Replacement Section TOC Retest After Repair Maximum Acceptable Output Voltage AT Minimum Output SettingInput Idle Amps Recommended Meters for Machine Output TestsPRO-CUT Electrical Diagrams Electrical DiagramsStatus Board Schematic Diagram H E M a T I C Bypass Board Schematic Diagram M15603Bypass Board Schematic Diagram M17322 PRO-CUT Electrical Diagrams Identification Control BoardPower Board Identification Power BoardM15601 Status Status PC BoardM15601 Status PC BoardBypass Bypass PC Board M15603Bypass PC Board M15603 Bypass PC Board M17322 Bypass PC Board M17322 0 , J 2 Wiring Diagram for Codes 10112Wiring Diagram for Codes 9819 Control Board Schematic Drawing G2015 Power Board Schematic Design SVM Error Reporting Form
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