Lincoln Electric SVM104-A service manual General Description, Recommended Processes and Equipment

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OPERATION

B-2

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GENERAL DESCRIPTION

The PRO-CUT 60 is a constant current, single range, continuous control plasma cutting system. The microprocessor-based PRO-CUT 60 is capa- ble of cutting with compressed air or nitrogen gas. Nitrogen gas is used to cut aluminum or other non-ferrous metals. This sophisticated system has excellent starting characteristics, cutting visibility, and arc stability. The machine automatically per- forms fundamental troubleshooting when turned ON.

The PRO-CUT 60 is equipped with a patented plasma torch that has a safety mechanism that assures consumables are in place before cutting or gouging. This is extremely important due to the high voltages involved. Two standard torch cable lengths are available: a 25 ft. (7.6m) torch cable or a 50 ft. (15.2m) torch cable. The machine also comes with an air regulator, coarse air filter, pressure gage, and spare parts kit. The standard undercarriage is shipped assembled, except for the handle.

RECOMMENDED PROCESSES AND EQUIPMENT

The PRO-CUT 60 is capable of all cutting and gouging applications within its output capacity of 25 to 60 amps. These applications include thin gage sheet metal and expanded metal.

OPERATIONAL FEATURES AND CONTROLS

The PRO-CUT 60 comes with an ON/OFF POWER SWITCH, OUTPUT CURRENT CON- TROL, and a RUN/PURGE SWITCH.

DESIGN FEATURES AND

ADVANTAGES

The microprocessor controlled PRO-CUT 60 design makes plasma cutting and gouging tasks uncomplicated. This list of design features and advantages will help you understand the machine's total capabilities so that you can get maximum use of your machine.

Single continuous output range of 25-60 amps.

Microprocessor controlled overshooting limiting function increases consumable life.

High intensity, high frequency starter.

Unique microprocessor controlled starting sequence for consistent starting and torch protection.

Solid state pilot duty cycle limiting.Protects components without fuses that would have to be replaced.

Bright 2.5-second timed pilot arc.

Purge/Run switch.

Two independent mechanisms for sensing a shorted torch. Needed for safety and torch protection.

Patented safety sensor monitors if torch parts are in place.

Latching safety circuit mechanism requires that the operator reset the circuit.

Exposed torch parts voltage monitoring with safety shutdown.

Built-in undercarriage for portability.

Built-in air controls, including air pressure regulator.

Air line filtering.

Preflow/Afterflow timing. Preflow stops if cutting or gouging resumes in previous afterflow.

Easy to use torch trigger switch.

Line voltage compensated.

Thermostatically protected.

Solid state overcurrent protection.

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