Lincoln Electric SVM104-A Cutting and Gouging Capability, Limitations, Controls and Settings

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B-3

OPERATION

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Works with pure nitrogen for cutting non-ferrous metal.

Smart switching of pilot contactor so that it does not switch under load.

Low fan noise at idle.

Modular construction for easy servicing.

CUTTING AND GOUGING

CAPABILITY

The PRO-CUT 60 is rated at 60 amps, 115 VAC, at 60% duty cycle on a 10 minute basis or 45 amps, 115VAC, at 100% duty cycle. If the duty cycle is exceeded, a thermal protector will shut off the output of the machine until it cools to the nor- mal operating temperature.

LIMITATIONS

Do not exceed output current and duty cycle rat- ing of machine. Do not use the PRO-CUT 60 for pipe thawing.

CONTROLS AND SETTINGS

All operator controls and adjustments are located on the Case Front Assembly of the PRO-CUT 60. See Figure B.1 for the location of each control.

1.SAFETY RESET BUTTON:The SAFETY RESET BUTTON is pressed to resume opera- tion after the SAFETY LED glows and the operating problem is cleared.

2.PURGE/RUN SWITCH: This switch controls the air supply to the machine. In the PURGE position, air flows continuously through the torch to allow for the adjustment of air pres- sure. Note that the output is disabled in this mode. In the RUN position, air flows through the torch when the torch trigger is activated.

3.STATUS LED DISPLAY: The following machine conditions are displayed:

MACHINE ON LED: The green POWER ON LED glows when the POWER LINE SWITCH is in the ON position and AC power is con- nected to the machine.

OUTPUT ON LED: The OUTPUT ON LED glows when the pilot arc starts and remains glowing during cutting.

AIR PRESSURE LED: The AIR PRESSURE LED glows whenever there is adequate air pressure (above 50 psi).

THERMAL LED: The THERMAL LED glows when the machine overheats.

FAULT LED (MALFUNCTION LED): The FAULT LED glows/blinks if a short circuit has occurred in the torch, in the machine, or when the air pressure is too low.

SAFETY LED: The SAFETY LED glows when there is an operating problem with the machine, torch, or torch consumables.

4.OUTPUT CURRENT CONTROL: The OUT- PUT CURRENT CONTROL adjusts the cur- rent flow for maximum cutting results. See User Chart Range guide on machine's name- plate for recommended range settings based on thickness of steel being cut.

5.ON/OFF POWER SWITCH: Turns the machine ON or OFF.

PRO-CUT 60

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Contents SVM104-A Safety Electric Shock can killWelding or Cutting Sparks can cause fire or explosion Iii Electric and Magnetic FieldsPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Technical Specifications PRO-CUTHigh Frequency Interference Protection Safety Precautions Electric Shock can KillSelect Proper Location Tilting➁ ➂ ➀ ➃ Input Electrical ConnectionsFuse and Wire Sizes Input Power Supply ConnectionsGround Connection AIR Input Connections Reconnect Procedure 208/230/460 VAC machinesOutput Connections WorkTable of Contents Operation SectionOperation Electric Shock can killGeneral Description Operational Features and ControlsDesign Features Advantages Recommended Processes and EquipmentControls and Settings Cutting and Gouging CapabilityLimitations Operating Steps ON/OFFCutting Procedure Recommendations Use Pilot Arc ProperlyCutting Thin Gauge Sheet Metal Cutting Expanded Metal Figure B.3 -- Gouging Metal Return to Section TOC Accessories Section Accessories OPTIONS/ACCESSORIESMaintenance Section Section DCapacitor Discharge Procedure MaintenanceSafety Precautions Procedure DescriptionProcedure Figure D.1 Capacitor Discharge ProcedureRoutine and Periodic Maintenance Perform the following dailyMaintenance PRO-CUT Theory of Operation Section Theory of Operation SectionTheory of Operation Input Line Voltage and Main TransformerOutput Rectification Control and Feedback Figure E.3 Output Rectification, Control and FeedbackHigh Voltage / High Theory of Operation Pilot ARCTransistor Switching Operation Figure E.7 Transistor Switching OperationThermostat Pulse Width ModulationThermal Protection Thermal SensorPRO-CUT Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuideTroubleshooting PC Board Troubleshooting Procedures Board can be dam- aged by static electricityTroubleshooting Guide Troubleshooting Guide PRO-CUTConnect ALL Input Disconnect ALL Input Machine Troubleshooting & Repair Function Problems AIR Flow Problems Cutting Problems Control Board Connector Location Power Board Connector LocationCapacitor Discharge Procedure Figure F.19-Capacitor Discharge Procedure Insulated Pliers GlovesTest Description Torch and Cable Resistance Test Procedure WorkFigure F.4 Torch and Cable Resistance Test Points Safety Circuit Test Internal TriggerReturn to Return to Section TOC Figure F.6-Control Board and 4-pin Locations Transistor Module Test Test DescriptionTest Procedure J21 Main Transformer Test Test Procedure Test a Main Secondary Voltage TestCR2 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 ON/OFF Power Switch Removal REMOVAL/REPLACEMENT DescriptionREMOVAL/REPLACEMENT Procedure ➂ ➃ ➄Control Board Removal To Section TOC Power Board Removal Figure F.14-Power Board Removal/Replacement Return to Return to Section TOC 41TROUBLESHOOTING & Repair Transistor Module RemovalRemoval 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 Input Idle Amps Maximum Acceptable Output Voltage AT Minimum Output SettingRetest After Repair Recommended Meters for Machine Output TestsPRO-CUT Electrical Diagrams Electrical DiagramsStatus Board Schematic Diagram Bypass Board Schematic Diagram M15603 H E M a T I CBypass Board Schematic Diagram M17322 PRO-CUT Electrical Diagrams Control Board IdentificationPower Board Power Board IdentificationStatus PC Board M15601 StatusStatus PC Board M15601Bypass PC Board M15603 BypassBypass PC Board M15603 Bypass PC Board M17322 Bypass PC Board M17322 Wiring Diagram for Codes 10112 0 , J 2Wiring Diagram for Codes 9819 Control Board Schematic Drawing G2015 Power Board Schematic Design SVM Error Reporting Form