Lincoln Electric SVM104-A Theory of Operation, Input Line Voltage and Main Transformer

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E-1

THEORY OF OPERATION

 

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Return to Master TOC

 

FIGURE E.2. - Input Line Voltage and Main Transformer

 

 

 

 

 

 

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Return to Master TOC

 

 

 

 

 

Section TOC

Master TOC

INPUT LINE VOLTAGE AND MAIN

 

 

to

to

 

 

TRANSFORMER

 

 

 

Return

Return

 

 

 

The desired single-phase input power is connect-

isolated auxiliary windings (115vac, 24vac and

 

 

 

 

ed to the Pro-Cut 60 through a line switch located

12vac). The 115vac winding supplies power for

 

 

on the front panel of the machine.

 

the cooling fan and powers the air solenoid , the

 

 

 

 

 

CR2 relay and the high voltage transformer via

 

 

A reconnect panel allows the user to configure the

the control board. One 24vac winding produces

 

 

machine for the desired input voltage.

This AC

supply power for the control board.

The other

 

 

input voltage is applied to the primary of the main

24vac winding is applied to the control board and

TOC

TOC

transformer. This main transformer changes the

is used in the Pro-Cut 60 torch safety and trigger

input voltage and current to the voltage and cur-

network. The 12vac winding is required to oper-

rent levels

necessary for plasma cutting. In addi-

ate the power board.

 

to Section

to Master

 

tion, the

main transformer also has

several

 

 

 

 

 

 

 

Return

Return

 

NOTE: Unshaded areas of Block Logic

 

 

Diagram are the subject of discussion

 

 

 

 

 

 

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 ConnectionsInput Power Supply Connections Fuse and Wire SizesGround 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 EquipmentCutting and Gouging Capability Controls and SettingsLimitations 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