Lincoln Electric SVM104-A service manual Troubleshooting Guide

Page 44

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F-3

TROUBLESHOOTING & REPAIR

 

TROUBLESHOOTING GUIDE

 

 

 

Observe Safety Guidelines

 

 

 

 

 

 

 

detailed in the beginning of this manual.

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

Major Physical or Electrical

 

1.

 

Contact

The

Lincoln

 

 

Damage is Evident

 

 

 

Electric

Service

Dept.

 

 

 

 

 

 

(216)383-2531

or

 

 

 

 

 

 

1-800-833-9353 (WELD)

 

 

 

 

 

 

No LEDs light when the

1.

Make sure input voltage

1. Make sure ON/OFF Power

ON/OFF Power Switch

is

 

 

corresponds to

machine

Switch (S1) is operating

turned "ON". Machine is dead.

 

 

nameplate voltage.

 

properly.

 

Fan is not running.

 

 

 

 

 

 

 

 

 

 

2.

Make sure the reconnect

2. Check the main transformer

 

 

 

 

panel is configured properly

primary leads to the re-

 

 

 

 

for the input voltage being

connect panel

for loose or

 

 

 

 

applied to the PRO-CUT 60

faulty connections.

 

 

 

 

(Single Phase).

 

 

 

 

 

3.

 

Check the input line fuses.

3. Check the leads from the

 

 

 

ON/OFF Power Switch (S1)

 

 

 

 

Replace if blown.

 

to the reconnect panel (T1

 

 

 

 

 

 

 

and T2) for loose or faulty

 

 

 

 

 

 

 

connections.

 

 

 

 

 

 

 

 

4. Perform Main

Transformer

 

 

 

 

 

 

 

Test. The main transformer

 

 

 

 

 

 

 

could be faulty. Check for

 

 

 

 

 

 

 

an open or

grounded

 

 

 

 

 

 

 

primary winding.

 

 

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.

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-CUTSafety Precautions Electric Shock can Kill Select Proper LocationHigh Frequency Interference Protection Tilting➁ ➂ ➀ ➃ Input Electrical ConnectionsGround Connection Fuse and Wire SizesInput Power Supply Connections AIR Input Connections Reconnect Procedure 208/230/460 VAC machinesOutput Connections WorkTable of Contents Operation SectionOperation Electric Shock can killOperational Features and Controls Design Features AdvantagesGeneral Description Recommended Processes and EquipmentLimitations Controls and SettingsCutting and Gouging Capability 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 DMaintenance Safety PrecautionsCapacitor Discharge Procedure 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 OperationPulse Width Modulation Thermal ProtectionThermostat 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 Maximum Acceptable Output Voltage AT Minimum Output Setting Retest After RepairInput Idle Amps 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