Lincoln Electric SVM104-A service manual Disconnect ALL Input

Page 47

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TROUBLESHOOTING & REPAIR

 

 

 

 

 

F-6

Observe Safety Guidelines

 

 

 

 

 

TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

 

 

RECOMMENDED

 

 

 

(SYMPTOMS)

MISADJUSTMENT(S)

 

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

 

 

 

 

The air begins to flow, the

1.

The pilot arc will shut

off

1.

The torch and cable assembly

"OUTPUT ON" LED lights for a

 

after 2.5 seconds unless it is

 

may be faulty.

Perform Torch,

short time, but no pilot arc is

 

brought in contact with the

 

Torch

Cable

Assembly,

and

established.

 

work and the cutting arc is

 

Internal Trigger and

Safety

 

 

established.

This

is

a

 

Circuit Tests.

 

 

 

 

 

 

 

 

If

the high

frequency "spark"

 

 

normal condition.

 

 

 

 

 

 

 

 

is present at the spark gap (for

 

 

 

 

 

 

 

 

 

2. Check the

torch consum-

 

1 second) go to step #3.

 

 

 

2. If the high frequency "spark" is

 

 

ables to be sure they are

 

 

 

not present at the spark gap,

 

 

installed properly.

Make

 

check that the pilot control

 

 

sure they are not dirty or

 

relay

(CR2)

contacts

close

 

 

greasy and are in good con

 

when the torch trigger is

 

 

dition. Replace the consum-

 

pulled.

 

 

 

 

 

 

 

 

ables if necessary.

 

 

 

a.

If

pilot control relay

(CR2)

 

 

 

 

 

 

 

 

contacts close when torch trig-

 

3.

Check for the

presence

of

 

ger

is pulled,

perform

High

 

 

Voltage Transformer Test.

 

 

 

 

high frequency "spark" at the

 

 

 

 

 

 

b.

If

pilot control relay

(CR2)

 

 

spark gap,

located

inside

 

 

 

 

contacts DO NOT close, test

 

 

the right panel of the

 

 

 

 

for 115 VAC between leads

 

 

machine.

The

"spark"

will

 

#36 and #31 on pilot control

 

 

normally be present for a

 

relay (CR2) when the torch trig-

 

 

second or two when the

 

ger

is

pulled.

Refer

to

wiring

 

 

torch trigger is pulled.

 

 

 

diagram. If 115 VAC is present,

 

 

 

 

 

 

 

 

pilot

 

control

relay

 

(CR2)

 

4.

Check the

high frequency

 

could be faulty.Replace.

 

 

 

 

c. If 115 VAC IS NOT present,

 

 

spark gap setting. It should

 

 

 

 

check

plug

J10 on

Control

 

 

be set at

.060"(1.5mm).

 

 

 

 

Board

and

associated

wires

 

 

DISCONNECT ALL INPUT

 

 

 

 

for loose or faulty connections.

 

 

POWER BEFORE ADJUST-

 

 

 

 

Refer

to wiring diagram.

If

 

 

ING THE HIGH FREQUEN-

 

none are found, Control Board

 

 

CY CIRCUIT.

 

 

 

 

could be faulty. Replace.

 

 

 

 

 

 

 

 

 

3.

Check

resistor

R2.

Normal

 

5.

The machine's upper com-

 

resistance is 2 ohms.

Refer to

 

 

partment could be dirty, blow

4.

wiring diagram.

R7.

Normal

 

 

out the upper compartment

Check

resistor

 

 

 

resistance is 5 ohms. Refer to

 

 

with compressed air.

 

 

 

 

 

 

 

 

wiring diagram.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.

Check the two "jump-start"

 

 

 

 

 

 

 

 

diodes mounted on a plastic

 

 

 

 

 

 

 

 

board just in front of the shunt.

 

 

 

 

 

 

 

 

Refer to wiring diagram.

 

 

 

 

 

 

 

 

 

6. If check 3, 4,

and 5

are

OK,

 

 

 

 

 

 

 

 

the Control Board could be

 

 

 

 

 

 

 

 

faulty. Replace.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 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 InstallationTilting Safety Precautions Electric Shock can KillSelect Proper Location High Frequency Interference ProtectionInput 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 OperationRecommended Processes and Equipment Operational Features and ControlsDesign Features Advantages General DescriptionLimitations 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 SectionProcedure Description MaintenanceSafety Precautions Capacitor Discharge ProcedureFigure 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 Sensor Pulse Width ModulationThermal Protection ThermostatPRO-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 Recommended Meters for Machine Output Tests Maximum Acceptable Output Voltage AT Minimum Output SettingRetest After Repair Input Idle AmpsPRO-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