Lincoln Electric SVM104-A service manual Internal Trigger, Safety Circuit Test

Page 59

 

 

TROUBLESHOOTING & REPAIR

F-18

TOC

TOC

TORCH, TORCH CABLE ASSEMBLY, INTERNAL TRIGGER,

AND SAFETY CIRCUIT TEST

 

to Section

to Master

 

c. If any of the above tests do not

d. Go to INTERNAL

TRIGGER

Return

Return

agree with the expected normal

AND SAFETY CIRCUIT TEST if

 

 

 

 

resistance specifications, then

all resistance values are within

 

 

the torch and/or cable must be

the specified range.

 

 

 

repaired or replaced.

 

 

TOC

TOC

 

 

CONDUCTOR IN GAS TUBE

 

 

 

 

 

ELECTRODE

 

 

 

 

 

Section

Master

 

 

 

 

 

 

 

 

 

 

 

N.C.

CONE

 

 

 

 

 

 

SWITCH

 

 

 

 

 

THERMOSTAT

 

 

#336

 

RED

SAFETY WIRE

to

to

 

6J5

Pin #1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Return

Return

 

 

#2

 

BLUE

GUN TRIGGER

 

 

3J5

Pin #2

 

 

 

 

 

 

 

 

 

 

 

#4

 

PURPLE

 

 

 

 

 

 

4J5

Pin #4

 

 

 

 

 

C1

 

 

 

 

ELECTRODE

 

 

5J5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VAC

24 VAC

7J5

 

 

 

 

 

 

 

 

#337

 

WHITE

 

 

NOZZLE

 

24

#335

8J5

Pin #3

 

 

 

 

 

 

 

 

 

 

#3L

3J10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6J10

 

PILOT

 

TORCH HEAD

 

Section TOC

 

 

 

 

 

 

Master TOC

 

FIGURE F.5-Torch and Cable Wiring Diagram

 

to

to

 

 

 

 

 

 

 

 

 

 

Return

Return

 

INTERNAL TRIGGER AND

4.

Perform

the

CAPACITOR

 

SAFETY CIRCUIT TEST

 

 

DISCHARGE PROCEDURE.

 

 

 

 

 

 

 

 

PROCEDURE

 

 

 

 

 

 

 

1. Turn the PRO-CUT 60 ON/OFF

5.

Disconnect

the

4-pin

 

 

 

connector.

 

 

 

 

 

Power Switch to OFF.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2.

Disconnect input power

supply

6. Locate Plug J5 on the Control

 

 

 

Board.

See

Figure

F.6 and

TOC

TOC

 

to machine.

 

 

 

 

 

Figure F.1 for the location of the

 

 

 

 

 

 

 

 

 

 

Section

Master

 

using a 5/16” nut driver.

 

7.

Control Board and Plug J5.

 

 

Locate

the

4-pin

recepta-

 

 

3. Remove the roof and the Right

 

 

 

 

 

 

 

 

and Left Case Side Assemblies

 

 

 

 

 

to

to

 

 

 

 

cle. See Figure F.6 for location.

Return

Return

 

 

 

 

 

 

 

 

PRO-CUT 60

Image 59
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