Lincoln Electric SVM104-A service manual Test Procedure, Test a Main Secondary Voltage Test

Page 66

Section TOC

Master TOC

F-25

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER TEST

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TEST PROCEDURE

1.Connect main input power supply to machine.

NOTE: When performing Tests A and

B

a.If any one voltage is missing or below the specification, inspect the associated plugs and wiring. If there are no loose plugs or wiring, then the associated winding in the main transformer could be defective. Replace the main transformer.

b.If all secondary and auxiliary voltages are missing, then inspect the Reconnect Panel to make sure the machine is con- nected for the proper operating voltage. If the machine is con- nected properly, the primary winding in the main transformer could be defective. Replace.

Test A: Main Secondary Voltage Test

1.Locate on the Power Board leads H1 and H2 to the SCR module. See Figure F.2.

2.Turn ON/OFF Power Switch to ON.

3.Test for 190 VAC across leads H1 and H2.

4.Turn ON/OFF Power Switch to OFF.

Test B: Auxiliary Winding Tests

1.Perform the four Auxiliary Winding Tests in Table F.2. Turn the ON/OFF Power Switch to

ON for each test. Turn the ON/OFF Power Switch to OFF between each test. When testing a lead connected to a Molex plug, carefully insert the probe into the cavity of the plug to make contact with the lead. See Figures F.1, F.2, and F.10 for component and lead connec- tion locations. Refer to wiring diagram.

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Auxiliary Winding Test #

Test Voltage

 

Expected Voltage

From

To

 

 

1

Lead #31 on

Lead #32 on

115 VAC

Control

Control Board at

 

 

 

Relay CR2

Plug location 6J10

 

 

 

 

 

2

Lead #C1 on

Lead #32 on

24 VAC

Control Board at

Control Board at

 

 

 

Plug location 5J5

Plug location 6J10

 

 

 

 

 

3

Lead #C2 on

Lead #H6 on

24 VAC

Control Board at

Control Board at

 

 

 

Plug location 1J7

Plug location 3J7

 

 

 

 

 

4

Lead #H3 on

Lead #H4 on

12 VAC

Power Board at

Power Board at

 

 

 

 

Plug location 3J22

Plug location 1J22

 

 

 

 

 

Table F.2-Auxiliary Winding Tests

PRO-CUT 60 (12/95)

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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
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