Lincoln Electric SVM104-A Safety Precautions Electric Shock can Kill, Select Proper Location

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INSTALLATION

A-2

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Read entire Installation Section before installing the PRO-CUT 60.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK CAN KILL.

Only qualified personnel

should install this machine.

Turn the input power OFF at the disconnect switch or fuse box before working on the equipment.

Do not touch electrically hot parts.

Always connect the PRO-CUT 60 ground- ing terminal (located on the side of the Case Back Assembly) to a good electrical earth ground.

Turn the PRO-CUT Power Switch OFF when connecting power cord to input power.

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SELECT PROPER LOCATION

TILTING

The PRO-CUT 60 must be placed on a stable, level surface using the attached undercarriage so it will not topple over.

HIGH FREQUENCY INTERFERENCE PROTECTION

Locating, installing, or maintaining the PRO-CUT 60 incorrectly could cause interference with prop- er radio, TV, or electronic equipment operation and result in poor cutting and gouging perfor- mance. The spark gap oscillator in the machine's high frequency generator generates electrical sig- nals like a radio transmitter that can cause high frequency interference. Therefore, properly locat- ing, installing, and maintaining the machine can reduce or eliminate the effects of high frequency interference or the loss of high frequency machine operating power.

The following procedures should be followed to minimize interference to the following areas:

the machine

the cutting leads

feedback into the power lines

ungrounded metallic objects

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Place the PRO-CUT 60 where clean air can freely circulate in through the front intake and out through the rear louvers. Dirt, dust, or any foreign material that can be drawn into the machine should be kept at a minimum. Not following these precautions can result in the nuisance shutdown of the machine because of excessive operating temperatures.

The location or improper installation of the machine could affect the operation of radio, TV, or electronic equipment. See the HIGH FREQUEN- CY INTERFERENCE PROTECTION Section for more information.

1.Make the power supply lines as short as possible.

2.Enclose power supply lines entirely in rigid metallic conduit (or equivalent shielding)

a.Provide a good electrical ground between the conduit and the machine.

b.Connect both ends of the conduit to a driven ground.

c.Entire conduit length should be continuous.

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STACKING

NOTE: The machine frame must be grounded.

The PRO-CUT 60 cannot be stacked.The work terminal ground DOES NOT ground the machine frame.

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 InstallationSelect Proper Location Safety Precautions Electric Shock can KillHigh Frequency Interference Protection TiltingInput Electrical Connections ➁ ➂ ➀ ➃Fuse and Wire Sizes Input Power Supply ConnectionsGround Connection AIR Input Connections 208/230/460 VAC machines Reconnect ProcedureWork Output ConnectionsOperation Section Table of ContentsElectric Shock can kill OperationDesign Features Advantages Operational Features and ControlsGeneral Description Recommended Processes and EquipmentControls and Settings Cutting and Gouging CapabilityLimitations 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 SectionSafety Precautions MaintenanceCapacitor Discharge Procedure Procedure DescriptionFigure 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 Protection Pulse Width ModulationThermostat Thermal SensorPRO-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 Retest After Repair Maximum Acceptable Output Voltage AT Minimum Output SettingInput Idle Amps Recommended Meters for Machine Output TestsPRO-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