Main
PPRROO--CCUUTT 6600
((SSiinnggllee PPhhaassee))
SERVICE MANUAL
SVM104-A
Safety Depends on You
WARNING
FUMES AND GASES can be dangerous.
SAFETY
i
FOR ELECTRICALLY powered equipment.
SAFETY ii
SAFETY iii
ELECTRIC AND MAGNETIC FIELDS may be dangerous
FOR ENGINE powered equipment.
SAFETY iv
PRCAUTIONS DE SRET
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
v
Section A
TABLE OF CONTENTS - INSTALLATION SECTION-
A-1
INPUT - SINGLE PHASE / 60 HERTZ ONLY
RATED OUTPUT OUTPUT RECOMMEND INPUT WIRE AND FUSE SIZES
PHYSICAL DIMENSIONS
TECHNICAL SPECIFICATIONS - PRO-CUT 60
A-2
SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL.
SELECT PROPER LOCATION
STACKING
TILTING
A-4
A-5
__________________
AIR INPUT CONNECTIONS
RECONNECT PROCEDURE
FIGURE A.3a-Voltage Link Positions for 208/230/460 VAC machines.
FIGURE A.3b - Voltage Link Positions for 460/575 VAC machines.
A-6
A-7
OUTPUT CONNECTIONS
FIGURE A.4. -- Connect Torch Cable To Machine
TABLE OF CONTENTS - OPERATION SECTION -
Section B
B-1
SAFETY PRECAUTIONS -
B-2
GENERAL DESCRIPTION
RECOMMENDED PROCESSES AND EQUIPMENT
OPERATIONAL FEATURES AND CONTROLS
DESIGN FEATURES AND ADVANTAGES
B-3
CUTTING AND GOUGING CAPABILITY
LIMITATIONS
CONTROLS AND SETTINGS
1.
B-5
CUTTING PROCEDURE RECOMMENDATIONS
Use Pilot Arc Properly
Cutting and Gouging Recommendations General
Cutting Thin Gauge Sheet Metal
B-6
B-7
Cutting Expanded Metal
Cutting Thick Sections of Metal
FIGURE B.3 -- Gouging Metal.
B-8
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OPTIONS/ACCESSORIES
ACCESSORIES
3/99
C-1
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SAFETY PRECAUTIONS
PROCEDURE DESCRIPTION
D-1
D-2
D-3
ROUTINE AND PERIODIC MAINTENANCE
Perform the following daily:
Perform the following every three months or sooner:
Perform Periodically:
D-4
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INPUT LINE VOLTAGE AND MAIN TRANSFORMER
FIGURE E.2. - Input Line Voltage and Main Transformer
E-1
E-2
FIGURE E.3 - Output Rectification, Control and Feedback
OUTPUT RECTIFICATION, CONTROL AND FEEDBACK
HIGH VOLTAGE / HIGH FREQUENCY AND BY-PASS CIRCUIT
E-3
FIGURE E.4 - High Voltage/High Frequency and By-Pass Circuit
E-4
PILOT ARC
E-5
FIGURE E.7 - Transistor Switching Operation
TRANSISTOR SWITCHING OPERATION
E-6
FIGURE E.8 - Pulse Width Modulation
PULSE WIDTH MODULATION
THERMAL PROTECTION
THERMOSTAT
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Section F
TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR SECTION -
F-1
HOW TO USE TROUBLESHOOTING GUIDE
HIGH VOLTAGE / HIGH FREQUENCYcan damage test equipment.
Step 1. LOCATE PROBLEM(SYMPTOM).
Step 2. PERFORM EXTERNAL TESTS.
F-2
PC BOARD TROUBLESHOOTING PROCEDURES
F-3
F-4
F-5
F-6
F-7
F-8
F-9
FUNCTION PROBLEMS
F-10
AIR FLOW PROBLEMS
F-11
CUTTING PROBLEMS
CONTROL BOARD CONNECTOR LOCATION
F-12
FIGURE F.2 - Power Board Connector Locations
FIGURE F.1 - Control Board Connector Locations
POWER BOARD CONNECTOR LOCATION
PROCEDURE DESCRIPTION
F-13
F-14
INSULATED INSULATED
PLIERS GLOVES
F-15
F-16
TORCH AND CABLE RESISTANCE TEST
F-17
F-18
INTERNAL TRIGGER AND SAFETY CIRCUIT TEST
F-19
PROCUT 60 SINGLE PHASE
4- PIN RECEPTACLE IN BULKHEAD
F-20
FIGURE F.7-Control Board and 4-Pin Connector Test Points
FIGURE F.6-Control Board and 4-pin Locations.
F-21
F-22
F-23
F-24
F-25
TEST PROCEDURE
F-26
F-27
TROUBLESHOOTING &REPAIR
F-28
F-29
F-30
F-31
HIGH VOLTAGE/HIGH FREQUENCYCAN DAMAGE TEST EQUIPMENT
F-32
F-33
F-34
ON/OFF POWER SWITCH REMOVAL
ON/OFF POWER SWITCH REMOVAL (LATER CODES MAYHAVE TOGGLE SWITCH)
F-35
0 1
F-36
CONTROL BOARD REMOVAL
F-37
CONTROL BOARD REMOVAL
F-38
F-39
F-40
F-41
TRANSISTOR MODULE REMOVAL
F-42
TRANSISTOR MODULE REMOVAL
F-43
SCR MODULE REMOVAL
F-44
F-45
SCR MODULE REMOVAL
F-46
F-47
F-48
F-49
F-50
F-51
F-52
RETEST AFTER REPAIR
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G-2
STATUS BOARD SCHEMATIC DIAGRAM
G-3
71 POS
TP1
BYPASS BOARD SCHEMATIC DIAGRAM (M15603)
C2 C7 C8 C1 C3 C5 C6 C10 C4 C9
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G-7
CONTROL BOARD
Item Identification Item Identification
Page
G-9
POWER BOARD
G-10
STATUS PC BOARD
M15601
CONNECTOR ON BOARD BACK
G-11
STATUS PC BOARD M15601
G-12
BYPASS PC BOARD (M15603)
M15603
BYPASS
G-13
BYPASS PC BOARD (M15603)
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G-15
BYPASS PC BOARD (M17322)
ELECTRICAL DIAGRAMS G-16
WIRING DIAGRAM FOR CODES 10112, 10118
L1
575V
460 V
ELECTRICAL DIAGRAMS G-17
WIRING DIAGRAM FOR CODES 9819, 10096
460 V
CLEVELAND, OHIO U.S.A.
CAPACITORS = MFD/VOLTS
ELECTRICAL DIAGRAMS G-18
CONTROL BOARD SCHEMATIC DRAWING (G2015)
FILE: G1951-4HB
NOTES :
LABELS
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SVM ERROR REPORTING FORM