Lincoln Electric SVM104-A F-52

INPUT IDLE AMPS

MAXIMUM ACCEPTABLE OUTPUT VOLTAGE -

AT MINIMUM OUTPUT SETTING

MINIMUM ACCEPTABLE OUTPUT VOLTAGE -

AT MAXIMUM OUTPUT SETTINGS

RECOMMENDED METERS FOR MACHINE OUTPUT TESTS

VOLTMETER: Analog type meter

TROUBLESHOOTING & REPAIR

PRO-CUT 60

F-52

RETEST AFTER REPAIR

Should a machine under test be

rejected for any reason requiring the

removal of any mechanical part that

could affect the machine’s electrical

characteristics, or if any electrical

components are repaired or

replaced, the machine must be

retested.

INPUT VOLTS / HERTZ

208 / 60

230 / 60

460 / 60

575 / 60

MAXIMUM IDLE AMPS

4.4

4.0

2.0

1.6

Output Control at Minimum 26 Amps @ 43VDC

Output Control at Maximum 60 Amps @ 90VDC

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Contents

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 Page Page OPTIONS/ACCESSORIES ACCESSORIES 3/99 C-1 Page 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 Page Page 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 Page 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 Page Page 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 Page Page Page 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) Page 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 Page SVM ERROR REPORTING FORM