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Lincoln Electric SVM200-A service manual J4, J3 J2

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J4J3J2

PLUG

J1

FIGURE F.22 – PLUG LOCATION

RELAY PC BOARD REMOVAL AND REPLACEMENT PROCEDURE

(continued)

REPLACEMENT PROCEDURE

1. Replace the Relay PC Board.

2. Mount the board to the machine by carefully

pressing the board onto the four mounting

stand-offs.

3. Insert previously removed 8-pin molex plug J1.

4. Connect the three cables (J2, J3 & J4) previ-

ously removed.

5. Perform the Case Cover Replacement

Procedure.

6. Perform the Monitor and Pedestal

Replacement Procedure.

7. See Retest After Repair.

TROUBLESHOOTING AND REPAIR

F-57 F-57

VRTEX TM360

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Contents

Main SVM200-A April, 2010 AD1332-2 VRTEX360 NOTICE Page VRTEXTM 360 i i FOR ENGINE powered equipment. WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous ii ii ARC RAYS can burn. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. iii iii FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. WELDING and CUTTING SPARKS can cause fire or explosion. Refer to http://www.lincolnelectric.com/safetyfor additional safety information. PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR iv iv VRTEXTM 360 PRCAUTIONS DE SRET WARNINGS Recycling Welding Equipment at End of Life Waste Electrical and Electronic Equipment (WEEE) Recycling WEEE in Europe This instruction is mandatory for equipment in Europe that displays this symbol: - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - TABLE OF CONTENTS - INSTALLATION SECTION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL U1 I1 TECHNICAL SPECIFICATIONS: VRTEX C 360 - VIRTUAL REALITY WELDING TRAINER TILTING HIGH FREQUENCY INTERFERENCE PRO- TECTION Safety Precautions STRAPS GENERAL DESCRIPTION DESIGN FEATURES HARDWARE UNCRATING: HARDWARE OVERVIEW: MULTIPLE SYSTEM INSTALLATIONS FRONT (upper) BOLTS FRONT (lower) Page MONITOR: ADDITIONAL FEATURES: TRACKING SYSTEM FUNDAMENTALS: MONITOR (Mounting Screws) Screws Input Power Page TABLE OF CONTENTS - OPERATION SECTION Page USER INTERFACE OVERVIEW HARDWARE SPECIFICS: VR GMAW/FCAW GUN VR SMAW DEVICE Helmet Coupon Drawer 5 4 1 Stand Post Coupon Positioning In Swing Arm Table Login Screen: 1. On Screen Keyboard Powering Up Your System: 2. Language 3. Measurement Units 4. Menu B-9 B-9 Joint Configuration Selection Screen: JOINT CONFIGURATION CHART - MILD STEEL Pipe Plate SMAW Process Selection Screen: Change Coupon Type Stand Set-Up Screen: Coupon Insertion Table/Arm Rotation Pin Positions Environment Screen: Gas Set-Up Screen: Weld Machine Settings Screen: Virtual Welding Overview Polarity Selector Upper Overlays Push Buttons Action Button Visual Cues New Coupon White Screen Select Arrows Welders View screen Instructors View screen LASER SCREEN Technique Parameters Page VRTEX TM360 Pass number Travel Direction Bead Render Discontinuity Indicator End Pass Instructor Mode Update Software Configuration File Options Weldometer Reset Trip Save to File Tolerance Editor Choose Tolerance Set-up Choose Tolerance to Load Edit USB Edit Tolerances Keyboard Screen Tolerances Joint Configuration Selection Screen Tolerances Process Selection Tolerances Value Modifying Next & Previous Prev Pass Next Pass Tolerances Equipment Settings TEE PIPE GROOVE COORDINATE CHART FOR WELD PLACEMENT (POSITION) Tolerances Whip and Travel Speed Tolerances Weave Screen B-28 B-28 VRTEX 360 - Default Weld Process Settings Page Page MAINTENANCE CLEANING & MAINTENANCE FMD Monitor Page Page TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 E-1 12 VDC VGA 3 + 4 AND AUDIO 2 FIGURE E.1 BLOCK LOGIC DIAGRAM GENERAL DESCRIPTION VGA 3 + 4 AND AUDIO 2 FIGURE E.2 - GENERAL DESCRIPTION < VRTEX 360 THEORY OF OPERATION INPUT POWER & DISTRIBUTION < VRTEX 360 THEORY OF OPERATION E-4 E-4 COMPUTER ASSEMBLY (CPU) FUNCTIONS, USER CONTROLS, INDICATORS & VIDEO/AUDIO COMPONENTS 12 VDC VGA 3 + 4 AND AUDIO 2 FIGURE E.4 - COMPUTER ASSEMBLY (CPU) FUNCTIONS, USER CONTROLS, INDICATORS & VIDEO/AUDIO COMPONENTS < FMD CONTROL UNIT, POLHEMUS INTERFACE MODULE, WELDING STAND, HELMET, RELAY BOARD AND WELDING DEVICES Page TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE VRTEX TM360 PC BOARD TROUBLESHOOTING PROCEDURES Page Page Page Page Page Page Page Page Page Page Page 5 VDC SUPPLY TEST PROCEDURE 5 VDC SUPPLY TEST PROCEDURE (continued) 5 VOLT SUPPLY + + - - 81 81 50 50 DPP25-5 N L N LN L DPP50-15DPP50-15 Page 12/15 VDC SUPPLY TEST PROCEDURE 12/15 VDC SUPPLY TEST PROCEDURE (continued) 12/15 VOLT SUPPLY + + - - + + - - 71 71 72 72 DPP25-5DPP25-5 N LN L N LN L DPP50-15DPP50-15 + + - - + + - - Ground (Green) 102B (White) 103C (Pink/Red) Page FACE MOUNTED DISPLAY (FMD) CONTROL UNIT TEST FMD CONTROLLER HORIZONTAL MOUNTING SHELF FACE MOUNTED DISPLAY (FMD) CONTROL UNIT TEST (continued) DOOR FMD (HELMET) RED LED FRONT FACE MOUNTED DISPLAY (FMD) CONTROL UNIT TEST (continued) Page INTERFACE DIGITAL MODULE I/O TEST PROCEDURE Page INTERFACE DIGITAL MODULE I/O TEST PROCEDURE (continued) Page USB INTERFACE MODULE TEST PROCEDURE Page USB INTERFACE MODULE TEST PROCEDURE (continued) Page POLHEMUS INTERFACE MODULE TEST PROCEDURE POLHEMUS INTERFACE MODULE TEST PROCEDURE (continued) POLHEMUS MODULE HORIZONTAL MOUNTING SHELF SENSOR 1 SENSOR 2 SOURCE RS 232 USB CONFIG ON OFF FRONT LED BACK POLHEMUS INTERFACE MODULE TEST PROCEDURE (continued) Page Page Power Cord VGA Phillips Screws (4) Page Page CASE COVER REMOVAL AND REPLACEMENT PROCEDURE CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) Drawer Release Tabs (one tab on each side) CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) Page POLHEMUS MODULE REMOVAL AND REPLACEMENT PROCEDURE POLHEMUS MODULE HORIZONTAL MOUNTING SHELF POLHEMUS MODULE REMOVAL AND REPLACEMENT PROCEDURE (continued) SENSOR 1 SENSOR 2 SOURCE RS 232 USB CONFIG ON OFF FRONT LED BACK POLHEMUS MODULE REMOVAL AND REPLACEMENT PROCEDURE (continued) Page Page FMD CONTROLLER HORIZONTAL MOUNTING SHELF DOOR FMD (HELMET) Page Page Page RELAY BOARD J4 J3 J2 PLUG J1 Page Page 5 VOLT SUPPLY + + - - + + - - + + - - Page Page 12/15 VOLT SUPPLY + + - - + + - - Page ON BUTTON REMOVAL AND REPLACEMENT PROCEDURE ON BUTTON ON BUTTON REMOVAL AND REPLACEMENT PROCEDURE (continued) Page Page INTERFACE MODULE DIGITAL I/O HORIZONTAL MOUNTING SHELF INTERFACE MODULE (USB) SLIDE SWITCH USB RIBBON CABLE SCREW Page Page Page 16-PIN TERMINAL STRIP INTERFACE MODULE DIGITAL (USB) Page Page DISPLAY BOARD REMOVAL AND REPLACEMENT PROCEDURE DISPLAY BOARD PLUG J37 (VIEWED FROM REAR) DISPLAY BOARD Page MOTOR CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE MOTOR CONTROL BOARD MOTOR CONTROL BOARD Page VR SMAW (STICK) DEVICE REMOVAL AND REPLACEMENT PROCEDURE Page VR SMAW (STICK) DEVICE Page Page Page Page Page VGA SPLITTER REMOVAL AND REPLACEMENT PROCEDURE VGA SPLITTER FMD CONTROLLER VGA SPLITTER REMOVAL AND REPLACEMENT PROCEDURE (continued) Page TABLE SWING ARM REMOVAL AND REPLACEMENT PROCEDURE SOURCE TABLE SWING ARM Page CPU REMOVAL AND REPLACEMENT PROCEDURE CPU Page Page Page RETEST AFTER REPAIR Page ELECTRICAL DIAGRAMS A.06 VRTEX 360 SCHEMATIC - ENTIRE MACHINE - G3244-565 VRTEX 360 MACHINE SCHEMATIC G3244-565 VIEW OF CONNECTOR ON PC BOARD 8 LATCH EXAMPLE: THIS IS PIN 7 3 Page ELECTRICAL DIAGRAMS J2 J3 VRWELDER 56 TYP