Lincoln Electric SVM146-A - Manual

Lincoln Electric SVM146-A

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Table of Contents:

  • Page 2 – SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
  • Page 3 – ii; ELECTRIC SHOCK can kill.
  • Page 4 – iii
  • Page 5 – iv; PRÉCAUTIONS DE SÛRETÉ
  • Page 6 – MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page; RETURN TO MAIN INDEX
  • Page 7 – TABLE OF CONTENTS; Installation
  • Page 8 – INSTALLATION; INPUT RATINGS; Duty Cycle
  • Page 9 – GAS REQUIREMENTS; Ambient Temperature 30°C or Less; AC Input Voltage; PHYSICAL DIMENSIONS
  • Page 10 – SAFETY PRECAUTIONS; SELECT SUITABLE LOCATION; STACKING; • Make sure the power supply chassis is connected to
  • Page 11 – INPUT CONNECTIONS; GROUND CONNECTION; Technical; FIGURE A.1 – RATING PLATE LOCATION
  • Page 12 – ONLY; connected from the input power.; FIGURE A.2 – RECONNECTION DIAGRAM; CAUTION; RECONNECT PROCEDURE
  • Page 13 – GAS INPUT CONNECTIONS; NOTE
  • Page 14 – OUTPUT CONNECTIONS; TORCH CONNECTION; AT CASE FRONT
  • Page 15 – Operation
  • Page 16 – OPERATION
  • Page 17 – GENERAL DESCRIPTION
  • Page 18 – CUTTING CAPABILITY; Amps; CONSUMABLE LIFE
  • Page 19 – CONTROLS AND SETTINGS
  • Page 21 – USER RESPONSIBILITY; GENERAL - IN ALL CASES; Torch Standoff
  • Page 22 – THICK SECTIONS OF METAL; • Turn off machine at the disconnect
  • Page 23 – MACHINE INTERFACE
  • Page 24 – NOTES
  • Page 25 – Accessories
  • Page 26 – ACCESSORIES
  • Page 27 – Maintenance
  • Page 28 – ELECTRIC SHOCK; MAINTENANCE; FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS
  • Page 29 – ROUTINE MAINTENANCE; SEE; PERIODIC MAINTENANCE
  • Page 30 – FIGURE D.2 – MAJOR COMPONENT LOCATIONS
  • Page 31 – FIGURE E.1 – PRO-CUT 80 BLOCK LOGIC DIAGRAM
  • Page 32 – THEORY OF OPERATION; FIGURE E.2 – INPUT LINE VOLTAGE
  • Page 33 – PRECHARGE AND PROTECTION; IGBT Operation
  • Page 34 – FIGURE E.4 – MAIN TRANSFORMER; MAIN TRANSFORMER
  • Page 35 – OUTPUT BOARD AND TORCH; sensor regulates pilot and cutting current. The other sen-; FIGURE E.5 – PLASMA OUTPUT BOARD AND TORCH
  • Page 36 – CONTROL AND DISPLAY BOARDS; Pulse Width Modulation; FIGURE E.6 – CONTROL AND DISPLAY BOARDS
  • Page 37 – PROTECTION CIRCUITS; OVERLOAD PROTECTION
  • Page 38 – FIGURE E.7 – CONTROL AND DISPLAY BOARDS
  • Page 39 – PULSE WIDTH MODULATION; MINIMUM OUTPUT; conducting for 1 microsecond. The negative; MAXIMUM OUTPUT; FIGURE E.8 – TYPICAL IGBT OUTPUTS
  • Page 41 – Test Procedures
  • Page 42 – HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; The; Step 3. PERFORM COMPONENT TESTS
  • Page 43 – PC BOARD TROUBLESHOOTING PROCEDURES
  • Page 44 – Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS; Auxiliary
  • Page 45 – FUNCTION PROBLEMS
  • Page 46 – Torch Continuity
  • Page 47 – CUTTING PROBLEMS
  • Page 48 – LED FUNCTION PROBLEMS
  • Page 49 – The Thermal LED is lit.
  • Page 50 – INPUT FILTER CAPACITOR DISCHARGE PROCEDURE; DESCRIPTION; This procedure takes approximately 10 minutes to perform.
  • Page 51 – DISCHARGE PROCEDURE; FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS
  • Page 52 – INPUT RECTIFIER TEST; This procedure takes approximately 15 minutes to perform.
  • Page 53 – TEST PROCEDURE; Input Filter Capacitor; FIGURE F.2 – INPUT RECTIFIER AND LEADS; TOP VIEW
  • Page 54 – Acceptable Meter Readings; If the input rectifier does not meet the accept-; TABLE F.1 INPUT RECTIFIER TEST POINTS
  • Page 55 – This procedure takes approximately 25 minutes to perform.
  • Page 56 – PRIMARY POWER BOARD RESISTANCE TEST AND; FIGURE F.3 – PRIMARY POWER BOARD REMOVAL
  • Page 57 – TEST POINT TERMINALS; Power
  • Page 59 – Check for the appropriate voltages outlined; EXPECTED VOLTS
  • Page 60 – OUTPUT POWER BOARD RESISTANCE TEST; This procedure takes approximately 18 minutes to perform.
  • Page 61 – FIGURE F.4 – OUTPUT POWER BOARD LEAD LOCATIONS
  • Page 62 – TABLE F.4 - OUTPUT POWER BOARD RESISTANCE
  • Page 63 – TORCH CONTINUITY AND SOLENOID TEST
  • Page 65 – AIR/GAS SOLENOID TEST; This procedure takes approximately 13 minutes to perform.
  • Page 66 – Input Capacitor Discharge; FIGURE F.6 – AIR SOLENOID; FIGURE F.7 – PLUG J31 LOCATION
  • Page 68 – FIGURE F.8 – T2 AUXILIARY TRANSFORMER; PROCEDURE; Remove main input power to the PRO-CUT
  • Page 70 – TRIGGER CIRCUIT TEST; This procedure takes approximately 19 minutes to perform.
  • Page 71 – FIGURE F.9 – SIMPLIFIED TRIGGER CIRCUIT DIAGRAM; SIMPLIFIED TRIGGER CIRCUIT; not
  • Page 73 – FIGURE F.10 - OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS; This light indicates that 24 VAC is
  • Page 74 – CONTROL BOARD LED DEFINITIONS; This light indicates that 18 VAC is
  • Page 75 – LOW VOLTAGE CIRCUIT TEST; This procedure takes approximately 20 minutes to perform.
  • Page 76 – FIGURE F.12 - LOW VOLTAGE CIRCUIT DIAGRAM
  • Page 78 – FIGURE F.13 – OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs
  • Page 79 – FIGURE F.14 – CONTROL BOARD LEDs
  • Page 80 – CONTROL BOARD REMOVAL AND REPLACEMENT
  • Page 81 – Remove the wraparound cover and perform; FIGURE F.17 - CONTROL BOARD MOLEX PLUG REMOVAL; Screws
  • Page 82 – FIGURE F.18 - CONTROL BOARD REMOVAL FROM MOUNTING PINS
  • Page 83 – DISPLAY BOARD REMOVAL AND REPLACEMENT
  • Page 84 – Remove the input power to the PRO-CUT 80; DISPLAY BOARD REMOVAL & REPLACEMENT
  • Page 85 – FIGURE F.20 – DISPLAY BOARD REMOVAL; CASE FRONT
  • Page 86 – OUTPUT POWER BOARD REMOVAL AND REPLACEMENT
  • Page 87 – FIGURE F.21 – OUTPUT POWER BOARD REMOVAL; OUTPUT POWER BOARD REMOVAL & REPLACEMENT; Remove the case wraparound and perform; OUTPUT POWER BOARD
  • Page 88 – FIGURE F.22 – OUTPUT BOARD LEAD LOCATIONS; and B21 from the output power board.
  • Page 89 – REPLACEMENT PROCEDURE
  • Page 90 – This procedure takes approximately 40 minutes to perform.
  • Page 91 – FIGURE F.23 – PRIMARY POWER BOARD REMOVAL; PRIMARY POWER BOARD AND FILTER CAPACITOR; REMOVAL PROCEDURE; Input Filter Capacitor Discharge
  • Page 92 – FIGURE F.24 – POWER BOARD HEATSINK AND CAPACITOR REMOVAL; Using the Phillips Head screw driver, remove; Heatsink Mounting
  • Page 93 – CAPACITOR REMOVAL
  • Page 94 – INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT; This procedure takes approximately 16 minutes to perform.
  • Page 95 – FIGURE F.25 – INPUT RECTIFIER LEAD LOCATIONS
  • Page 96 – Carefully remove the input rectifier bridge.
  • Page 97 – RETEST AFTER REPAIR; INPUT IDLE AMPS AND WATTS; Idle Amps
  • Page 99 – ELECTRICAL DIAGRAMS
  • Page 100 – WIRING DIAGRAM - PRO CUT 80
  • Page 101 – SCHEMATIC - CONTROL PC BOARD
  • Page 104 – SCHEMATIC - POWER PC BOARD
  • Page 105 – PC BOARD ASSEMBLY - POWER BOARD
  • Page 106 – SCHEMATIC - OUTPUT PC BOARD
  • Page 107 – PC BOARD ASSEMBLY - OUTPUT BOARD
  • Page 108 – SCHEMATIC - DISPLAY PC BOARD
  • Page 109 – PC BOARD ASSEMBLY - DISPLAY BOARD; C 5; DISPLAY
  • Page 110 – SVM ERROR REPORTING FORM; Please give detailed description below:
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SVM146-A

September, 1999

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part.

DO NOT INSTALL,

OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT.

And,

most importantly, think before
you act and be careful.

SERVICE MANUAL

For use with machine code numbers

10573, 10574, 10577, 10578

PRO-CUT

™

80

Retur

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iew Safety Info

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iew Safety Info

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RETURN TO MAIN INDEX

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• World's Leader in Welding and Cutting Products •

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Summary

Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY i i PRO-CUT 80 FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. _____________________________________...

Page 3 - ii; ELECTRIC SHOCK can kill.

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY ii ii PRO-CUT 80 ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield a...

Page 4 - iii

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iii iii PRO-CUT 80 FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S...

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