Lincoln Electric SVM149-A - Manual

Lincoln Electric SVM149-A

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Table of Contents:

  • Page 2 – PERFORMED ONLY BY QUALIFIED INDIVIDUALS.; ELECTRIC SHOCK can kill.; PLASMA CUTTING or GOUGING can be hazardous.; SAFETY
  • Page 3 – ii
  • Page 4 – iii; PRÉCAUTIONS DE SÛRETÉ
  • Page 5 – MASTER TABLE OF CONTENTS FOR ALL SECTIONS; iv; Page
  • Page 6 – NOTES
  • Page 7 – TABLE OF CONTENTS; Installation
  • Page 8 – INSTALLATION; * Included with machine
  • Page 9 – SAFETY PRECAUTIONS; Do not touch electrically hot parts.; SELECT PROPER LOCATION; STACKING; (1) Make sure the power supply chassis is connected; INPUT ELECTRICAL CONNECTIONS
  • Page 10 – • Failure to wire as instructed may cause personal; GAS INPUT CONNECTIONS; NOTE: Oil in the air supply to the PRO-CUT 25 can; WARNING
  • Page 11 – NOTE: When using nitrogen gas from a cylinder, the; OUTPUT CONNECTIONS; Torch
  • Page 13 – Operation
  • Page 14 – OPERATION
  • Page 15 – USER RESPONSIBILITY
  • Page 16 – CUTTING CAPABILITY
  • Page 17 – LIMITATIONS
  • Page 18 – PILOT ARC DISCUSSION; ELECTRIC SHOCK CAN KILL.
  • Page 19 – PROCEDURE RECOMMENDATIONS; General - In All Cases; Torch Standoff
  • Page 21 – Accessories
  • Page 22 – ACCESSORIES; • Only Genuine Lincoln Electric consumables yield the
  • Page 23 – Maintenance
  • Page 24 – MAINTENANCE; PERIODIC MAINTENANCE; THERMAL PROTECTION; NOTE: If the fuse blows again after power is restored,; ELECTRIC SHOCK; ROUTINE MAINTENANCE; • When using a low pressure aistream, wear
  • Page 25 – FIGURE D.2 – MAJOR COMPONENT LOCATIONS
  • Page 27 – Output Sect; FIGURE E.1 – PRO-CUT 25 BLOCK LOGIC DIAGRAM
  • Page 28 – FIGURE E.2 – INPUT LINE VOLTAGE; GENERAL DESCRIPTION; THEORY OF OPERATION
  • Page 29 – PRECHARGE AND PROTECTION; IGBT Operation; FIGURE E.3 – PRECHARGE AND PROTECTION
  • Page 30 – FIGURE E.4 – MAIN TRANSFORMER; MAIN TRANSFORMER
  • Page 31 – OUTPUT SECTION AND TORCH; G Section; FIGURE E.5 – PLASMA OUTPUT SECTION AND TORCH
  • Page 32 – CONTROL BOARD; FIGURE E.6 – CONTROL BOARD
  • Page 33 – PROTECTION CIRCUITS; OVERLOAD PROTECTION
  • Page 35 – Test Procedures
  • Page 36 – HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; CAUTION; The; Step 3. PERFORM COMPONENT TESTS
  • Page 37 – PC BOARD TROUBLESHOOTING PROCEDURES
  • Page 38 – Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS; Input Voltage
  • Page 39 – FUNCTION PROBLEMS; Torch Continuity
  • Page 41 – Clamp directly to the piece to
  • Page 42 – LED FUNCTION PROBLEMS; One of the machine’s thermal
  • Page 43 – INPUT FILTER CAPACITOR DISCHARGE PROCEDURE; DESCRIPTION
  • Page 44 – DISCHARGE PROCEDURE; RIGHT SIDE OF MACHINE; FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS
  • Page 45 – MAIN INVERTER BOARD RESISTANCE TEST; Analog Volt/Ohmmeter
  • Page 46 – TEST PROCEDURE; Input Filter Capacitor Discharge
  • Page 47 – FIGURE F.3 LOCATION OF IGBT; IGBT’s; Also check each device from Gate to Emitter.; GCE
  • Page 51 – INPUT BOARD VOLTAGE TEST; mm Nut Driver
  • Page 52 – Capacitor Discharge; A B; AC; TEST POINTS; Figure F.6 Input Board Description
  • Page 53 – After the relays activate check for; Figure F.7 Input Board Test Points
  • Page 55 – MAIN INVERTER BOARD VOLTAGE TEST
  • Page 56 – Remove carrying handle using a 4mm; detailed earlier in this; MAIN INVERTER BOARD VOLTAGE TEST (CONTINUED)
  • Page 57 – Figure F.9 Test Points
  • Page 59 – TORCH CONTINUITY AND SOLENOID TEST; 2 VDC @ 1 Amp Power Supply
  • Page 60 – Electrode Lead
  • Page 63 – mm Allen Wrench
  • Page 64 – AIR/GAS SOLENOID TEST; Input Capacitor Discharge; FIGURE F.12 – AIR SOLENOID; LEFT SIDE OF MACHINE; Air Solenoid
  • Page 66 – PROCEDURE; Remove carrying handle using a 4mm allen; CONTROL BOARD REMOVAL AND REPLACEMENT
  • Page 67 – Screws
  • Page 68 – Do Not; Replace the carry handle.
  • Page 69 – mm Allen Wrench
  • Page 70 – Capacitor Discharge Procedure.; INPUT BOARD REMOVAL & REPLACEMENT; FIGURE F.16 Input Board Location; Input Board
  • Page 71 – FIGURE F.17 – INPUT BOARD REMOVAL; Do Not Over tighten; Reconnect the harness plug.; Do Not Over
  • Page 74 – FIGURE F.18 – MAIN INVERTER BOARD REMOVAL; MAIN INVERTER BOARD REMOVAL & REPLACEMENT; Perform; Main Board
  • Page 75 – FIGURE F.19 – INVERTER BOARD LEAD LOCATIONS; Leads; Harness plugs; Reconnect all leads to the new board.
  • Page 78 – Switch; SWITCH; Replace the carry handle
  • Page 80 – FIGURE F.21 – FAN LOCATION; Fan; FAN REMOVAL AND REPLACEMENT
  • Page 81 – Replace the case wraparound.
  • Page 82 – RETEST AFTER REPAIR; Machine Input and Output; Input Current; Pilot Current; Functional Test; Turn on the machine and verify the following:
  • Page 83 – ELECTRICAL DIAGRAMS
  • Page 85 – WIRING DIAGRAM W/ADDITIONAL INFO; pressure; Thermo; Input Power; card
  • Page 86 – SCHEMATIC- CONTROL PRINTED CIRCUIT BOARD - SHEET 1
  • Page 87 – SCHEMATIC- CONTROL PRINTED CIRCUIT BOARD - SHEET 2
  • Page 88 – SCHEMATIC- CONTROL PRINTED CIRCUIT BOARD - SHEET 3
  • Page 89 – PC BOARD ASSEMBLY - MAIN INVERTER BOARD
  • Page 90 – PC BOARD ASSEMBLY - INPUT BOARD
  • Page 91 – PC 25 TORCH DETAILS; COMPRESSED AIR FLOW; VENT; Lift start type feature during pilot; Air Flowing & Torch Solenoid is; PILOT CURRENT PATH; CUTTING CURRENT PATH; NOZZLE; ELECTRODE; CURRENT PATH THROUGH TORCH; through plasma arc and yellow color parts
  • Page 92 – SVM ERROR REPORTING FORM; Please give detailed description below:
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SVM149-A

October, 2006

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

10661

PRO-CUT 25

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n to Master TOC

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• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 1-888-935-3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Copyright © 2006 Lincoln Global Inc.

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Summary

Page 2 - PERFORMED ONLY BY QUALIFIED INDIVIDUALS.; ELECTRIC SHOCK can kill.; PLASMA CUTTING or GOUGING can be hazardous.; SAFETY

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For ...

Page 3 - ii

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 4.c. When not cutting or gouging, make certain no part of the elec- trode circuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard. 4.d. Do not cut or gouge tanks, ...

Page 4 - iii; PRÉCAUTIONS DE SÛRETÉ

SAFETY iii iii Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de...

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