Lincoln Electric PRO-CUT 55 SVM140-A User Manual

SVM140-A
July, 2005
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.
For use with machine code numbers Below 11000
PRO-CUT
™
55
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SERVICE MANUAL
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• World's Leader in Welding and Cutting Products •
Copyright © 2005 Lincoln Global Inc.

Lincoln Electric PRO-CUT 55 SVM140-A Specifications

General

Input Frequency	50/60 Hz
Power Factor Corrected	Yes
Thermal Overload Protection	Yes
Pilot Arc Starting	Yes
Work Cable Included	Yes
Input Power Cord Included	Yes
Rated Output	55 A
Maximum Open Circuit Voltage	300 V
Torch Included	Yes

Summary

Comprehensive Safety Precautions

Electric Shock Hazards

Details dangers and precautions related to electric shock.

Fumes and Gases Hazards

Explains risks from fumes and gases during operation.

Cutting Sparks Hazards

Warns about fire/explosion risks from cutting sparks.

Arc Rays Hazards

Installation Safety and Guidelines

Safety Precautions for Installation

Key safety warnings for installation procedures.

Operating Instructions and Safety

General Operating Instructions

Read and understand operating instructions before use.

Key Safety Instructions

Overarching safety guidelines for operation.

Controls, Settings, and Operation

Controls and Settings Overview

Cutting Operation Steps

Step-by-step guide for performing cutting operations.

Maintenance Procedures and Safety

Maintenance Schedules

Routine Maintenance Schedule

Regular cleaning and inspection tasks.

Periodic Maintenance Actions

Precharge and Protection Circuits

Precharge and Protection Circuitry

Explanation of precharge and voltage monitoring circuits.

Control and Display Boards

Control and Display Board Functions

How the control and display boards manage machine operations.

Machine Protection Circuits

Overload Protection Mechanisms

How the machine protects against current and voltage issues.

Thermal Protection Systems

How thermostats prevent overheating.

IGBT Operation Details

Insulated Gate Bipolar Transistor (IGBT) Function

Explanation of how IGBTs work in passive and active modes.

Pulse Width Modulation (PWM)

Pulse Width Modulation Explained

Description of how PWM controls output power.

Troubleshooting Guide Usage

Guide to Using the Troubleshooting Guide

Steps for effectively using the troubleshooting guide.

PC Board Troubleshooting

PC Board Troubleshooting Procedures

Steps for troubleshooting and replacing PC boards.

Troubleshooting Common Output Problems

Machine Dead - No Output

Troubleshooting steps when the machine has no output.

Machine Dead - No Output, Fans Run

Steps for diagnosing no output with fans running.

No Status Indicators After Power Up

Troubleshooting Function Problems

Status Lights Blinking

Diagnosing issues when all status lights blink.

No Response to Trigger Pull

Steps when the machine powers up but trigger does not respond.

No Pilot Arc Established

Troubleshooting Cutting Problems

Arc Will Not Transfer to Workpiece

Steps for when the pilot arc is normal but does not transfer.

LED Indicator Troubleshooting

Air Low LED Indicator

Safety LED Flashing Indicator

Safety LED Ready Indicator

Thermal LED Indicator

Troubleshooting Flowchart

Pro-Cut Troubleshooting Flowchart

Visual guide to diagnosing machine issues.

Input Filter Capacitor Discharge

Capacitor Discharge Procedure

Safety steps to discharge capacitors before maintenance.

Primary Power Board and Capacitor Tests

Resistance and Voltage Test Procedure

Tests for shorts/leaks and capacitor charging.

Capacitor Voltage Test

Torch Continuity and Solenoid Test

Testing Torch Cable and Solenoid

Verifies torch cable, consumables, and solenoid function.

Trigger Circuit Test

Testing the Internal Trigger Circuit

Procedure to diagnose faults in the trigger circuit.

Low Voltage Circuit Test

Testing Low Voltage Circuits

Verifies correct DC voltages applied to PC boards.

Control Board Replacement

Control Board Removal and Replacement

Step-by-step guide for replacing the control board.

Display Board Replacement

Display Board Removal and Replacement

Procedure for removing and replacing the display board.

Output Power Board Replacement

Output Power Board Removal and Replacement

Steps for removing and replacing the output power board.

Primary Power Board and Capacitor Replacement

Primary Power Board and Capacitor Removal/Replacement

Procedures for removing and replacing the primary power board and capacitors.

Capacitor Removal Steps

Capacitor and PC Board Replacement

Input Rectifier Bridge Replacement

Input Rectifier Bridge Removal and Replacement

Steps for removing and replacing the input rectifier bridge.