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Python Service Manual - Red-D

1. POWER SUPPLY I XFMR AIR SOLENOID IGBT DRIVE GENERAL INFORMATION NOTES NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHA NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LABELS A SUPPLY VOLTAGE NET Q POWER SUPPLY SOURCE POINT COMMON CONNECTION 471 2 FRAME CONNECTION ME EARTH GROUND CONNE r MACHINE OVERVIEW PRO CUT 80 PC BOARD ASSEMBLY CONTROL BOARD CODE 10574 ONLY LINCOLN je ELECTRIC NOTE T 80 CONTROL ELECTRICAL DIAGRAMS G3443 1 39 D p 2 CAPACITORS MFD VOLTS INDUCTANCE HENRIES RESISTANCE OHMS ITEM PART NO DESCRIPTION SED FEN C2 C8 C10 011 C13 014 C17 30 816668 5 022 50 C20 23 C24 031 034 035 C36 037 038 039 040 C41 C47 049 C51 053 055 C63 C64 C65 C66 C68 C69 T11577 52 13490 72 13490 93 13490 126 16668 11 1 0047 or 005 1400 50 21 39 018 50V 1 50 2 60 15 016 032 033 042 C58 71 72 19 025 050 C21 026 028 030 054 057 062 067 22 043 044 21 048 o Zi 13490 25 4 17 35 13490 42 1 0 35 Rh E
2. J40 OOVDODOOOVDOOO0OO000 EI GENERAL INFORMATION LAST NO USED R 20 DZ C 5 LED 9 rm CH HLMP 2655 Dv ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS NOTES DIODES A 400V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE O POWER SUPPLY SOURCE POINT WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE W COMMON CONNECTION NUMBER 77 FRAME CONNECTION lt gt EARTH GROUND CONNECTION 10 31 97D M8920 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E PRO CUT 80 PC BOARD ASSEMBLY DISPLAY BOARD LINCOLN B NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage t
3. 87 81 48 Input Currents 48 44 25 0 61 Amps RATED OUTPUT OUTPUT Open Circuit Voltage 335VDC Maximum PRO CUT 80 LINCOLN 5 A 2 Rated Output Amps 80 80 80 Rated Output Amps IDLE CURRENT AND WATTS 140 Watts Rated Output Amps 80 60 Pilot Current 20 Amps 100 Duty Cycle INSTALLATION TECHNICAL SPECIFICATIONS Cont d PRO CUT 80 GAS REQUIREMENTS Required Gas Flow Rate 70 PSI 480 SCHF 4 8 Bar 13550 LHR Required Gas Inlet Pressure 80 to 150 PSI 5 4 Bar to 10 2 Bar RECOMMENDED INPUT WIRE AND FUSE SIZES For all plasma cutting applications based on U S National Electrical Code Ambient Temperature 30 C or Less AC Input Voltage Fuse Super Lag Type 75 C at Circuit Breaker Copper Wire in Conduit AWG 60 Hertz Delay Type IEC Sizes 230VAC Single Phase 4 21 1mm 4 21 1mm 460VAC Single Phase 8 8 4mm 8 8 4mm 230VAC Three Phase 8 8 4mm 8 8 4mm 460VAC Three Phase 10 5b 3mm 10 5 3mm PHYSICAL DIMENSIONS Height Width Depth Weight with Torch Cable 98 Ibs 44 5 kg 25 ft cable 16 5 Inches 13 75 Inches 29 5 Inches 419 mm 349 mm 749 mm 113 Ibs 51 4 kg 50 ft cable PRO CUT 80 LINCOLN A 4 INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS AA WARNING ELECTRIC SHOCK can kill Turn the inp
4. DES ESS 7 ER 6 4 SR SEC 618 E C20 022 C73 024 C29 C38 MG ESE 022 50 ee pum RECH ESTSTOR E re ery E i a a EE SSC 87 ESCH 9 ERR EIER KOU E Ee E STET OR TOMS 400MA tr tg LE Oe EE KU CAPACITORS MFD VOLTS RESISTORS OHMS G 3439 1 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine PRO CUT 80 ELECTRICAL DIAGRAMS G 10 SCHEMATIC DISPLAY PC BOARD READY SIGNAL HLMP 2855 HLMP 2550 CONTROL 10K POT AIR LOW SIGNAL HLMP 2350 m Iw HLMP 2655 Kat HLMP 2755 THERMAL SIGNAL HLMP 2450 SAFETY SIGNAL HLMP 2350 HLMP 2400
5. 1 nozze TORCH CONNECTOR REMOTE INTERFACE RECEPTACLE E 2 E 2 THEORY OF OPERATION FIGURE E 2 D INPUT LINE VOLTAGE POWER BOARD INPUT LINE INPUT SWITCH RECTIFIER R E C o N N E C T i I c H AIR E PRESSURE 9 SWITCH T um m L o E N SIGNAL A D 18 36VAC D E THERMOSTATS A D Y OUTPUT CONTROL _ St 3 E a 115VAC AUXILIARY FAN MOTOR GENERAL DESCRIPTION The PRO CUT 80 is a constant current continuous control plasma cutting power source The inverter based power supply design is controlled by a micro processor control board The control system has a safety mechanism to insure that the nozzle and elec trode are in place before cutting or gouging The PRO CUT 80 initiates the plasma arc with a simple yet reli able touch start mechanism This system eliminates many of the problems associated with hi frequency type start systems When powered up the machine performes some rudimentary self diognostics LA l Sa TRANSFORMER l GATE SIGNA CONTROL BOARD DISPLAY BOARD WORK O e O il NOZZLE ELECTRODE TRANSFORMER x Nt EE DIEN TRANSISTOR OUTPUT BOARD TORCH ay CONNECTOR TRIGGER amp SAFETY AIR OLENOID REMOTE INTERFACE RECEPTACLE ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE gt Z DMI pM INPUT LINE VOLTAGE
6. 1 3 mm Orifice For 60 85 Amps 22147 082 Vortech nozzle with an 082 2 1 mm Orifice For Gouging at 60 85 Amps 22149 Electrode replacement electrodes for cut ting 22150 Shield Cup This shields the torch tip and provides more visibility to the workpiece than the drag cup Note the shield cup does not prevent the torch tip from touching the workpiece 22151 Drag Cup The drag cup protects the torch by preventing the torch from touching the workpiece K1571 Series PCT 80 Torches come in 25 and 50 lengths in either hand held or mechanized versions ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH NOZZLES Y Only Genuine Lincoln Electric consumables yield the best cutting performance for the PRO CUT 80 Y The patent pending VORTECH nozzle pr ovides an extra Okick of swirl as the ar exits the nozzle which improves cutting performance No other noz zle has this capability or can match its performance PRO CUT 80 LINCOLN Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE Maintenance LIE Section D E UE D 2 Input Filter Capacitor Discharge Procedure ENEE D 2 Routine MAIMTON En Le D 3 Penodi E ag Eeer D 3 Major ComponentiloCations sassis runninn raea aa aN NRE a aaa NSE aai adaini D 4 PRO CUT 80 LINCOLN 5 MAINTENANCE D 2 A WARNING ELECTRIC SHOCK can kill km A Have an electrician install and service this equipment Turn the
7. LINCOLN D 4 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION Section E 1 Theory of Operation cccccccccecee eee eeeeeeceeee eases eee eeee eee cecaaaaaeaaeceeeeeeeeeeeseceneaaaeeeeeeeeeeeess Section E General DESCHIPTON os oerte dhe xe sensei eshadexeivecandeniars e Fes x YER duse EENEG E 2 Input Line Voltage Contactor and Main Transtormer E 2 NC ele E ne Me e E 3 Main Aen Ne EA Output Board and TOrch ui ete tree E ERR ENRRENS INSERERE S HENARES NS EEN YER RR NN ec ERR E 5 Control and Display Boards arcent erosion dE ie ERR E n oed E 6 Proleciion erre M E 7 Overload BL BET E 7 Thermal Protection oe eti er bebat Cei osa dnd eua Ce ra eege E 7 Insulated Gate Bipolar Transistor IGBT Operation cccccccsceeceessneeeeeeessneeeeeeesneeeeeseenaeeeeeee E 8 Pulse Width Modulation PWM EE E 9 Minimum OUT DUR ER HTC ERHIELT E 9 Maximum el EE E 9 FIGURE EI PRO CUT 80 BLOCK LOGIC DIAGRAM POWER BOARD MAIN TRANSFORMER ro OUTPUT BOARD NM INPUT RECTIFIER Zem omzzoom AIR PRESSURE SWITCH ELECTRODE amp TRANSFER CURRENT FEEDBACK zo JomJo v SIGNAL 18 36VAC THERMOSTATS ess MERE OUTPUT CONTROL AUXILIARY TRANSFORMER PRO CUT 80 LINCOLN 5 ELECTRODE TRIGGER amp SAFETY AIR SOLENOID O Qn O ozm oo DEER ACC WORK EN
8. ITE HEN HEADER OPTOTSOLATOR FET SS IC PKG MOSFET SS 200W R5 R6 R7 R8 R15 R16 R17 19400 100 1K 1 4W R18 R33 R37 R54 R55 R56 R57 R64 R65 R66 R67 R97 1001 R9 R10 R11 R12 RT3 R14 R19 19400 10R0 10 1 4W R20 R21 R22 R58 R59 R60 R61 R62 R63 R68 R69 R70 R23 R24 R25 R26 R34 R43 19400 1503 50K 1 4W ere m TOW R28 R36 R38 R44 R47 R87 19400 2213 221K 1 4W R88 R96 R118 R119 R29 R30 R31 R32 R73 R74 12 114648 19 1K SW SH TBK TAWN 619K 1740 ZOK aW MAW SE TEZICUAW R105 19400 1821 1 82K 1 4W R106 9400 2941 2 94K 1 4W R111 2300 79 1 WATT 1 OHM 1 RESISTOR R112 R113 9400 2211 2 21K 1 4W DEE TOK 1 20 TRIMMER E ERR ERR EIER LL CASTYOUAGEREE CAPACITORS MFD VOLTS RESISTORS OHMS 3 LESEN RR DESCRIPTION 4 4 3 3 2 1 2 1 1 2 T 1 3 a S ee E E R45 R48 R94 R50 R52 R101 R103 R72 R79 R82 R83 R84 R85 R89 R90 R92 BE ays l a 5 d G 3440 18 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result
9. Interface Er B 9 et B 9 aea ATCC DEE B 9 feno e EE B 9 PRO CUT 80 LINCOLN 5 OPERATION ep OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS AA WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing e Insulate yourself from the work and ground e Always wear dry insulating gloves FUMES AND GASES can be dangerous a X Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone _ CUTTING SPARKS can cause fire or explosion Keep flammable material away e Do not cut containers that have held combustibles ARC RAYS can burn A Wear eye ear and body protection PLASMA ARC can injure Keep your body away from nozzle and plasma arc Mas Operate the pilot arc with caution The pilot arc is capable of burning the oper ator others or even piercing safety clothing Observe additional Safety Guidelines detailed in the beginning of this manual PRO CUT 80 LINCOLN 5 BA B 3 OPERATION GENERAL DESCRIPTION The PRO CUT 80 is an inverter based constant cur rent continuous control plasma cutting power source It provides superior and reliable starting characteris tics cutting visibility and arc stability When cutting expanded metal the PRO CUT 80 out performs the
10. LINCOLN 5 F 33 F 33 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 10 OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS TEST POINT ek UI Te X20 x0 PRO CUT 80 OUTPUT BOARD LED DEFINITIONS LED1 Red This light indicates that 24 VAC is being supplied to the output board from the aux iliary transformer It also shows that the 24 VAC is being rectified to approximately 32 VDC This DC voltage is used for the parts in place check for the torch circuit LED2 Red This light indicates that 12 VAC is being supplied to the output board from the aux iliary transformer It also shows that the 12 VAC is being rectified to approximately 17 VDC This DC voltage is used to power the trigger circuit and solenoid driver circuits incorporated on the output board LED3 Green This light indicates that the air solenoid driver circuit is functioning When this LED is lit the air solenoid should be activated PRO CUT 80 G3439 PRO CUT 80 OUTPUT TEST POINT Te LED4 Green This light indicates that the trig ger circuit on the output board has been activat ed This LED should be lit when the torch or remote trigger is closed This trigger circuit on the output board then sends a signal to the control board LED5 Green This light indicates that the elec trode solenoid driver circuit is functioning When this light is lit the electrode solenoid should be activated Th
11. Pin test point measurements at the machine end of the torch assem 2 Remove the torch assembly from the bly See Figure F 5 machine TABLE F 5 TORCH ASSEMBLY RESISTANCES TEST CIRCUIT S BEING EXPECTED TEST POINTS TESTED RESISTANCE CONDITIONS Pin 7 to Pin 8 Parallel pilot arc 1 5 ohms maximum None leads Pin 7 to Torch One pilot arc lead to 1 0 ohm maximum Torch consumables Nozzle nozzle in place Pin 8 to Torch One pilot arc lead to 1 0 ohm maximum Torch consumables Nozzle nozzle in place Pin 1 to Pin 9 Torch trigger circuit 100K ohms minimum Torch trigger NOT pulled not activated Pin 1 to Pin 9 Torch trigger circuit 1 0 ohm maximum Torch trigger pulled activated Pin 2 to Pin 3 Electrode Solenoid 45 to 55 ohms None Pin 7 to Torch Pilot and Electrode 1 0 ohm maximum Torch consumables Electrode at machine circuit in place end of torch Pin 8 to Torch Pilot and Electrode 1 0 ohm maximum Torch consumables Electrode at machine circuit in place end of torch 4 f any of the resistance checks are not cor 5 Carefully apply the 12 VDC supply to the rect the torch assembly may be faulty electrode solenoid positive to Pin 2 and Repair or replace negative to Pin 3 The electrode solenoid should activate Listen for the solenoid action in the torch handle If the solenoid does not activate it may be faulty Replace PRO CUT 80 LINCOLN 5 F 25 F 25 TROUBLESHOOTING amp REPAIR AIR G
12. TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued FIGURE F 23 PRIMARY POWER BOARD REMOVAL REMOVAL PROCEDURE K Remove input power from the PRO CUT 80 machine Remove the case wraparound and perform the Input Filter Capacitor Discharge 6 Procedure detailed earlier in this section Locate the primary power board and associ ated lead and plug connections See Figure F 23 PRO CUT 80 LINCOLN 5 Primary Power Board With Input Filter Capacitors 4 Label the leads for reassembly 5 Remove Plug J10 and any necessary cable ties Using the 7 16 wrench remove leads 201 202 203 204 205 206 207 208 and 209 F 52 F 52 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued FIGURE F 24 POWER BOARD HEATSINK AND CAPACITOR REMOVAL 7 Using the Phillips Head screw driver remove the two mounting screws from the top right of the primary power board See Figure F 24 8 Using the 3 16 allen type wrench remove the eight socket head screws and lock wash ers mounting the primary power board to the heat sink PRO CUT 80 Heatsink Mounting Screws 4 Mounting Screws 2 Socket Head Screws 8 9 Carefully remove the primary power board from the heat sink ENiCAUTION Be sure to follow the recommended static free methods for handling prin
13. Yellow 7J21 7 If the correct test voltages are present the 9 auxiliary transformer is good 8 If any of the voltages are missing or very low with the proper primary voltage applied the auxiliary transformer may be faulty PRO CUT 80 LINCOLN 5 If the auxiliary transformer tests good but it does not function when connected to the PRO CUT 80 check the harness wiring to the auxiliary transformer See the Wiring Diagram When finished with the test replace plugs 21 and 22 and the case wraparound F 30 F 30 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The procedure will help the technician determine if there is a problem or fault in the inter nal trigger circuit MATERIALS NEEDED Ohmmeter voltmeter multimeter 5 16 Nut driver Simplified Trigger Circuit
14. dl A08 Edl Xnv 3NuQ LOMd A Lese ee DJ e Y A0008 L700 30001038 180 A000E p00 SISSWHO INH 10 lld azon e M0004 ve DO S100 HO BUZON peog uo Ovx pejeqe pieog uo D pajaqe7 pieog uo ZX pejaqe Don uo px pejeqe CSC Ba s aM a YIWHOJSNYHL NIV This diagram is for reference only It may not be accurate for all machines covered by this manual NOTE PRO CUT 80 LINCOLN E ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY OUTPUT BOARD LINCOLN B NOTE G3439 1 OUTPUT c16 g El AL GE Jet 4 e LE li HEM LEET NG ET el a 03 C11 015 C34 035 ra E 5 sits 2000V FEN DES EELER OE EREECHEN BECHER BAUER 904778888 31 G9
15. 80 LINCOLN 5 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S LED FUNCTION PROBLEMS RECOMMENDED COURSE OF ACTION The Thermal LED is lit 1 One of the machine s ther 1 A thermostat may be faulty mostats has tripped Do not Replace turn the PRO CUT 80 off Allow the machine to cool The ther mostat s will reset themselves Either the duty cycle has been exceeded the fan is not func The control board may be faulty Replace If the machine operates normal ly with the Thermal LED lit the tioning or the louvers are display noard stay De ER blocked Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 PRO CUT 80 LINCOLN 5 F 10 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE AA WARNING Service and repair should be performed by only Lincoln Electric factory trained person nel Unauthorized repairs performed on this equipment may result in danger to the tech nician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precaut
16. B ld uei nj B 2 General DescriptiODn eceno riter Eee FOR ENR RR EXIST EO ER ENGER ERE RES EE ERR EE Edge B 3 Recommended Processes and Equipment essen nennen nnn B 3 Operational Features and Controls 5 rino aena hate EX EN RARSREERER ced EERENR aa AEREN ONE aa B 3 Desigri Features and Advantages ieeieleo sc etiain cta ence RR B 3 Cutting Capability re teer E eter acu vlad eei entem eise eiat rt E n Dr ce HR A B 4 TE EI Nj eem B 4 Bild Lee cle B 4 GontrolS and Sallins esris RE B 5 Ee r B 5 Cutting Operations E B 5 UseriResporisiDIliLyi iioii oracio bp n vetrina EE B 7 Preheat Temperature for Plasma Cutting cceeceseecceeeeeseeeeeeeenseeeeeeseseeeeeeeseseeseeeseneeseeeetens B 7 Procedure RecommendatiOrs sansaara nanana aaan Ha RERAEERENR EN NEEN ENEE SR ERR R EG B 7 EE DEIER EE ree ELI IAE II IEEE LIE ELLE Section C Maintenance EE Section D Theory of Operation orienter Rete ix yes iaeaea ke eR ESA Ree quota Sekka en RE e due d Section E Troubleshooting and Repair Section F Safety Precautloris us ihe ie etit e EUR on denk adr uie Lade eh breve Seb eege eege F 2 How to Use Troubleshooting G ldoe rotten nora n Rea ta tok oie Rx Eo SEEEEn F 2 lee eet Te GUIDE e F 4 Test Procedures TE F 10 Replacement Procedures EEN F 40 Electrical DIagrams cisne aeaa Aa E A aE RaRa Sectio
17. B 7 OPERATION A WARNING ELECTRIC SHOCK can kill Turn off machine at the discon nect switch on the front of the Ye Check the conditions of the inside of the nozzle If debris has collected rub the electrode on the inside bottom of the nozzle to remove any oxide layer that may have built up Refer to OSuggestions for Extra Utility from the Pro Cut Checkthe condition of the electrode If the end has a crater like appearance replace it along with the nozzle The maximum wear depth of the electrode is approximately 062 in 1 6mm A green and erratic arc will indicate definite electrode failure The electrode should be replaced immediately machine before tightening cleaning or replacing consum ables Y Replace the nozzle when the orifice exit is eroded away or oval shaped Y After the problem is found or if there is nothing apparently wrong reset the machine by pressing the Reset button It is possible for electrical noise to trip the safety circuit on rare occasions This should not be a regular occurrence Y f the machine does not reset or continues to trip consult the Troubleshooting Section Y Use the proper cutting or gouging procedures referred to below USER RESPONSIBILITY Because design fabrication erection and cutting vari ables affect results the serviceability of a product or structure is the responsibility of the user Variation such as plate chemistry plate surface
18. Guide is provided to help you locate and repair possible machine malfunc tions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into four main categories Output Problems Function Problems Cutting Problems and LED Function Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Cont
19. PC board NOTE Allow the machine to heat up so that all elec trical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims PRO CUT 80 LINCOLN 5 F 4 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical dam age is evident when the sheet metal cover s are removed POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your local authorized Lincoln Electric Field Service Facility for technical assistance TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department
20. SWITCH AND MAIN TRANSFORMER The single phase or three phase input power is con nected to the machine via an input line cord to a switch located on the front panel A reconnect panel and voltage range switch allow the user to configure the machine for either a low or high input voltage and also connect the auxiliary trans former for the appropriate input voltage The auxiliary transformer develops the appropriate AC voltages to operate the cooling fan the control board and the plasma output board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRO CUT 80 LINCOLN E 3 E 3 THEORY OF OPERATION POWER BOARD ro4 so 4omzzooma AIR PRESSURE SWITCH zo domdozv 18 36VAC THERMOSTATS DE DH Sor DS r zZmr4 poen OUTPUT CONTROL AUXILIARY TRANSFORMER PRECHARGE AND PROTECTION The input voltage is rectified by the input rectifier The resultant DC voltage is applied through the reconnect Switch to the power board The power board contains precharging circuitry for the safe charging of the input filter capacitors Once the capacitors are precharged and balanced the control board activates the CR1 CR2 input relays This connects full input power to the filter capacitors When the filter capacitors are fully charged they act as power supplies for the IGBT switching circuit The Insulated Gate Bipolar Tran sistors supply the main transforme
21. and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c PRO CUT 80 za CYLINDER may explode Ss if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should al
22. bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the input rectifier bridge for main tenance or replacement MATERIALS NEEDED 3 16 Allen type wrench Phillips head screw driver Torque wrench Penetrox A13 Lincoln E2529 Electrical Joint Compound Dow Corning 738 Lincoln E2861 Electrical Insulating Compound This procedure takes approximately 16 minutes to perform PRO CUT 80 LINCOLN 5 F 55 F 55 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued PROCEDURE 5 With the phillips head screw driver remove the lead terminals connected to the rectifier 1 Remove input power to the PRO CUT 80 terminals 2 Perform the Input Filter Capacitor e Using the 3 16 allen wrench remove the two Discharge Procedure detailed earlier in this cap head screws and washers mounting the section input rectifier bridge to the center panel 3 Locate the input rectifier and the leads con assembly nected to it See Figure F 25 4 Identify and mark the leads connected to the rectifier terminals Geff 207 a of 20 UN eh Gas A Q Q 209 TOP VIEW FIGURE F 25 INPUT RECTIFIER LEAD LOCATIONS PRO CUT 80 LINCOLN 5 F 56 TROUBLESHOOTING amp REPAIR F 56 INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued 7 Carefully remove the input rectifier
23. iiron rarer eee G 8 OUTPUT PG BOARD ASSEMBLY EE G 9 DISPLAY PC BOARD SCHEMATIC iisssssssss II n G 10 DISPLAY PC BOARD ASSEMBLY PRO CUT 80 LINCOLN amp G 2 ELECTRICAL DIAGRAMS il WIRING DIAGRAM PRO CUT 80 RIGHT SIDE OF MACHINE Bat 1 N 8 uw HK 8 53 N 3 56 i cen 24V RA6 54 wur UX9 64 WX 5 62 18V UAE 61 Y lt 1 FAN La r YAT FAN VOLT AUXILIARY J21 P XFMR TRANSFORMER LOW_PSI LED CURRENT TRANSFORMER Sietetsteteie Tere THERMAL LED RESET LED C2 3000 450 3000 x4Q J33 AN Gi ELEC FER OG FRONT OF MACHINE OG Ta is rH H xO ptg L D M el CONTROL Turm POT OO E gt GND CW MAX 364 00 2 6 PSI SWITCH i g e D box 361 REAR OF MACHINE SHOWN FOR 400 460VAC OPERATION CONTROL ES SUPPLIED WITH INPUT CABLE ASE T CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE LEFT SIDE OF MACHINE PLY CIRCUIT COLOR CODE TH TAPE TO PROVIDE 600V INSULATION UI B BLACK I CO LEAD TO GROUND PER NATIONAL ELECTRIC CODE o 9 9 G GREEN PPLY CIRCUIT cS amp e R RED J40 CABLE W WHITE NE PER NATIONAL AND LOCAL ELECTRICAL CODES OUTPUT BASE CASE FRONT U BLUE RCUIT PC BOARD N BROWN PER NATIONAL AND LOCAL ELECTRICAL CODES Y YELLOW T J1 20 CIRCUIT PROTECTIVE BONDING CIRCUIT J3 ME N B SI TSO T TED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING Ss fu ii 0000000 Eeeee THE INTERCHANGEABILI L RD THIS D
24. in damage to the machine PRO CUT 80 G 8 81601 7 66 61 NOILO3NNOO QNnOUD HWS S NOLLO3NNOO 3 ivud LLY NOILO3NNOO NO WOO ZN 1NIOd SOUNDS A1ddns u3iiod e JEN 3OVLION aime d S138V1 03141034S ISIMYSHLO SS31Nn A0 NL aaidio3ds ASIMHAHLO SS3INQ Mart 03131039S 3SId3H10 SS3 TN YALLND VWSW1d dV 08 3009 NOWIAOO V 9NIAVH STOHLNOO 40 AYLINOYID HO SIN3NOdWOO LOVX 201 MOHS LON AWW WYHOVIG SIHL GHVO8 313 1dWO9 V 20 ALIIGYIONVHOUSINI JHL 9NLLO333V LNOHLIM 300ld SWYO SHOLSISSY A0s 220 Q3IN SHOLIOVdVO 2913 43d STOSINAS WO NOLLVINHOJNI IVH3N39 JONVHO AYN QuvO8 LINOHIO Q31NiHd Y NO AHLINOHIO HO SIN3NOdAOO 3ONIS V N SALON gt van LNI DTD vH TI een eer GR qi Wi AOS et 5 sissvHo M SISSYHO Alddh 83MOd e 30081933 LINHO xe TIEN QIONSIOS Iv N0810 i OIONTIOS 2s ELECTRICAL DIAGRAMS eld O 2000 LOMd 300419313 SCHEMATIC OUTPUT PC BOARD DN Lo 1000 met st 61g DEEN 07 0 WANININ SLINOYIO N33NU38 NOLLYIOS D Posh TOL Hot NOS Kat mm
25. input power off at the fuse box before working on equipment Do not touch electrically hot parts Prior to performing preventative maintenance per form the following capacitor discharge procedure to avoid electric shock INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 1 Turn off input power or disconnect input power lines 2 Remove the 5 16 in hex head screws from the side and top of the machine and remove wrap around machine cover 3 Be careful not to make contact with the capacitor terminals that are located on the top and bottom of the Power Board on the right side of the machine Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resis tor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Locate the two capacitor terminals large hex head cap screws at the bottom of the Power Board shown in Figure D 1 Use electrically insulated gloves and insulated pli ers Hold the body of the resistor and connect resistor leads across the two capacitor terminals Hold the resistor in place for 10 seconds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS Repeat the discharge procedure for the other capacitor Check voltage across the terminals of all capaci tors with a DC voltmeter Polarity of capacitor ter minals is marked on the Power Board above termi nals Voltage should be zero If any voltage remains repeat this cap
26. is operat ing normally the Power Switch may be left on and the reset should occur within a 15 minute period If the fan is not turning or the air intake louvers were obstructed then the power must be switched off and the fan prob lem or air obstruction must be corrected 2 Filter Capacitor Conditioning PRO CUT 80 400 460 VAC only A protection circuit is included to monitor the voltage across filter capacitors C1 and C2 In the event that the capacitor voltage is too high the protection circuit will prevent output The protection circuit may prevent output providing all these circumstances are met a Machine is connected for 400 460 or 460 575 VAC input b Machine did not have power applied for many months c Machine will not produce output when power is first switched on If these circumstances apply the proper action is to switch the machine on and let it idle for up to 30 min utes This is required to condition the filter capacitors after an extended storage time The protection circuit will automatically reset once the capacitor condition ing and resultant voltage levels are acceptable It may be necessary to turn the power switch off and back on again after this period PRO CUT 80 LINCOLN FIGURE D 2 D MAJOR COMPONENT LOCATIONS 1 Case Front 2 Base and Case Back 3 Center Panel Assembly 4 Output Board Heatsink 5 Power Board Assembly 6 Case Wraparound Maintenance PRO CUT 80
27. ohms Less than 100 ohms Greater than 1000 ohms 8 Carefully reconnect the leads and plugs previously removed Torque X2 X4 and B21 to 75 IN LBS F 23 F 23 TROUBLESHOOTING amp REPAIR TORCH CONTINUITY AND SOLENOID TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will help the technician determine if the torch cable consumables and elec trode solenoid are functioning properly MATERIALS NEEDED Volt ohmmeter 12 VDC 1 Amp Power Supply This procedure takes approximately 15 minutes to perform PRO CUT 80 LINCOLN 5 F 24 F 24 TROUBLESHOOTING amp REPAIR TORCH CONTINUITY AND SOLENOID TEST continued FIGURE F 5 TORCH CONNECTOR MACHINE END TEST PROCEDURE 3 Using the ohmmeter check the torch resis tances per Table F 5 1 Remove input power to the PRO CUT 80 machine NOTE Take the
28. or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the display board for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver Screw driver This procedure takes approximately 15 minutes to perform PRO CUT 80 LINCOLN 5 F 44 F 44 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL amp REPLACEMENT continued FIGURE F 19 CASE FRONT SCREW REMOVAL 4 Screws PROCEDURE 1 Remove the input power to the PRO CUT 80 4 machine 2 Remove the wraparound cover and perform the Input Filter Capacitor Discharge detailed earlier in this section 3 Using the 5 16 nut driver remove the four screws holding the front assembly to the top and base of the machine See Figure F 19 PRO CUT 80 LINCOLN 5 Carefully slide do not force the front away from the rest of the machine about one inch This will allow more working room to remove the display board F 45 F 45 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL amp REPLA
29. perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the control board for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver Needle nose pliers This procedure takes approximately 15 minutes to perform PRO CUT 80 LINCOLN 5 F 41 F 41 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued FIGURE F 16 CASE FRONT SCREW REMOVAL 4 Screws PROCEDURE 1 Remove input power to the PRO CUT 80 3 Using the 5 16 nut driver remove the four machine screws holding the front assembly to the top 2 Remove the wraparound cover and perform and bask df ine Machine EECH the Input Filter Discharge Procedure 4 Carefully slide do not force the front away detailed earlier in this section from the rest of the machine about one inch This will allow more working room to remove the control board FIGURE F 17 CONTROL BOARD MOLEX PLUG REMOVAL CONTROL BOARD MOLEX PLUGS 5 PRO CUT 80 LINCOLN 5 F 42 F 42 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued 5 Locate the control board and the five molex 6 type plugs connected to it See Figure F 17 Carefully remove the five molex type plugs by depressing the locking tabs and gen
30. pri CUT 80 mary leads 201 204 205 and 208 2 Perform the Input Filter Capacitor iene tne Rewer Board Discharge Procedure detailed earlier in 5 Use the analog ohmmeter to perform the this section test outlined in Table F 2 3 Locate the primary power board and asso ciated lead locations See Figure F 3 PRO CUT 80 LINCOLN 5 F 17 6 F 17 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST continued TABLE F 2 PRIMARY POWER BOARD RESISTANCE TEST POINTS TEST POINT TERMINALS ANALOG METER X10 RANGE Probe If the power board does not meet the acceptable readings outlined in Table F2 the board is faulty Replace See Power Board Removal and Replacement Procedure NOTE Complete power board and filter capacitor replacement is recom mended PRO CUT 80 LINCOLN 5 T Acceptable Meter Readings Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms If the power board passes the resistance test the IGBT portion of the board is good However other circuits on the power board may be faulty These circuits are NOT readi ly tested or service
31. rel S Fees 6J2 iila l hk est CONTROL BOARD 415VDC S M 18VAC BLUE r Dee as 219 l Gas Y J21 PROCEDURE 1 Remove input power to the PRO CUT 80 5 Check for the presence of 17 VDC on the out machine put board 2 Using the 5 16 nutdriver remove the case a LED2 should be lit when 17 VDC is present wraparound cover See Figure F 13 See Output Board LED Definitions and Figure F 12 Low Voltage A WARNING Circuit Diagram b To verify the presence of 17 VDC check ELECTRIC SHOCK can kill from plug J31 Pin 6 to diode D25 anode See Figure F13 F 13 Make certain the volt Dangi touch elecicaly kor parts meter probes make good contact with pin 6 and the diode anode lead It will be nec essary to penetrate the silicon sealant 6 Check for the presence of 15 VDC on the control board a LED1 should be lit when 15 VDC is pre 3 Apply the correct input power to the machine sent See Figure F 13 See and carefully check for the following voltages Board LED Definitions and Figure F 12 4 Check for the presence of approximately 32 Low Voltage Circuit Diagram VDC on the output board 7 Check for the presence of 15 VDC on the con a LED1 should be lit when 32 VDC is present trol board See Figure F 13 See Output Board LED a LED3 should be lit when 15 VDC is pre and Figure F 12 Low Voltage sent See Figure E13 See Control Board Circuit Diagram LED Definitions and Figure F 12 Low b To verify the presence
32. source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch FIGURE E 7 D CONTROL AND DISPLAY BOARDS GATE SOURCE O BODY REGION n lt DRAIN DRIFT REGION n lt BUFFER LAYER P lt INJECTING LAYER DRAIN A PASSIVE POSITIVE VOLTAGE ia APPLIED GATE SOURCE lt BODY REGION lt DRAIN DRIFT REGION lt BUFFER LAYER p lt INJECTING LAYER DRAIN B ACTIVE PRO CUT 80 LINCOLN THEORY OF OPERATION PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION describes how much time is devoted to conduction in the posi tive and negative portions of the cycle Changing the pulse width is known as MODULATION Pulse Width Modulation PWM is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during a cycle The top drawing below shows the minimum output signal possible over a 50 microsecond time period The positiv
33. the air filter See Figure A 3 e Compressed gas should be supplied to the fitting connection mounted on the filter at the rear of the machine If necessary this fitting can be removed allowing plumbing access through the 1 4 in 6 4mm NPT input port on the filter body AA WARNING CYLINDER could explode if damaged Keep cylinder upright and chained to a fixed support FIGURE A 3 COMPRESSED GAS CONNECTION 1 CASE BACK e Keep cylinder away from areas gt PNEUMATIC NIPPLE where it could be damaged 3 AIR FILTER 4 FLEX TUBE TO REGULATOR INSIDE MACHINE Never lift machine with cylinder attached Never allow the cutting torch to touch the cylinder Keep oylinder away from live elec trical parts e Maximum inlet pressure 150 psi NOTE When using nitrogen gas from a cylinder the cylinder must have a pressure regulator e Maximum psi from nitrogen gas cylinder to PRO CUT 80 regulator should never exceed 150 psi e Install a hose between the nitrogen gas cylinder regulator and the PRO CUT 80 gas inlet PRO CUT 80 LINCOLN 5 A 8 A 8 INSTALLATION OUTPUT CONNECTIONS FIGURE A 4 TORCH CONNECTION AT CASE FRONT TORCH CONNECTION Gas Status Reset Purge Gas The PRO CUT 80 is supplied from the factory with a Indicators Button Button Regulator PCT 80 cutting torch Additional cutting torches can Gauge be order
34. the correct capacitor polari ties PRO CUT 80 10 11 12 18 14 LINCOLN 5 Assemble the eight socket head screws and pre torque them to 25 inch pounds Make certain the capacitors are lined up cor rectly so that when the capacitor bolts are assembled through the P C board there will NOT be any distortion to the P C board Finish tightening the eight screws to 40 48 inch pounds Assemble the two Phillips Head screws pre viously removed Connect the J10 plug Connect leads 201 204 205 208 and 209 previously removed Torque to 75 IN LBS Connect leads 202A 207A 206 and 203A to the capacitor terminals Torque to 50 60 inch pounds Clear and reposition any leads that may be disturbed Replace wire ties Replace the case wraparound cover F 54 F 54 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou
35. time you use the machine e Turn the machine s ON OFF POWER SWITCH to the OFF position Connect the air supply to the machine e Turn the main power and the machine power switch on The fan should start The pre charge circuit will operate for 3 seconds then the green Power status indicator should turn on f the SAFETY status indicator is lit push the Reset button If there is no problem the status indicator will go off If there is a problem refer to STATUS INDICATOR in this section Be sure that the work lead is clamped to the work piece before cutting e Set the output current control knob for maximum current for high cutting speed and less dross forma tion per Figure B 1 Reduce the current if desired to reduce the kerf cut width heat affected zone or travel speed as required Push in and hold the Purge button to check or set the gas pressure Pull the pressure regulator cap out and turn it to set the pressure Adjust the gas regulator for 70 PSI for 25 foot 7 62m torches or 75 PSI for 50 foot 15 24m torches Release the Purge button PRO CUT 80 LINCOLN 5 B 6 OPERATION The gas will immediately turn off The pressure gauge may show an increase in pressure after the air turns off but this is normal Do NOT reset the pres sure while the air is NOT flowing When ready to cut place the torch near the work make certain all safety precautions have been taken and pu
36. 1 19200 5621 62K 17 T2O RTZLRT2Z RT23 71 S19400 2pR7 2 51900 1212 ERT 132 6296 5 TRIM RTO ATAT 7 810400 2670 267 17 152 9200 2002 POK 1 4 10812 30 TW 9400 6812 PEKT 176 9400 4750 188 9400 3022 SEAIA 2 T10812 08 RIMMER CAPACITORS MFD VOLTS P1 TPZ 2 1940 15 INDUCTANCE HENRIES 1 515128 CETIOT4 LINEAR INTEGRATED CIRCUIT RESISTANCE OHMS K 5128 3072A Op AMP O tH Gener TELNCONEECHCCO mie Uess THE LINCOLN ELECTRIC CO INVERTER WELDERS Be GE trourmecronesscnuscoucr BAR eg suse CONTROL P C BD AS BLY CANADIAN mL s THE LINCOLN ELECTRIC CO ig crier ba oss DATE 3 suPsDG no G 3560 183 SE Bo es Be E Ee aes z E 1 4W T 5j zj a EE E ES cj S E B 2 Kap ES IMMER zi z ES si E ES RS ES E cl E pe iy AI SE S KE z a SE NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN E machine ELECTRIC PRO CUT 80 ELECTRICAL DIAGRAMS G 6 S
37. 1 800 833 9353 WELD Machine is dead no output no fan no status indicator lights Make sure that the input power switch is in the ON position Check the input voltage at the machine Input voltage must match the rating plate and the reconnect panel Check for blown or missing fuses in the input lines and the 0 6 amp slow blow reconnect fuse Check the input power switch S1 for proper operation See the Wiring Diagram Check the leads associated with the power switch S1 and the auxiliary transformer T2 for loose or faulty connections See the Wiring Diagram Perform the Auxiliary Trans former Test Machine is dead not output no status indicator lights fans run All status indicators remain lit immediately after power up Check the input voltage at the machine Input voltage must match the rating plate and the reconnect panel The microprocessor has experi enced a memory fault Contact your Local Lincoln Authorized Field Service Facility 1 2 3 Perform the Transformer Test Perform the Low Voltage Circuit Test Perform the Input Rectifier The control board may be faulty Replace The display board may be faulty Replace The control board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Elect
38. 14 F 14 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST continued TABLE F 1 INPUT RECTIFIER TEST POINTS TEST POINT TERMINALS ANALOG METER X10 RANGE Acceptable Meter Readings Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms 6 If the input rectifier does not meet the accept 7 If the input rectifier is good be sure to recon able readings outlined in Table F 1 the com nect leads 207 207A and 209 to the cor ponent may be faulty Replace rect terminals and torque to 31 in lbs Apply T a coating of Essex D 4 8 insulating com NOTE Before replacing the input rectifier D1 B check the input power switch S1 and pound and Dow Coming 748 Silicone perform the Primary Power Board Sealant Resistance Test Also check for leaky 8 If the input rectifier is faulty see the Input or faulty filter capacitors Rectifier Bridge Removal amp Replacement procedure See the Wiring Diagram and PRO CUT 80 LINCOLN F 15 F 15 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST AA WARNING Service and repair should be perform
39. 4W 19400 1003 100K 1 4W H24 H35 R25 R47 R49 RBO RB9 R153 183 R28 R112 R115 R116 R117 R118 R133 29 R91 R102 19400 332 3 82K 1 4W E 825 1 4W 19400 1004 1M 1 4W 19400 619 6 19K 1 4W 19400 1502 15K 1 4W 19400 1 4 75K 41 H60 R135 H184 R43 R44 R45 R130 R136 R137 R170 R171 R172 a E SI S RN ES EA s Sese s lc ES E 19400 2802 28 0K 1 2W 57 F4 R56 19400 1000 100 172W 58 R76 R09 RT00 S19400 874 STAK TAW Pas S19400 201 221K 1 4W 67 R70 RBTRTOT 19400 4752 ZE sue S19400 150 Tok aw eu S19400 768 768K 1 4W 77 R82 RTTS RTT 519400 130 Tok aw 19400 121 TIIKAN 519400 2213 22K AW 519400 8252 B2 SK IAW 519400 243 EES S19400 681 SEN SE SEH 519400 26H7 267 AW 19400 1212 TTA 516296 5 TOK TRIMMER 519400 2670 267 iAW 19200 2002 ZOK TAN T10812 39 SOK 1 2W TRIMMER 519400 68 SR S 19400 1750 375 37A HEJ 19200 3927 EISEN CLO INEAN INTEGRATED CET Kee 1 STSTIZI2T2 TH Zi AIS E 59 79 R83 R155 R167 114 120 R121 H122 R123 R13 132 140 R14 R152 173 174 SE EE G 3443 183 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the d
40. 5 E 5 THEORY OF OPERATION FIGURE E 5 D PLASMA OUTPUT BOARD AND TORCH POWER BOARD CAPACITOR IGBT INPUT LINE INPUT SWITCH RECTIFIER On 4omzzooma CAPACITOR mE AIR PRESSURE SWITCH zo JAom Joxv OUTPUT CONTROL AUXILIARY TRANSFORMER OUTPUT BOARD AND TORCH The output board contains an Insulated Gate Bipolar Transistor IGBT which upon receiving a pilot signal from the control board either enables or disables the current in the pilot winding The cutting and pilot rectifier diodes are also incorporated in the output board There are two diodes for the pilot winding and four diodes for the cutting winding There are two P C board mounted current sensors One sensor regulates pilot and cutting current The other sen sor indicates to the control board when and how much current transfers to the workpiece The output board also includes the trigger circuitry the gas solenoid driver the electrode solenoid driver and the torch parts in place circuitry and remote interface circutry The output choke which is in series with both the pilot cir cuit and the cutting circuit provides current filtering to enhance arc stability The PCT 80 torch uses a patented touch start mechanism that provides superior starting performance over other touch start systems The torch head consists of 3 major parts torch body insulator and piston The insulator pro vides an electrica
41. AS SOLENOID TEST AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will help the technician determine if the solenoid is functioning properly MATERIALS NEEDED 5 16 Nut driver 12 VDC 3 amp supply Volt ohmmeter This procedure takes approximately 13 minutes to perform PRO CUT 80 LINCOLN F 26 F 26 TROUBLESHOOTING amp REPAIR AIR GAS SOLENOID TEST continued FIGURE F 6 AIR SOLENOID TEST PROCEDURE 1 2 3 Remove input power to the machine Perform the Input Capacitor Discharge Procedure detailed earlier in this section Locate the air solenoid and leads See Figure F6 Carefully remove plug J31 from the output power board See Figure F 7 Check the coil resistance of the solenoid at plug J31 pin 6 to J31 pin 5 Normal resis tance is approximately 20 ohms If the re
42. CEMENT continued FIGURE F 20 DISPLAY BOARD REMOVAL DISPLAY BOARD CASE FRONT 5 Locate the display P C board and the one 8 When replacing the display board carefully plug connected to it See Figure F 20 connect the plug into the board Make cer tain the plug is secure and the locking tab is 6 Gently remove the display P C board from in place the three mounting pins 9 Align the display board with the three mounting pins and slide the display board A CAUTION into place Be sure to follow the recommended static free 10 Carefully reposition the front assembly in methods for handling printed circuit boards place and install the four mounting screws Failure to do so can result in permanent damage previously removed to the equipment 11 Inspect clear and secure all leads in prepa ration for the case wraparound reassembly 7 Depress the locking tab and remove the plug 12 Using the 5 16 nut driver install the case connector from the display board wraparound PRO CUT 80 LINCOLN 5 F 46 F 46 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all s
43. CHEMATIC POWER PC BOARD 209 POSITIVE INPUT RECTIFIER A E P 2 Pa 150K 150K ES ER D x3 Fa LM224 CAPACITOR PRECHARGE Lm 3 UNDERVOLTAGE PROTECTION C 100 E 227 only ES Z zY RELAY DRIVE A jk S FROM CONTROL BD RECONNECT V gt gt 206 TEST D 1K 1K 1 00K 1 00K DW DW 02 ES r 1A 2000V 2000V 1000 I dis BLEEDER Gi RESISTORS PEAK DETECTOR TRANSFORMER gt PRIMARY Be 205 DZ15 al 613 15V zl 28 206 SE T eof 325VDC FILTER NOMINAL CAPACITOR oO 203 B208 TRANSFORMER I 5 gt PRIMARY pm 208 24 3K OVERVOLTAGE Dia TO CONTROL BD 3 PROTECTION AS ls e us MISCONNECTION VOLTAGE PROTECTION 2ogov 7T 200v PROTECTION GATE Es A A e 203A a RECONNECT l PS iy jj DRNE I du bai z qu wo TEST B c edt FROM os CONTROL eh 221K np BOARD Si PWM DRIVE p 100K 4 00K 490K g Do p s V F CONVERTER K l i Am A 15V oO C TRANSFORMER p m 150K 332K 16 5K PRIMARY sw
44. Diagram This procedure takes approximately 19 minutes to perform PRO CUT 80 LINCOLN 5 F 31 TRIGGER SWITCH IN TORCH HANDLE F 31 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 9 SIMPLIFIED TRIGGER CIRCUIT DIAGRAM SIMPLIFIED TRIGGER CIRCUIT OUTPUT BOARD TORCH RECEPTACLE AUX CONTROL BOARD 415VDC COM PROCEDURE 1 2 Remove input power to the PRO CUT 80 machine Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section Locate the torch cable receptacle and leads 2 and 4 See Figure F9 the Simplified Trigger Circuit Diagram These leads are best accessed at plug J31 on the output board See Figure F 10 Using the ohmmeter check for continuity less than one ohm from lead 2 to lead 4 The torch trigger must be pulled and all input power removed from the machine If conti nuity less than one ohm is not read check the leads from plug J31 to the torch cable 1 s mooomoomus COM If the correct voltage is present in Step 6 carefully check for the presence of approxi mately 15 VDC from plug J32 pin 3 lead 354 positive to plug J32 pin 14 lead 312 negative See Figure F 10 Also see and related figures If the correct voltage is not present perform the Low Voltage Circuit If the correct voltage is present in the above test carefully pull t
45. E Provides gas presssure reading as set by the gas regulator knob GAS PURGE BUTTON Used to check or set gas pressure Push in and hold to check pressure then continue to hold to set the pressure Shuts off gas when released RESET BUTTON Used to reset the machine following a safety circuit trip STATUS DISPLAY BOARD INDICATORS Four lights indicating Power Gas Low Thermal and Safety PILOT ARC CONSIDERATIONS The Pro Cut has a smooth continuous pilot arc The pilot arc is only a means of transferring the arc to the workpiece for cutting Repeated pilot arc starts in rapid succession is not recommended as these starts will generally reduce consumable life Occasionally the pilot arc may sputter or start inter mittently This is aggravated when the consumables are worn or the air pressure is too high Always keep in mind that the pilot arc is designed to transfer the arc to the workpiece and not for numerous starts without cutting When the pilot arc is started a slight impulse will be felt in the torch handle This occurrence is normal and is the mechanism which starts the plasma arc This impulse can also be used to help troubleshoot a no start condition CUTTING OPERATION When preparing to cut or gouge position the machine as close to the work as possible Make sure you have all materials needed to complete the job and have taken all safety precautions It is important to follow these operating steps each
46. E EE S 16668 9 516668 8 13490 135 516668 4 16668 13 13490 108 16668 3 13490 19 16668 10 112199 1 T5000 380pF7100 1 0 50V 2700pF 50 TOpF 100 15 100 100pF 100 1 8 20 4700pF 50 TN4004 3 SR BIN SAS s E 2 STT Ea E EA m E S CG E D ZS S E CG E zi r E z z D14 D19 D20 D22 D23 D24 1 012 013 6 D17 D18 112705 37 112705 34 112705 23 T12702 19 T12702 52 518248 4 18248 10 18248 16 518248 6 18248 8 113657 2 112704 68 112704 B0 112704 69 113165 19400 2671 19400 2430 1N5822 SCHOTTKY BARRIER DIODE 1N4936 NEI 1N4742 1N4733 HEADER HEADER HEADER HEADER HEADER RED LED 2N4401 HEXFET TRANS SS 2N4403 0 OHM 5W RESISTOR 2 67K 1 4W 243 1 4W Di iLED2 LED3 1 02 03 2 R46 R187 SISISTSISETSTSTSTSTSTSTSTRTSTSTE g S I A o E ols R38 R39 4 9400 30R1 30 1 1 4W 5 ERR REESEN 525 148 Rood RS RT5 REO ROT R8 R103 S19100 1001 TK TAW R113 POR SOTO 1 R17 R23 R26 R27 R61 H62 R23 R26 R27 R61 31 19400 1002 10K 1 4W R63 R68 R69 RB1 R84 R93 R94 R104 R106 R108 R134 R138 139 R154 R156 R158 R160 R164 R165 R166 R178 R179 R180 R181 R182 1 1 mg TT 24073 1 10K 1 2W TRIMMER R19 R53 R55 R57 R85 R149 T 19400 5111 5 1K 1 4W 12 19400 10R0 10 1 4 ES Ei zj ES SI xj Fae SI d el S zj Si EN x amp S zj aI 9400 2210 221 1
47. ETY AIR SOLENOID REMOTE INTERFACE RECEPTACLE ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE CSS Dm X mm o0 regulates the output of the machine by controlling the IGBT switching times through pulse width modulation circuitry Sed Pulse Width Modulation in this section The display board receives commands from the con trol board and via indicator lights communicates PRO CUT 80 status and operating conditions to the user PRO CUT 80 LINCOLN E 7 E 7 THEORY OF OPERATION PROTECTION CIRCUITS Protection circuits are designed into the PRO CUT 80 machine to sense trouble and shut down the machine before the trouble damages internal machine compo nents Both overload and thermal protection circuits are included OVERLOAD PROTECTION The PRO CUT 80 is electrically protected from pro ducing higher than normal output currents If the out put current exceeds 85 90 amps an electronic pro tection circuit limits the current to within the capabili ties of the machine Another protection circuit monitors the voltage across the input filter capacitors If the filter capacitor voltage is too high too low or not balanced the protection cir cuit may prevent machine output THERMAL PROTECTION Two thermostats protect the machine from excessive operating temperatures One thermostat is located on the output choke and the other on the po
48. IAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVI CODE NUMBER o 6 D m N C PLACE A LEAD ON APPROPRIATE CO FOR INPUT VOLTAGE T CONNECTOR CAVITY NUMBERING SEQUENCE CONNECTION SHOWN IS FOR 440 460V OPERATION VIEWED FROM COMPONENT SIDE OF BOARD EH ELECTRICAL SYMBOLS PER E1537 MT L10936 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN E PRO CUT 80 SCHEMATIC CONTROL PC BOARD LINCOLN amp LELECTRIC CONTROL_POT PURGE 5 SAFETY_RES ELECTRICAL DIAGRAMS Di6 1N4936 1N4936 THERMOSTAT OK CONTROL_POT PURGE SAFETY RI PSI OK NULL ours NULL TACH INPUT TACH INPUT PRIMARY VOLTAGE LAMPS PP ELECTRODE_AMPS SENSE AMPS ARC ELECTRODE_AMPS ole NC 2700p 50V X5 PWM COMP EA eT SHUTDOWN
49. J of the 14 pin MS connector The circuit provides a dry contact closure when the arc has transferred Input to this cir cuit should be limited to 0 3 A for either 120VAC or 30VDC ARC VOLTAGE The Arc Voltage circuit can be used for activating a torch height control This circuit can be accessed through pins D and G of the 14 pin MS connector The circuit provides full electrode to work arc voltage no voltage divider 335VDC maximum Arc Start K 2A J 347 Arc Initiated M 4A 1 348 D 344 Arc Voltage 14 PIN BOX RECEPTACLE FRONT VIEW Users wishing to utilize the Machine Interface can order a K867 Universal Adapter please adhere to the pin locations stated above or manufacture a 14 pin MS connector cable assembly PRO CUT 80 LINCOLN B 9 B 10 B 10 NOTES PRO CUT 80 LINCOLN Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES TEE Section C Optlons Accessorles essen eene nennen nenne ntes rese n nnne sese nnrnte sese n nnns rennen C 2 PRO CUT 80 LINCOLN 5 C 2 ACCESSORIES GENERAL OPTIONS ACCESSORIES The following options accessories are available for your PRO CUT 80 from your local Lincoln Distributor K1681 1 Undercarriage A valet style undercarriage with pull out handle for machine only Provides torch and work cable storage 22147 043 Vortech nozzle with an 043 1 2 mm Orifice For 35 60 Amps 22147 053 Vortech nozzle with an 053
50. M E3 Eg Bo ect E BS S zm E EI E ES E amp l a E amp 2 E Ei WS S 19400 30R1 D 1 1 4 W 19400 6190 4 1 19400 8251 8 7 R190 R191 R193 R194 5 519401 8 1 19400 2001 IR9 R15 R50 R64 R88 R103 7 519401 R113 10 R42 R96 3 819400 5110 11 R12 R13 H14 4 819400 334 16 R2 2 19400 332 17 R23 R26 R27 R61 31 R63 R68 R69 R81 R84 R93 R94 104 R106 R108 R134 R138 R139 R154 R156 R158 R160 R164 R165 R166 R178 R179 R180 R181 R182 1 24073 1 10 1 2W THIMMER 85 R149 71 1940 Es Es ES EE ole E I SI EI EI Bs zi E S cl p SR KSE SE R20 R22 R110 R111 R124 R125 R126 R127 R128 R142 R196 R197 2 19400 2210 H25 R4 R49 R80 R89 H153 1 9194001008 pOK 1 4W R183 R28 R112 R115 R116 R117 7 19400 32K 1 4W R118 R133 R29 R91 R102 3 19400 825 R31 19400 1004 40 1 19400 6191 H41 R60 R135 R184 4 519400 1 R43 R44 R45 R130 R136 R13 9 S184l aj T LIS EE 170 R171 8172 48 T_510400 2802 48 0K 1 4 52 R54 R56 3 519400 1000 100 1 58 R76 R99 A100 1 S19400 7 G5 R29 2519400221 67 A70 A87 RTOT 1 S19400 72 R95 S19400 150 73 R107 19400 7681 700K 1 77 R82 RITSRTIT 4 819400 1 Toy REN 78 R159 2 51940031211 2TCUEW 79 R63 RT55 R167 1 5194002413 2214 UZW TCU FJ E S Es 5 E D z Za EN z E amp ij TS zT S E no de E z FE amp a e e ZS E ES g 5 S BEREA E 1 519400 2431 109 19400 681
51. M 204 N 202 L K e e A o Ef sw D4 Loe Jon seovpo FILTER T ioo Tio NOMINAL CAPACITOR D 1D vo K OVERVOLTAGE 207 ow BEEEDER PROTECTION in RESISTORS e TRANSFORMER PRIMARY 201 c9 TEST E AS ET E D NEGATIVE 300 Volts 1kHz calibrated k x 9207 war RECTIFIER dF 9 5136 dV T FILE NAME 63518 1CA GENERAL INFORMATION ELECTRICAL SYMBOLS PER Et NOTE 202 203 206 amp 207 BOLT ON WITH FILTER CAPS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE FFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER A SUPPLY VOLTAGE NET C Power SUPPLY SOURCE POINT N7 COMMON CONNECTION 47771 FRAME CONNECTION gt EARTH GROUND CONNECTION NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E PRO CUT 80 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY POWER BOARD LINCOLN B NOTE PRO CUT 80 q POWER 20500 7 047 1600 516668 6 4700pF 50 S16668 DESEN ECH C C E E EE CR 5 6665 5 E 2 5 59 99 2755 Yi 513290 83 50 25V 2 5 50 42 EA SR 5 55039 EE 51590 1309 TEL 7 5299 16 _ DPS RELAY CR r9 DIO 10007 T12199 1 1N4004 D3 D4 D5 D6 D7 D15 D16 D18 D20 D21 D22 D23 D24 DZ1 DZ3 DZ5 DZ6 DZ8 DZ10 T12702 28 WH 5 3
52. OL BOARD LEDs PRO CUT 80 CONTROL G3443 CONTROL BOARD LED DEFINITIONS LED1 Red This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer It also shows that the 18 VAC is being rectified and should be regulated to 15 VDC This 15 VDC supply is used to power the circuitry on the control board LED2 Red This light indicates that the 5 5 VDC is present This voltage is derived from the 15 VDC supply The 5 5 VDC supply is used to power the circuitry on the control board LED3 Red This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer It also shows that the 18 VAC is being rectified and should be regulated to 15 VDC This 15 VDC supply is used to power the circuitry on the control board FIGURE F 15 DISPLAY BOARD TEST POINTS PRO CUT 80 LINCOLN 5 L10721 DISPLAY BOARD REAR VIEW F 40 F 40 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to
53. SVM146 A September 1999 PRO CUT 80 For use with machine code numbers 10573 10574 10577 10578 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 LINCOLN B e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following s
54. WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION These voltage checks will help the technician determine if the correct voltages are being applied and processed by the various P C boards Some of the voltage verification test points are not easily accessible The presence of these voltages can also be confirmed by LEDs on the various P C boards MATERIALS NEEDED 5 16 Nut driver Volt ohmmeter multimeter This procedure takes approximately 20 minutes to perform PRO CUT 80 LINCOLN 5 F 36 F 36 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST continued FIGURE F 12 LOW VOLTAGE CIRCUIT DIAGRAM T2 AUXILIARY TRANSFORMER r 4 TOH1 C TERMINAL BROWN 8 ipid LAC prown y 3 56 oan PLASMA OUTPUT Zz nen DER eil va BOARD Se 24VAC RED l 6 54 EE EN l TO a l PEDA l EN BLUE D S 18VAC
55. X40 6 Replace plugs J30 J31 J32 J33 and J34 7 Replace leads X4 and X2 then torque to 75 IN LBS 8 Replace lead B21 and torque it to 75 IN LBS 9 Clear and secure all leads and replace the wraparound cover PRO CUT 80 LINCOLN 5 F 49 F 50 F 50 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the primary power board and fil ter capacitors for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver 3 16 Allen type wrench 7 16 Wrench Phillips Head screw driver Torque wrench 3 8 Wrench Penetrox A 13 Lincoln E2529 Electrical Joint Compound This procedure takes approximately 40 minutes to perform PRO CUT 80 LINCOLN 5 F 51 F 51
56. able Carefully reconnect leads 201 204 205 and 208 to their appropriate terminals Torque To 75 IN LBS F 18 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST continued CAPACITOR VOLTAGE TEST This test will help the technician to determine if the input filter capacitors are being charged equally to the correct voltage levels NOTE This test should only be conducted with the PRO CUT 80 connected for 400 VAC or above and with the appropriate input voltage applied TEST PROCEDURE 1 Remove main input power to the PRO CUT 80 2 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 3 Locate and familiarize yourself with the capacitor test locations on the primary power board See Figure F 3 PRO CUT 80 4 The following tests will be performed with the input power applied to the PRO CUT 80 BE CAREFUL ALWAYS REMOVE THE INPUT POWER AND PERFORM THE INPUT FILTER CAPACITOR DISCHARGE PROCEDURE BEFORE TOUCHING ANY MACHINE COMPONENT A WARNING ELECTRIC SHOCK can kill vn Have an electrician install and service this equipment e Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts 5 Apply the correct input powert and turn ON the PRO CUT 80 T NOTE This test should only be conducted with the PRO CUT 80 reconnect switch and A jumper confi
57. acitor discharge proce dure FIGURE D 1 N LOCATION OF INPUT FILTER CAPACITOR TERMINALS POWER BOARD RIGHT SIDE OF MACHINE INSULATED GLOVES CAPACITOR TERMINALS POWER RESISTOR INSULATED PLIERS PRO CUT 80 LINCOLN 5 D 3 MAINTENANCE ROUTINE MAINTENANCE 1 Keep the cutting or gouging area and the area around the machine clean and free of combustible materials No debris should be allowed to collect which could obstruct air flow to the machine Every 6 months or so the machine should be cleaned with a low pressure airstream Keeping the machine clean will result in cooler operation and higher reliability Be sure to clean these areas FIGURE D 2 Power Output and Control printed circuit boards and heat sinks Power Switch Main Transformer Input Rectifier Examine the sheet metal case for dents or break age Repair the case as required Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained All external sheet metal screws must be in place to insure case strength and electrical ground continu ity Check the air regulator filter to be sure it does not become clogged The air filter on the machine is self draining and will not have to be emptied Check the filter element every several months to see if it is clogged weekly in very dirty environ ments Replace if necessary by first removing the two scre
58. afety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment BN 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 9 ELECTRIC AND MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld N may be dangerous ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current flowing through any conductor causes ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated Keep all equipment safety guards covers and devices in position and in good repair Keep h
59. afety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output power board for main tenance or replacement MATERIALS NEEDED 5 16 Nut driver 3 16 Allen type wrench 7 16 Wrench Penetrox A 13 Lincoln E2529 Electrical Joint Compound Phillips head screw driver Torque wrench This procedure takes approximately 25 minutes to perform PRO CUT 80 LINCOLN 5 F 47 F 47 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD REMOVAL amp REPLACEMENT continued FIGURE F 21 OUTPUT POWER BOARD REMOVAL ed OUTPUT POWER BOARD PROCEDURE 1 Remove input power to the PRO CUT 80 3 Locate the output power PC board and machine associated lead and plug connections See Figures F 21 and 2 Remove the case wraparound and perform the Input Capacitor Filter Discharge Procedure detailed earlier in this section PRO CUT 80 LINCOLN 5 F 48 F 48 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD REMOVAL amp REPLACEMENT continued FIGURE F 22 OUTPUT BOARD LEAD LOCATIONS G3439 PRO CUT 80 OUTPUT TEST POINT D25 TEST POINT Sch L re 4 Using the 7 16 wrench rem
60. ands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equip ment 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle con trol rods while the engine is running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate PRO CUT 80 localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electr
61. ator to 70 psi 448 kPa Do not reset the air pres sure while the air is off not flow ing TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION The pressure switch S5 or associated leads may be faulty See the Wiring Diagram The control board may be faulty Replace The Safety LED is flashing Make sure there is a Lincoln PCT 80 torch connected prop erly to the PRO CUT 80 Make sure the torch consum ables are in place and in good condition Perform the Torch Continuity and Solenoid Test Check leads N E 364 and 369 between the torch recep tacle the output board and the Transformer See the Wiring Diagram The output board may be faulty Replace The Safety LED is lit and steady Press the reset button f the torch and consumables are properly installed the Safety LED should turn off 2 The reset button or associated wiring may be faulty See the Wiring Diagram Perform the Torch Continui and Solenoid Test The control board may be faulty Replace If the machine operates normal ly with the Safety LED on the display board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 PRO CUT
62. ators for machine status K K e x Unique electrode and Vortech nozzle design for optimum cooling and long life Swirl texture inside Vortech nozzle for better start ing reliability and higher quality cuts Unique drag cup design for durability and elimina tion of double arcing PRO CUT 80 LINCOLN B 4 OPERATION CUTTING CAPABILITY The PRO CUT 80 is rated at 80 amps at 60 duty cycle on a 10 minute basis or 60 amps at 100 duty cycle If the duty cycle is exceeded a thermal protec tor will shut off the output of the machine until it cools to the normal operating temperature Figure B 1 shows the cut capacity of the PRO CUT 80 when cutting mild steel The graph plots cut thickness vs torch travel speed with a torch standoff of 0 15 in 3 8mm Example 0 5 material Amps Speed IPM 55 25 80 35 FIGURE B 1 LINCOLNOS PRO CUT 80 MILD STEEL CUT CARCITY CHART Lincoln s PRO CUT 80 Mild Steel Cut Capacity Chart E e o o o CH A o N o 25A Recommended Torch Travel Speed IPM 80 of Maximum Speed 85A 55A 80 A 0 0 000 0 125 0 250 0 375 0 500 0 625 0 750 1 00 Material Thickness CONSUMABLE LIFE The expected life for the PRO CUT 80 s electrode under normal operating conditions is approximately 160 starts cuts An erosion of 060 in 1 5mm is typ ical for end of electrode life However the electr
63. be Terminal X2 to Probe J33 Pin4 Probe J33 Pin4 to Probe Terminal X4 Probe Terminal X4 to Probe J33 Pin4 Probe D29 Test Point to Probe Terminal X20 Probe Terminal X20 to Probe D29 Test Point Probe D29 Test Point to Probe Terminal X40 Probe Terminal X40 to Probe D29 Test Point Probe D29 Test Point to Probe J32 Pin14 Probe J32 Pin14 to Probe D29 Test Point 6 If any of the resistance checks are not correct the output power board is faulty Replace See the CIRCUIT OR COMPONENT S BEING TESTED Diode A1 and associated trace Diode A1 and associated trace Diode A1 and associated trace Diode A1 and associated trace Diode A2 and associated trace Diode A2 and associated trace Diode A2 and associated trace Diode A2 and associated trace Transistor A2 and associated trace Transistor A2 and associated trace Output Power Board Removal and Replacement Procedure 7 If the output power board passes the resistance test the power diode and transistor portion of the board is good However other circuits on the power board may be faulty These circuits are NOT readily tested or serviceable PRO CUT 80 LINCOLN 5 EXPECTED RESISTANCE Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000
64. body to contact a hot surface SUGGESTIONS FOR EXTRA UTILITY FROM THE PRO CUT SYSTEM A WARNING ELECTRIC SHOCK can kill lt o Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replac ing consumables 1 Occasionally an oxide layer may form over the tip of the electrode creating an insulating barrier between the electrode and nozzle This will result in the tripping of the Pro Cut s safety circuit When this happens turn the power off remove the noz zle and electrode and use the electrode to rub against the inside bottom surface of the nozzle This will help remove any oxide buildup Replace the nozzle turn on the power and continue cutting If the Parts in Place circuit safety status indicator light continues to trip after cleaning the consum ables replace them with a new set Do not contin ue to cut with excessively worn consumables as this can cause damage to the torch head and will degrade cut quality 2 To improve consumable life here are some sug gestions that may be useful a Never drag the nozzle on the work surface if the output control knob is above 45 Amps b Make sure the air supply to the Pro Cut is clean and free of oil Use several extra in line filters if necessary c Use the lowest output setting possible to make a good quality cut at the desired cut speed d Minimize dross buildup on the nozzle tip by starting the cut from the edge
65. bridge When installing a new input rectifier apply a thin coating of Penetrox A 13 Heat Sink Compound Lincoln E2529 to the mating surfaces Torque the mounting cap screws and nuts to 44 in lbs Reconnect the 10 leads to the correct ter minals and torque the phillips head screws to 31 in Ibs 10 Apply Dow Corning 738 Insulating Com 11 pound to all six screw heads and termi nals The heavy input lead terminals should be against the rectifier terminals Assemble case wrap around cover PRO CUT 80 LINCOLN 5 F 57 F 57 TROUBLESHOOTING amp REPAIR 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 IDLE AMPS AND WATTS Output Current Range 35 85 Amps Maximum Open Circuit Voltage 335 Volts PRO CUT 80 LINCOLN 5 F 58 F 58 NOTES PRO CUT 80 LINCOLN 5 G 1 ELECTRICAL DIAGRAMS G 1 TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION SE SECTION G WIRING DIAGRAM WEE G 2 CONTROL PC BOARD SCHEMATIC 0 222222 000000 orrore eee eee G 3 CONTROL PC BOARD ASSEMBLY CODE 10574 n 0 000000 sss GA CONTROL PC BOARD ASSEMBLY CODE 10577 amp 10 G 5 POWER PC BOARD SCHEMATIG 000000000 cece eect e G 6 POWER PC BOARD ASSEMBLY 000000000 ccc se G 7 OUTPUT PC BOARD SCHEMATIC n n nousuun
66. competition due to its quick clean response to arc transfers The power supply design provides high transfer to cut distances which makes pierce cutting more reliable with less nozzle wear The control system has a safety mechanism to insure that the nozzle and electrode are in place before cutting or gouging This is extremely important due to the high voltages involved The PRO CUT 80 comes standard with an air regula tor coarse air filter and pressure gauge There are six different torch and cable systems to choose from hand held torch with 250 or 500 cable machine and robotic torch both with 250 and 500 cable Consumables are included so that cutting can begin right out of the box Consumables can also be ordered as individual packages The PRO CUT 80 initiates the plasma arc with a sim ple yet reliable touch start mechanism This system eliminates many of the failure problems associated with hi frequency start systems The PRO CUT 80 is capable of cutting with nitrogen or air The PRO CUT 80 is controlled by a microprocessor based control board The machine performs rudimen tary self troubleshooting when powered up which aids in field servicing RECOMMENDED PROCESSES AND EQUIPMENT The PRO CUT 80 is capable of all cutting and gouging applications within its output capacity of 35 to 85 amps These applications include thin gage sheet metal and expanded metal OPERATIONAL FEATURES AND CONTROLS The PRO CUT 80 co
67. condition oil scale plate thickness preheat quench gas type gas flow rate and equipment may produce results different from those expected Some adjustments to proce dures may be necessary to compensate for unique individual conditions Test all procedures duplicating actual field conditions in OPocedure Recommendations PREHEAT TEMPERATURE FOR PLASMA CUTTING Preheat temperature control is not necessary in most applications when plasma arc cutting or gouging Preheat temperature control may be necessary on high carbon alloy steels and heat treated aluminum for crack resistance and hardness control Job condi tions prevailing codes alloy level and other consider ations may also require preheat temperature control The recommended minimum preheat temperature for plate thickness up to 1 2 in 12 7mm is 70 F 21 1 C Higher temperatures may be used as required by the job conditions and or prevailing codes If cracking or excessive hardness occurs on the cut face higher pre heat temperature may be required PROCEDURE RECOMMENDATIONS When properly used plasma arc cutting or gouging is a very economical process Improper use will result in a very high operating cost GENERAL IN ALL CASES Follow safety precautions as printed throughout this manual and on the machine THIN GAUGE SHEET METAL Torch Standoff Machine Output Setting DRAG thru 1 16 Standoff Output Setting Min thru Mid Rang
68. crans lateraux dans les zones o l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir ttout risque d incendie d tincelles Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispostifis de s ret leur place PRO CUT 80 LINCOLN 5 MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page rr Se i iv E UE e M Section A Technical Specifications EE A 2 3 Salely PreCaUllOns T Rt A 4 Select Suitable Location A 4 eler ln DEE A 4 Ling and Moving ET A 4 Bil e DEE A 4 High Frequency Interference Protection cecccceeeeeeneeeeeeeseeeeeeeeeeaeeeeeteeaaeeeeeessaaeeeeesnnaeeeeeeeaas A 4 Input Electrical Connections EEN A 5 Input Power Cord Connector Installation A A 5 Frame GrouOpelmg e A 5 Gas Input Connections nennen nennt nennen sss s sn nnn ninh nennt nnenrs nsn nnne nnns A 7 O tput ee e A 8 cun gees naa Section
69. ction of this manual Make sure the work clamp is connected tightly to the work piece The workpiece must be electri cally conductive material RECOMMENDED COURSE OF ACTION Check the lead connections X2 X4 and B21 at the output board Check the output control potentiometer R1 Normal resistance is 10 ohms Also check the associated leads for loose or faulty connections to the display board See the Wiring Diagram Check leads 216 218 and 219 between the display board and the control board Check for loose or faulty con nections See the Wiring Diagram The control board may be faulty Replace The output board may be faulty Perform the Output Board Resistance Test The display board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 PRO CUT 80 LINCOLN 5 F 8 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The Air Low LED is lit POSSIBLE AREAS OF MISADJUSTMENT S LED FUNCTION PROBLEMS Make sure there is at least 70 psi 448 kPa of air pressure connected to the gas connec tion at the back of the PRO CUT 80 Press the purge button and set the regul
70. e Output set below 45 Amps The nozzle may be dragged on the metal surface touching it lightly to the surface after piercing a hole Current control should be set below the mid range Do not allow cable or body to contact hot surface PRO CUT 80 LINCOLN B 8 OPERATION THICK SECTIONS OF METAL Torch Standoff Machine Output Setting 1 8 thru 3 16 Standoff Output Setting Mid thru Max Range Output set above 45 Amps The best quality and consumable life will be obtained by holding the torch off the surface about 3 16 in 4 7mm Too long an arc may compromise cut quality and consumable life The nozzle should NOT be dragged on the work Y Use of the S22151 Drag Cup will maintain the prop er standoff The only time not to use the drag cup when the output control is set above mid range is in special tight corners Always hold at least a 1 8 in 3 2mm standoff in those situations If piercing is required slowly lower the torch at an angle of about 30 to blow the dross away from the torch tip and slowly rotate the torch to a vertical position as the arc becomes deeper This process will blow a lot of molten metal and dross Be care ful Blow the dross away from the torch the opera tor and any flammable objects Where possible start the cut from the edge of the workpiece Keep moving A steady speed is necessary Do not pause Do not allow the torch cable or
71. e electrode solenoid should be energized during gas air pre flow time During pilot and cutting arc periods the LED should be off When the arc goes out the machine enters the post flow state Two seconds after the start of post flow the electrode solenoid is activated a few times The LED should blink to indicate this activity The electrode solenoid will then be energized for the duration of post flow The LED should be on LINCOLN 5 F 34 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 11 CONTROL BOARD LEDs PRO CUT 80 CONTROL G3443 CONTROL BOARD LED DEFINITIONS LED1 Red This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer It also shows that the 18 VAC is being rectified and should be regulated to 15 VDC This 15 VDC supply is used to power the circuitry on the control board LED2 Red This light indicates that the 5 5 VDC is present This voltage is derived from the 15 VDC supply The 5 5 VDC supply is used to power the circuitry on the control board LED3 Red This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer It also shows that the 18 VAC is being rectified and should be regulated to 15 VDC This 15 VDC supply is used to power the circuitry on the control board PRO CUT 80 LINCOLN 5 F 34 F 35 F 35 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST A
72. e portion of the signal represents one IGBT group conducting for 1 microsecond The negative portion is the other IGBT group The dwell time off time is 48 microseconds both IGBT groups off Since only 2 microseconds of the 50 microsecond time period is devoted to conducting the output power is minimized MAXIMUM OUTPUT By holding the gate signals on for 22 microseconds each and allowing only 3 microseconds of dwell time off time during the 50 microsecond cycle the output is maximized The darkened area under the top curve can be compared to the area under the bottom curve The more dark area under the curve the more power is present 1 An IGBT group consists of two IGBT modules feeding one transformer primary winding FIGURE E 8 D TYPICAL IGBT OUTPUTS 1 usec KR 48 u sec 1 usec 50 u sec MINIMUM OUTPUT 22usec 3usec 50sec c 22u sec MAXIMUM OUTPUT PRO CUT 80 LINCOLN E 10 E 10 NOTES PRO CUT 80 LINCOLN Section F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION Troubleshooting amp Repair Section cece ee eccc cece eee e eter ee eeeeeceeaaaeeeeeeeeeeeeteeeeeeaaae Section F How to Use Troubleshooting Guide EEN F 2 PC Board Troubleshooting Procedures and Replacement AA F 3 Troubleshooting Guide F 4 Test Procedures Input Filter Capacitor Discharge Procecdure F 10 Input Rectifier est EE F 12 Primary Po
73. ed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will determine if the primary power board has any shorted or leaky power diodes or Insulated Gate Bipolar Transistors IGBTs Also it will help to indicate any shorted input filter capacitors MATERIALS NEEDED Analog voltmeter ohmmeter multimeter Wiring Diagram 7 16 Wrench This procedure takes approximately 25 minutes to perform PRO CUT 80 LINCOLN 5 F 16 F 16 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST continued FIGURE F 3 PRIMARY POWER BOARD REMOVAL Primary power board with input filter capacitors PRO CUT 80 POWER G3440 1 208 205 201 204 6 6 9 9 9 203 206 207 202 CAPACITOR C1 CAPACITOR C2 TERMINALS TERMINALS TEST PROCEDURE 1 Remove main input power to the PRO 4 Carefully remove the main transformer
74. ed from the K1571 series Hand held and x mechanized torches come with 25 or 50 foot cables d G Output as All torches are connected to the Pro Cut with a quick Control SE Knob nob connect at the case front for easy change over See Figure A 4 Cons mabie PRO CUT 80 For more information on the torch and its components d refer to the PCT 80 Operator Manual IM595 SC Input 9 Power Torch UJ LJ Switch Connector Work Cable Interface Connector PRO CUT 80 LINCOLN Section B 1 Section B 1 TABLE OF CONTENTS OPERATION SECTION e e EE Section B SIMA ee B 2 General Description B 3 Recommended Process and Eouipment ee B 3 Operational Features and Controls EEN B 3 Design Features and AAVantages cccccesseecceeeeseeeeeeceeseeseeeeeseeeeeeeessaeeeesanseeeseeeneeseeeeseneeneees B 3 Gutting Capability EE B 4 Gonsumable Lite rxetivssseistixtes a R disease B 4 Blogia c en B 4 G ntrols RE ne EE B 5 Pilot eene DL ET B 5 Etage Opora EE B 5 EEN le ee B 6 Usor RESPOMSIDIMY EE B 7 Preheat Temperature for Plasma Cutting B 7 Procedure Hecomrmiendaltlorns iO IER EE EHE EE Deeg VERTS ERRUE BEEN B 7 Cc m B 7 Thin Gauge Sheet Metal ii iuh titi a r oit retta no c Enea cx Fe aea R ER Fue Roa Pen S B 7 Thek Sections Of OT B 8 Suggestions for Extra Utility From the Pro Cut System esseseeeeeeee B 8 Machine
75. efonctionnement PR CAUTIONS DE S RET POUR LES d Ne jamais plonger le porte lectrode dans l eau pour le MACHINES A SOUDER A TRANSFOR refroidir MATEUR ET A REDRESSEUR e Ne jamais toucher simultan ment les parties sous ten sion des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines 1 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enroule le c ble lectrode autour de n importe quelle partie du corps 3 3 Un coup d arc peut tre plus s v re qu un coup de soliel donc 4 a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnementde l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laiter en fusion sont mises de l arc de soudage Se prot ger avec es v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec
76. ents to locate each specific Test Procedure All of the referred to test points Components terminal strips etc can be found on the referenced elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 PRO CUT 80 LINCOLN 5 F 2 F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES AA WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the machine OFF before working on equipment Do not touch electrically hot parts Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component caus ing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warnin
77. esign and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine PRO CUT 80 ELECTRICAL DIAGRAMS G 5 PC BOARD ASSEMBLY CONTROL BOARD CODE 10577 amp 10578 ONLY PART NO DESCRIPTION Ey RN zi D 2 CB 010 011 013 014 017 20 C23 024 031 084 035 36 C37 038 039 040 041 C47 C49 051 053 055 063 64 C65 066 68 069 3 T 51349021 1 ZE 2 513490 63 S13490 71 157752 3490 72 3490 93 12 660 2 515490 126 O15 016 032 033 042 058 8 S16668 171 072 19 025 050 21 C26 028 030 054 057 C62 C67 22 048 044 3 516668 9 150pF 1 27 048 2 516668 8 1 813490 135 1 816668 4 PRO4ZUT eg ROL 3560 1 26 82 DEE GR E 58 516668 3 E D C pe 23 13490 19 ED ST6668 10 De 16 eee x D14 D19 D20 D22 D23 D24 D25 D10 011 012 D13 13 112705 3 582 15D16D17 D18 1 112705 3 12705 23 T8 1 072 2 112702 19 1 T1270 En 8228 4 8248 10 8248 16 828 6 9225 8 D1 LEDZLED3 3 136572 3 112701 68 cq E E zz STol gg cl S ES s STOTOToTo EN pE E ps a c EL Si SITTI Suse See s c e cl ER s Ei c 5 Ri E EM ER ET s E 4 s ope DIODE fe Dx Dx os DA ol Si Je zi zs sri SC BEE aol al oJ EE EES sss da RES ES E m Is E N zf ERE a E SI A 3 5 E S E 12104 69 1 T13165 16 2 R46 R187 3 819400 267 co cc R188 R38 R39 Sj 23 BS of ES H
78. g inside the static resistant bag and perform the following procedures PC Board can be damaged by static electricity e Remove your body s static charge before opening the static shield ing bag Wear an anti static wrist strap For safety use a 1 Meg Aa ATTENTION dies Static Sensitive ohm resistive cord connected to a Devices grounded part of the equipment Handle only at frame Static Safe If you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to pre vent static build up Be sure not to touch any electrically live parts at the same time Workstations Reusable Container Do Not Destroy Tools which come in contact with the PC Board must be either conductive anti static or static dissipative e Remove the PC Board from the static shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag e f the PC Board uses protective shorting jumpers don t remove them until installation is complete f you return a PC Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis 4 Test the machine to determine if the failure symp tom has been corrected by the replacement
79. gured for 400 VAC and above LINCOLN 5 F 19 F 19 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST continued Check for the appropriate voltages outlined 7 in Table F 3 NOTE Voltages may vary with the input line voltage NOTE If the capacitor voltage is too high over 400 VDO or too low less than 220 VDO the control board will deactivate relay CR1 CR2 This will prevent output If the test voltages do not meet the expect ed values as listed in Table F 3 the capaci tors or other components on the power board may be faulty Replace NOTE If the capacitor voltages are NOT bal anced within 20 VDC the capacitors may need conditioning See the Maintenance section TABLE F 3 CAPACITOR VOLTAGES EXPECTED VOLTS DC AT CAPACITOR INPUT APPLIED TERMINALS 460VAC 440VAC 415VAC 380VAC 325VDC 311VDC 293VDC 269VDC NOTE If Capacitor C1 is found to be defective both Capacitors C1 and C2 must be replaced at the same time The capacitors must be replaced in matched sets PRO CUT 80 LINCOLN 5 F 20 F 20 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD RESISTANCE TEST AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to a
80. he torch trigger A WARNING PILOT ARC CUTTING ARC AND HIGH VOLT lt S e AGE MAY BE PRESENT AT THE receptacle Perform the Torch Continuity and Solenoid Test If less than one ohm is read only when the torch trigger is pulled proceed to the next step Definitions land related figures Apply the correct input power to the PRO CUT 80 Carefully check for approximately 17 VDC from plug J31 pin 1 lead 4 positive See to plug J31 pin 2 lead 2 negative If the correct voltage is not pre sent perform the Low Voltage Circuit Test Also see Output Board LED Definitions and related figures Also see Output Board LED PRO CUT 80 LINCOLN 5 TORCH HEAD Perform this test with the air input removed to avoid a pilot arc at the torch F 32 F 32 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued 9 With the torch trigger activated check the voltage at plug J32 pin 3 lead 354 posi tive to plug J32 pin 14 lead 312 nega tive Normal is less than 1 VDC If more than 1 VDC is indicated the power output board may be faulty Release deactivate the torch trigger and remove input power to the PRO CUT 80 10 Perform the Input Filter Capacitor Discharge Procedure 11 Check the continuity of leads 354 and 312 between the output board and the control board See the and 12 If all of the above checks are OK the con trol board may be faulty Replace PRO CUT 80
81. ions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will drain off any charge stored in the two large capacitors that are part of the power board assembly This procedure MUST be performed as a safety precau tion before conducting any test or repair procedure that requires you to touch internal components of the machine MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver Insulated gloves Insulated pliers High wattage resistor 25 to 1000 ohms 25 watts minimum This procedure takes approximately 10 minutes to perform PRO CUT 80 LINCOLN 5 F 10 F 11 TROUBLESHOOTING amp REPAIR A WARNING ELECTRIC SHOCK can kill e Have an electrician install and service this equipment 09 e Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts e Prior to performing preventative mainte nance perform the following capacitor dis charge procedure to avoid electric shock DISCHARGE PROCEDURE 1 Turn off input power and disconnect input power lines 2 Remove the 5 16 hex head screws from the wraparound machine cover 3 Be careful not to make contact with the capacitor termina
82. l barrier between the piston and torch body The piston provides a path for electrical current to the electrode The piston also drives the electrode to the nozzle for arc initiation The torch body contains the main torch components the trigger pilot arc cutting arc and air flow systems are included CONTROL BOARD DISPLAY BOARD ELECTRODE MAIN TORCH TRANSFORMER OUTPUT BOARD CONNECTOR issuer escas REMOTE INTERFACE RECEPTACLE ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE sor x Emm ES A copper nozzle with a patented internal swirl is used to focus the arc A small precise hole in the end of the noz zle constricts the arc and increases the current density As the air enters the torch head it is directed between the electrode and nozzle for maximum electrode cooling A portion of the cooling air exits the chamber through vents in the side of the nozzle A swirl texture located inside the bottom of the nozzle increases the plenum air swirl strength and improves arc start reliability and parts in place verification Plasma arc initiation occurs as follows First in the idle state a spring inside the torch head pushes the piston and electrode forward to make continuity with the nozzle When the trigger is pulled air flow begins and creates enough back force on the electrode to overcome the force of the spring However the s
83. l determine if the auxiliary transformer is functional when the correct primary volt age is applied to the primary winding MATERIALS NEEDED Volt ohmmeter Machine wiring diagram 5 16 Nut driver 230 VAC isolated power supply This procedure takes approximately 18 minutes to perform PRO CUT 80 LINCOLN 5 F 28 F 28 TROUBLESHOOTING amp REPAIR T2 AUXILIARY TRANSFORMER TEST continued FIGURE F 8 T2 AUXILIARY TRANSFORMER 10 PIN 6 1 AUXILIARY 7 TRANSFORMER 813 94 5 Plug J21 8 PIN H2 H4 H5 gt PROCEDURE 1 Remove main input power to the PRO CUT 5 Carefully apply the 230 VAC isolated supply 80 machine to leads H1 located at the D1 input bridge 2 Perform the Input Filter Capacitor pM CR cat and Ma eee orae Discharge Procedure detailed earlier in this y section 6 Carefully check for the presence of the fol 3 Locate the auxiliary transformer See Fig F 8 owing primary and secondary voltages at ine appropriate leads at plugs J21 and J22 See 4 Locate and disconnect plugs J21 and J22 Figure F 8 and Table F 6 from the wiring harness Cut any necessary cable ties See Figure F 8 PRO CUT 80 LINCOLN 5 F 29 TROUBLESHOOTING amp F 29 REPAIR T2 AUXILIARY TRANSFORMER TEST continued TABLE F 6 J21 AND J22 VOLTAGES H2 522 H4 722 H5 822 Brown 8J21 Brown 3J21 Red 2J21 Red 6J21 Blue 9J21 White 5J21 Blue 4J21 White 5J21 Yellow 1J21
84. ll the trigger The air will flow for a preflow time of 2 seconds and the pilot arc will start This is true unless the machine is in postflow then the preflow time is skipped and the pilot arc will start immediately The pilot arc will run for 3 seconds and shut off unless the arc is brought in contact with the work and the arc is transferred Avoid excessive pilot arc time by transferring the arc to the workpiece quickly to improve parts life When the arc is brought within 1 4 in 6 4mm from the workpiece the arc will transfer the cur rent will ramp up to the setting on the control panel and the cut can last indefinitely or until the duty cycle of the Pro Cut is exceeded Do not touch the nozzle to the work when cutting Damage to the consumables may result Pierce the workpiece by slowly lowering the torch onto the metal at a 30 angle away from the opera tor This will blow the dross away from the torch tip Slowly rotate the torch to vertical position as the arc becomes deeper TORCH AT 30 ANGLE TO PIERCE ROTATE TO 90 ANGLE TO CUT FOR CUTTING Y Hold the nozzle standoff 1 8 in 3 2mm to 3 16 in 4 7mm above the workpiece during cutting Do not let the torch nozzle touch the work or carry a long arc Keep moving while cutting Cut at a steady speed without pausing Maintain the cutting speed so that the arc lag is 10j to 20 behind the travel direction Y Use a 5j 15j leading angle in
85. ls located at the bottom of the Input Power Board INPUT FILTER CAPACITOR DISCHARGE PROCEDURE continued 4 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts mini mum This resistor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Locate the four capacitor terminals large hex head cap screws shown in Figure F 1 At the bottom of the PowerBoard 203 206 207 202 Use electrically insulated gloves and insu lated pliers Hold the body of the resistor and connect the resistor leads across the two capacitor terminals Hold the resistor in place for 10 seconds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS Repeat the discharge procedure for the capacitor on the other two terminals Check the voltage across the terminals of all capacitors with a DC voltmeter Polarity of the capacitor terminals is marked on the PC board above the terminals Voltage should be zero If any voltage remains repeat this capacitor discharge procedure FIGURE F 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS POWER BOARD CAPACITOR TERMINALS la Q POWER RESISTOR RIGHT SIDE OF MACHINE INSULATED GLOVES PRO CUT 80 LINCOLN 5 INSULATED PLIERS F 12 F 12 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained person nel Unauthorized repairs
86. mes with an ON OFF POWER SWITCH OUTPUT CURRENT CONTROL PURGE BUTTON STATUS INDICATORS and a SAFETY RESET BUTTON See Figure B 2 and related discus sion DESIGN FEATURES AND ADVANTAGES The microprocessor controlled PRO CUT 80 design makes plasma cutting and gouging tasks uncompli cated This list of design features and advantages will help you understand the machine s total capabilities so that you can get maximum use from your machine Light weight and portable design for industrial use Continuous control 35 85 amps Reliable touch start mechanism for plasma arc initi ation Unique microprocessor controlled sequence for safe and consistent starting starting Rapid arc transfer for fast cutting of expanded metal High transfer distance for ease of use Input overvoltage protection 3 0 second pilot arc Purge momentary push button K K KKK Air regulator and pressure gauge located on the front of machine for convenience Y Parts in Place mechanism to detect per instal lation of consumables and torch Automatic detection of faulty output control In line coarse air filter Y Preflow Postflow timing Preflow is eliminated if arc is re initiated in Postflow Thermostatic Protection Solid state overcurrent protection 4K Works with pure nitrogen for cutting nonferrous materials Reconnectable for multiple input voltages Quick disconnect torch Display indic
87. n G Parts Mangal issis doain eege eiaa ENEE haea ve eENEER NEEN Eed ech P 340 Series PRO CUT 80 LINCOLN 5 Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION Installation Technical ee ee A 2 Satety e LEE A 4 oelect Suitable Location vases erii iecit ence geesde teo tere Ev re Fr RE a MEE EeE EE Cu poen rud A 4 le lee EE A 4 Hng and Movin ET A 4 FINO ME A 4 High Frequency Interference Protection csseecceecesseeeceeeeseeeeeeseeseeeseeenseeeeeesesseeeeeesneeeeeaeeess A 4 Input Electrical Connectloris urina dia enu a eoan ENa rak SEKFER es KR TRES ERR ESAV aE KEENE A 5 Ground Connection isseire tiie NEE aor NEAR EEKAN EACEA EAEEREN PE Aada S A 5 Input Power Cord Connector Installation ccccceccceeeee eee eeeeeeeeeaaeeeeeeeeeeeeeeeeeeceeaeeeeeeeeeeeeeneees A 5 Input Wire and Fuse Glze ee A 5 Eelere EE A 6 Gas INPUt COMMECTIONS mse sorire nenea bars Deede Sue rwanda Sege SEENEN aiai A 7 Output ele Ee A 8 Torch GOMMSCH OM icc ches cnsicce lt eaneececceesaauctestasgssecscsseadeesaneateeeetaackaeet cagdiageecessavesteessagizunesdaaatee A 8 PRO CUT 80 LINCOLN 5 A 2 INSTALLATION TECHNICAL SPECIFICATIONS PRO CUT 80 Single Phase Input Voltage and Hertz 208 1 60 230 1 60 460 1 60 Three Phase Input Voltage and Hertz 208 3 60 230 3 60 460 3 60 230 1 60 Duty Cycle 60 100 Current Range 35 85 Amps INPUT RATINGS Input Currents
88. nection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 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 and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head
89. nstalled to lift the machine This handle is not designed to support the full weight of the machine Using it to lift the machine could cause per sonal injury or damage to the machine Either the front or rear handles or both may be used to lift or move the machine TILTING The PRO CUT 80 must be placed on a stable level surface so it will not topple over HIGH FREQUENCY INTERFERENCE PROTECTION The PRO CUT 80 employs a touch start mechanism for arc initiation This eliminates high frequency emis sions from the machine as compared with spark gap and solid state type high frequency generators Keep in mind though that these machines may be used in an environment where other high frequency generating machines are operating By taking the following steps you can minimize high frequency interference Make sure the power supply chassis is connected to a good earth ground The work terminal ground does NOT ground the machine frame X Keep the work ground clamp isolated from other work clamps that have high frequency X f the ground clamp cannot be isolated then keep the clamp as far as possible from other work clamp con nections When the machine is enclosed in a metal building several good earth driven electrical grounds around the periphery of the building are recommended Failure to observe these recommended installation pro cedures may cause improper function of the Pro Cut or possibly even damage the c
90. o the machine ELECTRICAL DIAGRAMS T L L L L L G G G GHT BAR LED YELLOW G G G Q7 02 03 04 T12704 68 2 PART No IDENTIFICATION C1 02 C8 04 S16668 4 2700pF 50 13490 25 4 7135 112702 27 1N4740 T BAR LED YELLOW T BAR LED RED T BAR LED RED T BAR LED YELLOW T BAR LED GREEN M18875 4 LIGHT BAR LED GREEN 401 3 32K 1 4W 6 8 R3 R4 R7 R8 R11 R12 6 91940 1000 100 1 2W 75 K 1 4W 4W 75 AW S19400 8250 825 1 4W R18 R19 19400 2671 2 67K 1 4W S19400 2430 248 1 4W PRO CUT 80 SVM ERROR REPORTING FORM We need to know if there are errors in our manuals We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you If you discover new or different Problems or Symptoms that are not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 ST Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below SD287 01 99 LINCOLN P
91. ode may last longer A green and erratic arc will indicate definite electrode failure and the electrode should be replaced immediately It is recommended that consumables be replaced in complete sets Example Electrode and Nozzle This will maximize the performance of the PRO CUT 80 system LIMITATIONS Do not exceed output current and duty cycle rating of machine Do not use the PRO CUT 80 for pipe thaw ing PRO CUT 80 LINCOLN B 5 B 5 OPERATION CONTROLS AND SETTINGS FIGURE B 2 CASE FRONT CONTROLS Gas Purge Gas Button Regulator Gauge Reset Status gt Button Indicators Output Gas Control Regulator Knob Knob LINCOLN amp Consumable PRO CUT 80 Storage behind door Input Te P4 Power Si Switch Connector Cable Interface Connector OUTPUT CURRENT CONTROL KNOB Adjusts the amount of cutting current applied Affects cutting speed dross formation cut width heat zone and trav el speed TORCH CONNECTOR Quick connect type coupling for the PCT 80 cutting torch WORK CABLE Provides clamp and cable connection to workpiece ON OFF POWER SWITCH Turns machine on or off GAS REGULATOR KNOB Adjusts compressed gas pressure delivered to the torch Length of torch hose is an adjustment factor Optimum setting is 70 75 psi The gas purge button must be pressed in to set pres sure GAS REGULATOR GUAG
92. ode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical con
93. of 32 VDC check Voltage Circuit Diagram across capacitor C13 Make certain the voltmeter probes make good contact with the capacitor leads See Figure F 13 PRO CUT 80 LINCOLN 5 F 37 F 37 TROUBLESHOOTING amp REPAIR 10 11 Check for the presence of 5 VDC on the control board a LED2 should be lit when 5 VDC is pre sent See Figure F 14 See Control Board and Check for the presence of 15 VDC being applied to the display board from the control board You may have to remove the display board to check it a 415 VDC should be present at leads 216 to 219 See Figure F 15 and Figure F 12 Low Voltage Circuit If any of the DC supply voltages are incorrect or missing make certain the correct AC sup ply voltages are being applied to the P C When the test is complete remove input power and replace the case wraparound cover PRO CUT 80 LINCOLN 5 F 38 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST continued FIGURE F 13 OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs TEST POINT m re x20 xo PRO CUT 80 OUTPUT BOARD LED DEFINITIONS LED1 Red This light indicates that 24 VAC is being supplied to the output board from the aux iliary transformer It also shows that the 24 VAC is being rectified to approximately 28 VDC This DC voltage is used for the parts in place check for the torch circuit LED2 Red This light indica
94. of the plate when possible e Pierce cutting should be done only when nec essary If piercing angle the torch about 20 from the plane perpendicular to the work piece transfer the arc then bring the torch perpendicular to the work and begin parallel movement f Reduce the number of pilot arc starts without transferring to the work g Reduce the pilot arc time before transferring to the work h Set air pressure to recommended setting A higher or lower pressure will cause turbulence in the plasma arc eroding the orifice of the nozzle tip i Use only Lincoln consumable parts These parts are patented Using any other replace ment consumables may cause damage to the torch or reduce cut quality PRO CUT 80 LINCOLN B 9 OPERATION MACHINE INTERFACE The PRO CUT 80 comes standard with a machine interface Interface signals provided include arc start arc initiated and arc voltage These signals are acces sible through the 14 pin MS connector on the case front ARC START The Arc Start circuit allows for triggering of the power source to commence cutting This circuit can be accessed through pins K and M of the 14 pin MS con nector The circuit has a 17 VDC nominal open circuit voltage and requires a dry contact closure to activate ARC INITIATED The Arc Initiated circuit provides information as to when a cutting arc has transferred to the work piece This circuit can be accessed through pins and
95. olenoid valve allows enough forward force on the piston to maintain continu ity between the consumables After this continuity has been verified by the Pro CutG parts in place circuit out put current is established and regulated Once the cur rent stabilizes the solenoid valve turns off removing the forward force on the piston The back pressure drives the piston and electrode away from the nozzle creating the plasma arc The air stream forces the arc out the ori fice of the nozzle This appears as a pilot arc which can then be transferred for cutting PRO CUT 80 LINCOLN E 6 E 6 THEORY OF OPERATION FIGURE E 6 D CONTROL AND DISPLAY BOARDS POWER BOARD LINE INPUT RECTIFIER IGBT CAPACITOR Om omzzoom AIR PRESSURE SWITCH zo dom Jozrv SIGNAL 18 36VAC THERMOSTATS OUTPUT CONTROL 115VAC AUXILIARY TRANSFORMER FAN MOTOR CONTROL AND DISPLAY BOARDS The control board receives status and analog feed back signals from the output board display board power board and various sensors The processor interprets these signals makes decisions and changes machine mode and output to satisfy the requirements as defined by the internal software The control board CONTROL BOARD DISPLAY BOARD WORK ELECTRODE NOZZLE MAIN TRANSFORMER ees TORCH OUTPUT BOARD T CONNECTOR B O ozmroo mooz omrem TRIGGER amp SAF
96. ontrol system or power supply components PRO CUT 80 LINCOLN INSTALLATION INPUT CONNECTIONS AA WARNING ELECTRIC SHOCK can kill _e Have a qualified electrician install and service this equipment Turn the input power off at the fuse box before working on this equipment Do not touch electrically hot parts Before installing the machine check that input supply voltage phase and frequency are the same as the machine voltage phase and frequency as specified on the machineG rating plate See Figure A 1 FIGURE A 1 RATING PLATE LOCATION 1 CASE BACK 2 RATING PLATE 3 POWER CORD CONNECTOR WITH STRAIN RELIEF The PRO CUT 80 should be connected only by a qual ified electrician Installation should be made in accor dance with the U S National Electrical Code all local codes and the information detailed below GROUND CONNECTION The frame of the PRO CUT 80 must be properly grounded A ground terminal marked with the symbol Km is mounted on the case bottom directly behind the input power switch for this purpose The ground lead of the input power cord that is attached to the machine must be connected to this ground terminal See the National Electric Code for details on proper grounding methods Install in accordance with all local and national electrical codes INPUT POWER CORD CONNECTOR INSTALLATION The PRO CUT 80 is supplied with one 11 foot 3 35m 8 AWG 3 lead input power co
97. out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b LINCOLN 5 7 WELDING SPARKS can ZZ cause fire or explosion 6 a Remove fire hazard
98. ove leads X4 X2 9 Carefully remove the output power board and B21 from the output power board from the heat sink 5 Remove plugs J30 J31 J32 J33 and J34 from the output power board A CAUTION 6 Remove leads X20 and X40 from the output power board Be sure to follow the recommended static free methods for handling printed circuit boards 7 Using the phillips head screw driver remove Failure to do so can result in permanent damage the four screws from the lower upper left to the equipment and right corners of the output power board 8 Using the 3 16 allen head wrench remove the four socket screws mounting the output power board to the heat sink PRO CUT 80 LINCOLN 5 F 49 TROUBLESHOOTING amp REPAIR REPLACEMENT PROCEDURE 1 Apply a thin coating of Penetrox A 13 Electrical Joint Compound to the mating sur faces of the output power board and the heat sink Make sure the surfaces are clean Do not allow the compound to get into the threaded holes or on the screw threads A CAUTION Be sure to follow the recommended static free methods for handling printed circuit boards Failure to do so can result in permanent damage to the equipment 2 Mount the output power board to the heat sink and pre torque the four socket head screws to 25 inch pounds 3 Finish tightening the four screws to 40 48 inch pounds 4 Replace the four phillips head screws previ ously removed 5 Replace leads X20 and
99. performed on this equipment may result in danger to the tech nician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if the input rectifier has shorted or open diodes MATERIALS NEEDED Analog voltmeter ohmmeter multimeter Phillips head screw driver Wiring diagram This procedure takes approximately 15 minutes to perform PRO CUT 80 LINCOLN F 13 F 13 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST continued TEST PROCEDURE 4 With the phillips head screw driver remove leads 207 207A and 209 from the rectifi er 2 Perform the Input Filter Capacitor 5 Use the analog ohmmeter to perform the Discharge Procedure detailed earlier in tests detailed in Table F 1 See the Wiring is section Diagram 1 Remove main input power to the machine 3 Locate the input rectifier D1 and lead loca tions See Figure F 2 Carefully remove the silicone sealant from leads 207 207A and 209 FIGURE EZ INPUT RECTIFIER AND LEADS TOP VIEW PRO CUT 80 LINCOLN F
100. r primary winding with DC current flow See IGBT Operation discussion and diagrams in this section CURRENT TRANSFORMER CONTROL BOARD ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE i DISPLAY BOARD ELECTRODE OUTPUT BOARD MAIN TRANSFORMER D Us EI Ho PILOT TRANSISTOR REMOTE INTERFACE RECEPTACLE ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE The power board also monitors the filter capacitors for voltage balance and under or overvoltage If either should occur the appropriate signal is sent to the con trol board to deactivate the CR1 CR2 input relay The machine output will also be disabled NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRO CUT 80 LINCOLN EA THEORY OF OPERATION FIGURE E 4 D MAIN TRANSFORMER POWER BOARD INPUT LINE INPUT SWITCH RECTIFIER R TER C o N N E c BE e E i T c H H AIR PRESSURE SWITCH OUTPUT CONTROL 115VAC AUXILIARY TRANSFORMER FAN MOTOR MAIN TRANSFORMER Each IGBT pair acts as a switch assembly Each assembly feeds a separate oppositely wound primary winding of the main transformer The reverse direction of current flow through the main transformer primaries and the offset timing of the IGBT pairs induce an AC square wave output signal at the secondary of the main transformer The DC current flow through each p
101. rd already connected to the machine A cord connector provides a strain relief for the input power cord as it passes through the left rear access hole The cord connector is designed for a cord diameter of 40 1 03 in 10 2 26 2mm if it becomes necessary to install a different input cord See Figure A 1 For three phase connection Replace the input power cord with a 10 AWG 4 lead cable Connect the leads of the cable to a fused power panel Make sure the green lead is connected to the panel and the panel is connected to a good earth ground Install in accordance with all local and national electric codes INPUT WIRE AND FUSE SIZE Fuse the input circuit with the super lag fuses or dela type circuit breakers recommended on the Technical page Choose an input and grounding wire size according to local or national codes also see the page Using fuses or circuit breakers smaller than recommended may result in Onuisance shut d from inrush currents even if you are not cutting at high currents PRO CUT 80 LINCOLN A 6 INSTALLATION RECONNECT PROCEDURE FIGURE A 2 RECONNECTION DIAGRAM When received directly from the factory the machines are internally connected for 230 VAC Reconnection RECONNECT PROCEDURE will be necessary if a higher input voltage is used To reconnect the Pro Cut to 460 VAC or to connect back to 230 VAC follow the directions as outlined below Follow this proced
102. ric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 PRO CUT 80 LINCOLN 5 F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS All the status lights begin to blink within 5 seconds of power up Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Make sure the PRO CUT 80 is reconnected correctly for the input voltage being applied Be sure to remove input power and wait at least one minute before changing the position of the input voltage range Switch RECOMMENDED COURSE OF ACTION Perform the Board Resistance Test and Capacitor Voltage Test Perform the Input Rectifier The control board may be faulty Replace The primary power board may be faulty Replace The machine powers up properly but there is no response when the gun trigger is pulled Only the power LED is lit Make sure the torch is connect ed properly to the PRO CUT 80 machine Make sure the air supply is con nected and operating properly Make sure the torch head con sumable parts are in place and in good condition Replace if necessary 1 Perform the Auxiliary Trans 2 Perform the Trigger Circuit 3 Perform the Gas Solenoid 4 Perform the Torch Continuity and Solenoid Test The control board may be faulty Replace The outp
103. rimary winding is redirected or clamped back to each respective filter capacitor when the IGBTs are turned off This is need ed due to the inductance of the transformer primary winding The primary currents also pass through the current transformer which sends a signal to the control board If the primary currents are not equal the control board compensates by adjusting the IGBT gate signals CURRENT TRANSFORMER DISPLAY BOARD WORK ELECTRODE li NOZZLE MAIN TRANSFORMER pes TORCH OUTPUT BOARD 4 CONNECTOR PILOT TRANSISTOR TRIGGER amp SAFETY AIR SOLENOID REMOTE INTERFACE RECEPTACLE ELECTRODE amp TRANSFER CURRENT FEEDBACK ae The firing of both IGBT pairs occurs during halves of the 50 microsecond intervals creating a constant 20KHZ output The secondary portion of the main transformer is made up of two separate windings One secondary winding supplies the electrode to work voltage This is the high current winding which is capable of supplying maximum output current during the cutting process The other secondary winding supplies the electrode to nozzle voltage for the pilot arc current The con ductor in this winding is smaller since the pilot current is considerably less than the cutting current While one winding is conducting the other winding is at a lim ited voltage and aids in the arc transfer to and from the workpiece PRO CUT 80 LINCOLN E
104. s from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes
105. sis tance is abnormal check the continuity zero or very low resistance of leads 366 and 361 between the solenoid and plug J31 See the Wiring Diagram If the leads are good the solenoid coil may be faulty 6 Carefully apply the 12 VDC supply to the solenoid leads at plug J31 positive to J31 pin 6 lead 366 and negative to J31 pin 5 lead 361 With proper air pressure applied the sole noid should activate and air should flow If the solenoid activates but air does not flow check for a restriction in the air line Install plug J31 back into the output power board FIGURE F 7 PLUG J31 LOCATION TEST POINT D29 PRO CUT 80 LINCOLN G3439 PRO CUT 80 OUTPUT TEST POINT F 27 F 27 TROUBLESHOOTING amp REPAIR T2 AUXILIARY TRANSFORMER TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The test wil
106. sure the torch consum 2 The output board may be faulty ables are in place and in good Replace condition The control board may be Make sure the air flow is not faulty Replace restricted The cutting arc starts but sputters Make sure the operating proce 1 Perform the Torch Continuity badly dure is correct for the process and Solenoid Test See the section of this manual The output board may be faulty Replace Make sure the work clamp is connected tightly to the work piece The control board may be faulty Replace Make sure the torch consum ables are in place and in good condition Make sure the air supply is not contaminated with oil or exces sive water Make sure the air pressure is set at 70 psi 448 kPa A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 PRO CUT 80 LINCOLN 5 F 7 F 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The pilot arc is normal but the arc will not transfer to the workpiece Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S CUTTING PROBLEMS Make sure the operating proce dure is correct for the process See the Operation se
107. ted circuit boards Failure to do so can result in permanent damage to the equipment LINCOLN 5 F 53 F 53 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued CAPACITOR REMOVAL 1 Using the 3 8 wrench remove the four screws holding the heat sink to the center panel assembly Take note of the insulator placement for reassembly The four screws have insulating washers on both sides of the panel assembly These must be properly replaced upon reassembly Carefully push the heat sink in towards the center of the machine This is necessary to gain clearance for capacitor s removal Carefully slide the capacitor s from the heat sink assembly Observe polarity markings and terminal position CAPACITOR REPLACEMENT AND P C BOARD REPLACEMENT 1 Carefully slide the new capacitor s into the heat sink assembly Reassemble the heat sink assembly to the center panel using the four screws and insu lated washers previously removed Note insulation placement Position the capacitors to the P C Board for assembly Note the polarity of the capacitors Apply a thin coating of Penetrox A 13 Electrical Joint Compound to the mating sur faces of the P C board and the heat sink and capacitor terminals Mount the P C board to the heat sink and capacitor assembly Make sure the capacitor terminals line up with the holes in the P C board and with
108. tes that 12 VAC is being supplied to the output board from the aux iliary transformer It also shows that the 12 VAC is being rectified to approximately 17 VDC This DC voltage is used to power the trigger circuit and solenoid driver circuits incorporated on the output board LED3 Green This light indicates that the air solenoid driver circuit is functioning When this LED is lit the air solenoid should be activated PRO CUT 80 G3439 PRO CUT 80 OUTPUT TEST POINT sch Le LED4 Green This light indicates that the trig ger circuit on the output board has been acti vated This LED should be lit when the torch or remote trigger is closed This trigger circuit on the output board then sends a signal to the control board LED5 Green This light indicates that the elec trode solenoid driver circuit is functioning When this light is lit the electrode solenoid should be activated The electrode solenoid should be energized during gas air pre flow time During pilot and cutting arc periods the LED should be off When the arc goes out the machine enters the post flow state Two seconds after the start of post flow the electrode solenoid is activated a few times The LED should blink to indicate this activity The electrode solenoid will then be energized for the duration of post flow The LED should be on LINCOLN 5 F 39 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST continued FIGURE F 14 CONTR
109. the direction of the cut Y Use the drag cup to maintain constant standoff for better cut quality and to protect the nozzle from spatter Y Use the drag cup with a metal template to prevent nozzle double arcing 5Y ver Leading Angle X Direction of Travel Y H d LEN Arc Lag Y Finish the cut to be made and release the trigger Y When the trigger is released the arc will stop The gas will continue to flow for 10 seconds of postflow If the trigger is activated within this time period the pilot arc will immediately restart Y If the dross is difficult to remove reduce the cutting speed High speed dross is more difficult to remove than low speed dross Y The right side of the cut is more square than the left as viewed along the direction of travel Y Clean spatter and scale from the nozzle and drag cup frequently Y For gouging tilt the torch about 45j from the work piece and hold the nozzle 1 8 in 3 2mm to 3 160 4 7mm above the workpiece ANGLE OF APPROACH Ke HELD AT a 45 ANGLE I THROUGHOUT GOUGE I ANGLE MAINTAINED THROUGHOUT SAFETY STATUS INDICATOR If the SAFETY status indicators light at any time check the following Check the assembly of the torch consumables If they are not properly in place the machine will not start Make sure that the shield cup is hand tight Do not use pliers or overtighten PRO CUT 80 LINCOLN
110. tly extracting the plugs from the P C board receptacles FIGURE F 18 CONTROL BOARD REMOVAL FROM MOUNTING PINS CONTROL BOARD 7 Using the needle nose pliers and screwdriv 9 er gently remove the control board from the eight mounting pins by depressing the tabs on the mounting pins and carefully removing the board from the pins See Figure F 18 WN Meio Be sure to follow the recommended static free methods for handling printed circuit boards 12 Failure to do so can result in permanent damage to the equipment 8 When replacing the control board align the mounting holes with the eight mounting pins and gently slide the P C board onto the mounting pins until the board snaps onto the pins PRO CUT 80 LINCOLN 5 10 DEPRESS LOCKING TAB ON MOUNTING PIN MOUNTING PIN 8 Replace the five molex type plugs in their respective receptacles Be certain they are securely in place Carefully reposition the front assembly in place and install the four mounting screws previously removed Inspect clear and secure all leads before installing the case wrap around reassembly Using the 5 16 nut driver install the case wraparound F 43 F 43 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician
111. ude dans des endroits humides ou sur un planch 10 er metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse c Maintenir le porte lectrode la pince de masse le cable de soudage et la machine souder en bon et s r tat Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de la faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou atres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fum es toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op erations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment roxique ou autres produits irritants d
112. ure ONLY while the Pro Cut is dis connected from the input power A CAUTION Failure to follow these instructions can cause immedi ate failure of components in the welder 1 Open the access door on the side of the machine Connection instructions are also included on the inside of the door 2 For 230 Position the large switch to 200 230 See Figure A 2 For 460 Position the large switch to 380 460 See Figure A 2 3 Move the OA lead to the appmpriate terminal AA WADMNG CH oe Disconnect input power before inspecting or servicing machine Do not operate with wraparound removed ELECTRIC Do not touch electrically live parts SHOCK X Only qualified persons should install CAN KILL use or service this equipment 1 BE SURE POWER SWITCH IS OFF 2 CONNECT LEAD A TO DESIRED INPUT VOLTAGE RANGE 440 460V 380 415V 220 230V 200 208V 3 POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE Ens 1 VOLTAGE 380 460V 9 9 Bg D VOLTAGE 200 230V PRO CUT 80 LINCOLN A 7 INSTALLATION GAS INPUT CONNECTIONS Supply the PRO CUT 80 with clean compressed air or nitrogen e Supply pressure must be between 80 psi and 150 psi e Flow rate should be approximately 6 0 cfm 170 I min NOTE Oil in the air supply to the PRO CUT 80 can cause severe problems Use only a clean air supply e Connect the gas supply to the PRO CUT 80 s pneumatic nipple at
113. ut power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equip ment Do not touch electrically hot parts or electrodes with your skin or wet clothing Always connect the 80 grounding terminal located on the side of the Case Back Assembly to a good electrical earth ground Always wear dry insulating gloves Y Turn the 80 Power Switch OFF when connecting power cord to input power Only qualified personnel should install use or ser vice this equipment SELECT SUITABLE LOCATION Place the PRO CUT 80 where clean cool air can freely circulate in through the rear louvers and out through the front bottom opening Dirt dust or any foreign material that can be drawn into the machine should be kept at a minimum Failure to observe these precau tions can result in excessive operating temperatures and nuisance shutdown of the machine A source of clean dry air or nitrogen must be supplied to the PRO CUT 80 Oil in the air is a severe problem and must be avoided The supply pressure must be between 80 and 150 psi The flow rate is approximate ly 6 0 cfm 170 I min Failure to observe these pre cautions could result in excessive operating tempera tures or damage to the torch STACKING The PRO CUT 80 cannot be stacked LIFTING AND MOVING AA WARNING FALLING EQUIPMENT can cause injury Do not use the pull handle on the optional undercarriage if i
114. ut power board may be faulty Perform the Output Board Resistance Test When the torch trigger is pulled air begins to flow but no pilot arc is established Make sure the torch consum ables are in place and in good condition Replace if neces sary Make sure the air pressure is set at 70 psi 448 kPa Make sure there are no kinks or restrictions for air flow in the torch cable 1 Perform the Torch Continuity and Solenoid Test 2 Perform the Low Voltage Circuit Test The output board may be faulty Perform the Output Board Resistance Test The control board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 PRO CUT 80 LINCOLN 5 F 6 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS The air begins to flow when the Make sure the air pressure is 1 Perform the Torch Continuity torch trigger is pulled There is a Set at 70 psi 448 kPa and Solenoid Test very brief pilot arc Normal is 3 seconds The sequence is repeat ed with subsequent trigger pulls Make
115. void elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help the technician determine if the output power board is faulty MATERIALS NEEDED 5 16 Nut driver Analog Volt ohmmeter 7 16 Wrench This procedure takes approximately 18 minutes to perform PRO CUT 80 LINCOLN 5 F 21 F 21 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD RESISTANCE TEST continued FIGURE F 4 OUTPUT POWER BOARD LEAD LOCATIONS G3439 PRO CUT 80 OUTPUT TEST POINT D25 TEST POINT D29 X20 xo TEST PROCEDURE 1 Remove input power to the PRO CUT 80 4 Carefully remove leads X4 X2 B21 X20 X40 machine and plugs J33 and J32 from the output 2 Perform the nput Filter Capacitor power board See Figure Fe Discharge Procedure detailed earlier in this 5 Using the analog ohmmeter perform the section resistance checks Ger Table F 4 3 Remove the torch assembly from the machine PRO CUT 80 LINCOLN 5 F 22 F 22 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD RESISTANCE TEST continued TABLE F 4 OUTPUT POWER BOARD RESISTANCE TEST POINTS Probe J33 Pin4 to Probe Terminal X2 Pro
116. ways be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations LINCOLN 5 SAFETY PRECAUTIONS DE SURETE 5 Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce 8 manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter tou jours tout contact entre les parties sous tension et la 9 peau nue ou les v tements mouill s Porter des gants Secs et sans trous pour isoler les mains b Faire tr s attention de bien s isoler de la masse quand on so
117. wer Board Resistance Test and Capacitor Voltage Test F 15 Output Power Board Resistance Test F 20 Torch Continuity and Solenoid Test ccceccesseecceeeeseeeeeeeeseceeeeeeeseceeeesesseeeseeseeseeeeeees F 23 Air Gas Solenoid Test F 25 T2 Auxiliary Transformer Test eeseeeeseeseeeeeessseseeeeeeee nemen ennemi nnnm F 27 IJ ear EIER F 30 Low Voltage Circuit Test iei ies orient irte cease certus idles o dna RES Eege F 35 Replacement Procedures Control Board Removal and Replacement ssnnssssnnenreeeeeeeeennnnnnnrnnenrerrnnnnnnnnnnnneeennna F 40 Display Board Removal and Replacement sssssssssseeeeeeeeeeeenes F 43 Output Power Board Removal and Hepnlacememt F 46 Primary Power Board and Filter Capacitor Removal and Replacement F 50 Input Rectifier Bridge Removal and Heplacement F 54 RRetest after IRE DANN iz sitet geesde ERR EE ne plex utu eR epum ea F 57 PRO CUT 80 LINCOLN TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting
118. wer board IGBT heat sink Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond the duty cycle and output rating If excessive operating temperatures should occur the thermal status indicator will light and the thermostat will prevent output voltage or current Thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fan is oper ating normally the power switch may be left on and the reset should occur within a 15 minute period If the fan is not turning or the air intake louvers are obstructed the input power must be removed and the fan problem or air obstruction must be corrected PRO CUT 80 LINCOLN E 8 E 8 THEORY OF OPERATION INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT is a type of transistor IGBTs are semicon ductors well suited for high frequency switching and high current applications Drawing A shows an IGBT in a passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain terminal of the IGBT may be connected to a voltage supply but since there is no conduction the circuit will not supply cur rent to components connected to the source The cir cuit is turned off like a light switch in the OFF position Drawing B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the
119. ws that attach the filter cage to the back panel assembly then slide the cage away from the back of the machine and remove Next twist the clear filter bowl until it comes off be careful not to lose the o ring seated at the top of the bowl threads Unscrew the filter element and replace with new element Assemble parts in reverse order as described above Inspect the cable periodically for any slits or punc ture marks in the cable jacket Replace if neces sary Check to make sure that nothing is crushing the cable and blocking the flow of air through the air tube inside Also check for kinks in the cable periodically and relieve any so as not to restrict the flow of air to the torch PERIODIC MAINTENANCE A WARNING ELECTRIC SHOCK can kill 0 e Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replacing consumables Change consumables as required 1 Thermal Protection Two thermostats protect the machine from excessive operating temperatures Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond the duty cycle and output rating If excessive operating temperatures should occur the yellow thermal LED will light and the thermostat will prevent output voltage or current Thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fan

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