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Viper Service Manual - Red-D

1. ITEM REQ D PART NO DESCRIPTION Ci T 913490 92 3300750 C2 C8 C10 C13 C14 C17 C20 31 16668 5 022 50 C23 C24 C29 C31 C34 C35 C36 C37 C39 C40 C41 C47 C53 C55 C58 C63 C64 C65 C66 C68 C69 C73 C74 C75 C3 1 813490 121 1000735 C4 C18 2 813480 63 47750 C5 1 813490 71 100750 C6 i T11577 52 0047 or 00571400 C7 1 813490 72 50750 C8 i 813490 93 27735 C15 C16 C32 C33 C42 5 516668 11 1 50 C18 C25 C50 3 513490 25 43 7738 C21 C26 C28 C30 C54 C57 8 S13490 42 T 0735 c62 C71 C22 C43 C44 3 516665 9 150pF7 100 C45 1 816668 4 2700pF750 C46 C52 2 S16668 13 TOpF 7100 C48 i 616668 8 330pF7 100 C56 1 13490 108 157100 C58 1 S16668 3 100pF7 100 C60 1 813480 126 018750V C61 1 513490 19 1 8720 C72 1 516668 10 4700pF 50 C76 1 13490 135 1 0 50V Di D2 D3 D4 DS DG D7 D8 DS i5 Ti2188 1 1N4004 D 14 D20 D23 D25 D26 D27 Did D11 Die Di3 4 T12705 37 1N5822 SCHOTTKY BARRIER DIODE EO 015 016 017 018 4 T12705 34 IN4936 r 7 V D21 1 Ti2
2. 15V Aes 100K J10 1 KE E UNDERVOLTAGE PROTECTION Z Ka ae lt oci 2 m g 8 3 C3 Lx fel Is Ga Oar RELAY DRIVE 8 8 B 2 8 FROM CONTROL BD ges 23 Eg 2288 cig 18 zB Q5 SSES 35V wo Sed Ci 28888 100V fp 4 RECONNECT i i SI Op 200 9 A 9 209 POSITIVE INPUT RECTIFIER V Ri TEST D e F be 1 RI3 Ri Ris RIG a UN Ga re J 150K 150K 150K 150K S bg 27 5W R10 RH R12 I1 1 00K Be m m 5 PEAK DETECTOR gL rm ye dch m be W I 10W 10W 10W i i Sue 1w 1 0K 1 00K 1 00K 1 00K A 1A E 5W L i at H ocn zl S Dza 1000V CAPACITOR E G A 7 ONYAT 3V ah y gee s 5 le F Fl H E PRECHARGE i EE Zar ww T 205 V E 5 e e e O 8 Sz 5 lt 48 78 N TRANSFORMER S z Se Z PRIMARY 5 B 10 0 g S52 E e o _ ik GEEER zi 825VDC FILTER 5W ol aussa d NOMINAL CAPACITOR 100 h O NI 18V R6 TRANSFORMER sw O PRIMARY Po e P O 208 RIO R109 e tik 10 0 h 8 DZ5 ca Sw SW X la C7 z5 G ETS ge S ey 1000V T1431 REF v T 28 m M Hr S eus TB ovERVOLTAGE F 15V 27 SW Ed ZS OL A sw sw PROTECTION gi gl S B2 DZ7 amp 5w v mE o 15V uz
3. woo a gt z ASE ort NOILOSNNOO ONNOH uge os NOLLONNOO EH A T i NOLLOSNNOO NOWWOO AN 3000 MORE V NIAYH S TOLNOO 40 RICH HO SININOJWOO NG JHL MOHS LON EY gt ANN WYHOVIG SIH GHVO8 313 WICH JO ALMTIGVIONVHOWSINI JHL ONILO344Y LNOHLIM 1N Od Z0uNOS eum eg O JONYHO AVN QuVOG LINOWIO GBINIed Y NO AHLINOHIO HO SININOdNOO 3ONS WN Y 21000 04 y 03141034S 3SIMYSHLO SSN vn s3000 SILON Sav JO SHOLSISSE 0 QIN SUOLIOYYO 3 U3d STOBNAS IVOILO3H pA e pH NOLLVINHO3NI TVH3N39 Kess ATE E eb A08 EE dou Le m E P D VER amp i wy Blech ALIANS 5 a 09 ose en wer Di E 70 918 Siu t V can AE AGL 8 san Y nR ci z nos x H i S m dozz E 9 ovr 8 eu S56 ege r gt Y i C orf eal z Xt or Hm Im i 13934 orr 00r Or o o D orf 215 E e Aim A E NI LE 2 wm 2 z AE 5 do ovr 5 UF z9 mm B LL EIE 8 b ou gt eg 5 Es mm ees mb OH 5 20 d 0 24 dd oor OOF e Mie 908 ATE iod 01NOO E 8E ng Eu li Y spe dt Hm ET ASL TI Do VER N ni gt A08 uve Bn ovr y u mr pn M18920 10 31 97D LINCOLN E Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your
4. 4 4 8 ls a s E mm mm mmm eee eee mom mmm momo mm m D v ITEM REQ D PART NO IDENTIFICATION B1 B2 2 T13157 14 TAB TERMINAL B11 B12 B21 3 523006 TERMI NAL C1 C3 CIL CIS 4 S20500 5 00 15 2000V c2 1 IS 13490 42 1 07 35 C5 C6 C7 C29 4 520500 1 171000 C8 C12 C17 C19 4 IS 16668 7 820pF 50 C9 C 10 C21 3 IT L1577 52 0047 or 005 1400 C13 1 IS 13490 72 50 50 C 14 1 IS 13490 71 100750 C 16 1 IS 13490 93 27 35 C18 T S 13490 121 1000 35 C20 C22 C23 C24 C25 5 IS 16668 5 022 50 C27 C30 a IT 11577 58 0047 3000V C28 1 IS 16668 11 1 50 C3 1 C32 2 IT 11577 46 05 600V D 1 02 03 04 D5 06 07 08 D9 22 IT 12199 1 IN4004 D 10 011 D13 D14 D15 D16 D 17 D19 D20 D2 1 D23 D25 D26 D 12 D22 2 T 12705 34 IN4936 D 18 024 2 T12705 50 DIODE D27 028 D29 030 4 T 12705 46 1000v 34MP DI ODE DZ 1 022 DZ9 DZ 10 4 IT 12702 29 IN4744A D23 1 T12702 23 IN5352B DZ7 028 DZ 11 DZ 12 4 IT 12702 19 1N4742 J30 1 S 18248 6 HEADER J31 1 S 18248 10 HEADER J32 1 IS 18248 14 HEADER J33 1 IS 18248 4 HEADER J34 1 IS 18248 8 HEADER L1 i IT 122 18 2 5 6mH LED 1 LED2 2 IT 13657 2 RED LED LED3 LED4 LEDS LEDS 4 IT 13657 3 GREEN LED OCI 1 1 IS 15000 26 OPTOCOUPLER LOGI C OUT 0C12 OCI 3 OCL 4 3 515000 10 OPTO ISOLATOR 0 1 03 07 08 4 IT 12704 73 IC PKG MOSFET SS 02 04 2 T 12704 80 HEXFET TRANS SS 05 1 IT 12704 68 2N4401 06 1 IT
5. OUTPUT FAN MOTORS CONTROL AUXILIARY TRANSFORMER GENERAL DESCRIPTION The Pro Cut 55 is a constant current continuous con trol plasma cutting power source The inverter based power supply design is controlled by a microprocessor control board The control system has a safety mech anism to insure that the nozzle and electrode are in place before cutting or gouging The Pro Cut 55 initi ates the plasma arc with a simple yet reliable touch start mechanism This system eliminates many of the problems associated with hi frequency type start sys tems CURRENT TRANSFORMER CONTROL BOARD ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE DISPLAY BOARD jS MEETS ELECTRODE TORCH Cl CONNECTOR MAIN TRANSFORMER OUTPUT BOARD ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE INPUT LINE VOLTAGE CONTACTOR AND MAIN TRANSFORMER The single phase or three phase input power of 200 230 or 400 to 460 volts AC is connected 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 fans the control board and the plasma output board NOTE Unshaded
6. 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 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 ohms Less than 100 ohms Greater than 1000 ohms 6 If any of the resistance checks are not correct the 8 Reconnect the leads and plugs previously output power board is faulty Replace See the removed Output Power Board Removal and Replacement 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 LINCOLN amp 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 pl
7. PRO CUT 55 LINCOLN Also see Output Board LED CONTROL BOARD 15VDC P R O C E S S O R 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 344 positive to plug J32 pin 14 lead 312 negative Suse Figure 10 Also see and related figures If the correct voltage is not present perform the Law Voltage Crai If the correct voltage is present in the above test carefully pull the torch trigger A WARNING PILOT ARC CUTTING ARC AND HIGH VOLT lt S o AGE MAY BE PRESENT AT THE TORCH HEAD Perform this test with the air input removed to avoid a pilot arc at the torch F 32 10 11 12 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued With the torch trigger activated check the voltage at plug J32 pin 3 lead 344 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 55 Perform the Input Filter Capacitor Discharge Procedure Check the continuity of leads 344 and 312 between the output board and the control board See the and Figure F 10 If all of the above checks are OK the con trol board may be faulty Replace LINCOLN P F 32 F 33 TROUBLESHOOTING amp REPAIR TRIGGER CIR
8. factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided 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 NOTE ELECTRICAL DIAGRAMS G 7 Control Schematic G3327 HV GATE DRIVE PULSE XFMR GND NN CONTROL POT E 10 0K PURGE 8 0MHz T C48 330p 100V SAFETY RESET COM
9. 10010W OSOS 150K 1 4W R17 R18 R77 EIN NJN i cie 9400 1821 19400 2673 100 1 4W 1 82K 1 4W R29 R73 R37 R30 R74 R55 R81 R91 R19 R28 R32 R71 R72 R33 R38 R58 R36 R52 R89 R90 R92 kel 0 a 0812 41 4648 12 CO j 00 3321 9400 6191 9400 1502 Gs M nm wm 4 ce Ix R39 R53 9400 1652 9400 3323 00 1372 1 SB po we pI Kop i a i 267K 1 4W 10K 1 2W TRIMMER 1500 OHM 5 WATT RESISTOR O 389XK14W O O OE 1 4W 13 7K 1 4W R40 R56 i ep ep i 00 1002 00 2213 O O O oO S R BR Es 10K 1 4W 221K 1 4W R84 R87 R54 R61 94 fi Di R95 ROG 2 wm wm i 00 5620 00 2801 00 2001 00 4751 00 4752 00 2211 2300 79 wm NM oO Ln rail wm i ce Ln is m i M wm re ee codo Bm kel feel ra pure e E 13000 46 562 1 4W Doo TRANSFORMER 15128 10 VOLTAGE REF 9 X1 1 X2 1 i 15128 4 15128 18 LM224 OP AMP QUAD OP AMP 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 provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise
10. BUFFER LAYER p lt INJECTING LAYER DRAIN A PASSIVE POSITIVE VOLTAGE o GATE SOURCE Q ZA ZA lt BODY REGION lt DRAIN DRIFT REGION lt BUFFER LAYER lt INJECTING LAYER DRAIN B ACTIVE LINCOLN amp 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 positive 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
11. Control P C Board Assembly G3328 1 LINCOLN P ELECTRICAL DIAGRAMS 7 71 IT SEE SN 1 l M ae a 1 PRO CUT 50 CONTROL Li ML BY 1 tho le bel lb e espe N oN ste BEER e is je i 1 i PTT TT T T TEE ot TTT m i A 1 X8 d X18 ale EEBS bas C Y D SU TE LLLI ERE D H y F Slam e Bee s d vE gd ZE Ei X5 R8 SS t MI I EF EE 2 mee ESCH H C3 m l ju Q Tri
12. F 49 F 50 F 50 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR 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 perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 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 Slot Head screw driver Torque wrench 3 8 Wrench Penetrox A 13 Lincoln E2529 Electrical Joint Compound This procedure takes approximately 40 minutes to perform LINCOLN P F 51 F 51 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued FIGURE F 23 PRIMARY POWER BOARD REMOVAL REMOVAL PROCEDURE s Remove input power from the Pro Cut 55 machine Remove the case wr
13. I invalidate your factory warranty Individual Printed Circuit Board Components are not troubleshooting and repair since it may compromise the quality of the design and may result 00 INDIININ SLINOHIO N33138 NOLLV1OSI Wei wei ye ye EEN ES MSL MSL yi yi e ou osu 0001 820 wm eld O INYA 101ld 2s iod lt Sed 2 g 2S a 8 amp id MOL Ke L Kt Stoo JE o O ler 2 m E Ps aedi er V peg ET 3TIZZON D Y zg 8 Ke 300419313 300419373 W3AHOJSNVuL Men NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs w available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board leve in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LINCOLN E ELECTRICAL DIAGRAMS G 4 Power P C Board Schematic L10616 15V
14. 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 Contents 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
15. 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 LINCOLN P F 47 idi TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD REMOVAL amp REPLACEMENT continued FIGURE F 21 OUTPUT POWER BOARD REMOVAL OUTPUT POWER BOARD PROCEDURE 1 Remove input power to the Pro Cut 55 3 Locate the output power P C board and machine associated lead and plug connections See 2 Remove the case wraparound and perform Figures F 21Jand F 22 the Input Capacitor Filter Discharge Procedure detailed earlier in this section LINCOLN P F 48 F 48 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD REMOVAL amp REPLACEMENT continued FIGURE F 22 OUTPUT BOARD LEAD LOCATIONS G3326 PRO CUT 55 OUTPIUT dE J3 4 Using the 7 16 wrench remove 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 and J33 from the output power board A C
16. Probe 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 6 If the power board does not meet the 7 If the power board passes the resistance acceptable readings outlined in Table F2 test the IGBT portion of the board is good the board is faulty Replace See However other circuits on the power board Board Removal and Replacement may be faulty These circuits are NOT readi ly tested or serviceable NOTE Complete power board and filter 8 Reconnect leads 201 204 205 and 208 capacitor replacement is recom to their appropriate terminals mended PRO CUT 55 LINCOLN P 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 55 connected for 400 VAC and above and with the appropriate input voltage applied TEST PROCEDURE 1 Remove main input power to the Pro Cut 55 2 Perform the Input Filter Capacitor
17. Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase 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 powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 h To avoid scalding do not remove the radiator pressure cap when the engine is 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors a ELECTRIC AND oa E MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame weld Sieg 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
18. 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 216 383 2531 or 1 800 833 9353 PRO CUT 55 LINCOLN P 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 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 Tel Operation section of 13 The output board may be faulty this manual Replace Make sure the work clamp is connected tightly
19. 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 on the top and 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 capacitor discharge proce dure FIGURE D 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS POWER BOARD INSULATED GLOVES UPPER CAPACITOR TERMINALS LOWER CAPACITOR TERMINALS INSULATED PLIERS LINCOLN P D 3 MAINTENANCE ROUTINE MAINTENANC
20. cate EI 203A F ei e e 9 zE LN foe RECONNECT 53 a pave DIE 7 Seet MISCONNECTION ae o ei ER ety PROTECTION 26 268 RH TEST_8 RECONNECT e fru BE z SE NUMBER FROM o S 1 004 R61 CONTROL d 2 T go Zb SIE 150K BOARD fey eg uu aw dp PWM DRIVE ad m 3 hit 8 150K 1 00K 1 00K 1 00K 1 00K E R43 R44 N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE NOTES DA SEI a 8 E pag R47 Lil zu S o o V F CONVERTER An El e 1000V E gt 5 gt c t e ANSORA A E Lelee R88 E T LT 5 Ga ca 15 150K 332K 16 5K 6 19K 15 0K 1 5 w ai PRIMARY E VV Tar Al SC 1K 5 p X d Ze a wll l 5 2 sw Nal r Ch TO CONTROL BD Ka 325VDC FILTER BP i a s V ot 1 2 E C10 Rr NOMINAL CAPACITOR B n m2 e p T ug ol e o z 5w e ms e ne R85 d 15 0 a Ci 50K 332K 10 0K E eer a 201 c dt E TEST_A n em p9 0O RS Fis E 15V E2 ww L TRANSFORMER D K ww T gt PRIMARY
21. contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 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 55 LINCOLN P F 26 F 26 TROUBLESHOOTING amp REPAIR AIR GAS SOLENOID TEST continued FIGURE F 6 AIR SOLENOID TEST PROCEDURE 1 2 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 resis tance is abnormal check the continuity zero or very low resistance of leads 366 and 361 between the solenoid and plug J31 AIR SOLENOID 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
22. soudage Utiliser des lunettes avec 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 55 LINCOLN amp MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page rr E i iv E UE e Me Section A Technical Specifications ENEE A 2 Salety e E A 4 Select Suitable Location A 4 edu A 4 Ling and Moving ET A 4 Bil e DEE A 4 High Frequency Interference Protection cceccceeeeeeeneeeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeeseaaeeeeesnnaeeeeeseaes A 4 Input Electrical Connections EEN A 5 Input Power Cord Connector Installation A A 5 Frame Grounding e EE eEESEEH A 5 Gas Input Conpnectlons nennen nnne Didi siansa dahi danai hada siagan nnn ss nnne nnns A 7 Output Connections des cin
23. such as plate chemistry plate surface 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 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 LS Machine Output Setting DRAG thru 1 16 Standoff Output Setting Min
24. 12704 86 TRANSISTOR ERT 1200V 45A R 1 R3 R4 R21 R37 R38 R39 7 IT 14649 11 1607 10W R2 1 S 19400 5110 511 174W R5 1 IT 14648 2 25 5W R6 R8 R28 R58 4 IS 19400 1501 l SK 1 4W R7 Y IS 19400 3320 332 1 4W R9 R 13 R27 3 IS 19400 2213 221K 1 4W R 10 R 1 1 R24 R29 4 S 19400 1211 1 21K 1 4W R 12 R26 2 IS 19400 3921 3 92K 1 4W R 14 R15 R16 R17 R33 5 518380 3 PTC THERMI STOR R 18 R19 2 523995 1 SHUNT RESISTOR 001 OHM 4W R20 R54 2 IS 19400 2001 2 0K 1 4W R22 1 S 19400 3321 3 32K 1 4W R23 R25 2 T 14650 4 15W 2500 OHM RESISTOR R30 1 5 19400 4751 4 75K R31 R32 2 IS 19400 4750 475 174W R34 R61 2 IS 19400 3741 3 74K 1 4W R35 1 T 14649 4 100 10W R36 1 S 19400 1000 100 1 4W R50 R51 R52 R53 4 T14650 1 1500 OHMS 15 w RESISTOR R55 R60 2 S 19400 1001 IK 1 4W R56 1 IS 19400 8250 825 l 4W R57 1 S 19400 825 1 8 25K 1 4W R59 1 S19400 5111 5 LIK 1 4W TP 1 TP2 TP3 3 IT 13640 20 480V 180J MOV TP4 1 IT 13640 9 20J TPS 1 IT 13640 15 15J x1 1 IS 150 18 19 1C DRIVER FET 6A 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 provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design
25. 13490 48 47 160 C14 1 13490 71 100 50 C16 1 13490 39 18 15 C18 1 513490 121 1000735 C19 1 516668 9 150pF 100 C20 C22 C23 C24 4 516668 5 022 50 C27 1 13490 42 1 0 35v C28 1 T11577 58 0047 3000V 01 D2 03 04 D5 06 07 D8 D9 22 T12199 1 1N4004 010 011 D13 D14 D15 D16 017 019 020 021 023 025 026 D12 D22 2 T12705 34 1N4936 D18 D24 2 T12705 50 DI ODE DZ 1 DZ2 024 DZ5 DZ6 5 T12702 29 1N47444 DZ3 1 T12702 19 1N4742A J30 1 518248 6 HEADER J31 1 518248 10 HEADER J32 1 518248 14 HEADER J33 1 518248 4 HEADER LED1 LED2 2 T13657 2 RED LED LED3 LED4 LEDS 3 T13657 3 GREEN LED DCI 1 1 15000 26 OPTOCOUPLER LOGI C OUT OC1 2 0C13 OC14 2 515000 10 OPTO ISOLATOR 01 03 2 T12704 73 IC PKG MOSFET SS 02 04 2 T12704 80 HEXFET TRANS SS R 1 R37 R38 R39 4 T14649 11 160 10W R3 R4 2 T14649 4 100 10W R5 1 T14648 4 5W 40 OHM RESISTOR RE 1 19400 4752 47 5K 1 4W R7 R20 R54 3 S 19400 3320 332 1 4W R8 R10 R 1 1 R 12 R24 R26 R28 9 19400 1211 121K 1 4W R31 R32 R9 R 13 R27 R42 R47 5 19400 1003 lOOK 1 4W R14 R15 R IG R17 4 518380 3 PTC THERMI STOR R18 R19 2 23995 1 SHUNT RESISTOR R21 1 T 14648 20 150 OHM 5 WATT RESISTOR R22 1 19400 3321 3 32K 1 4W R23 1 519400 1002 lOK 1 4W R29 R33 2 19400 2671 2 67K 1 4W R30 1 519400 4751 4 75K R34 1 19400 3741 3 74K 1 4W R35 1 T14648 17 270 OHM 5 WATT RESISTOR R36 1 19400 1000 100 1 4W R40 R
26. 2 Filter Capacitor Conditioning Pro Cut 55 400 460 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 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 55 LINCOLN P D 4 Maintenance FIGURE D 2 MAJOR COMPONENT LOCATIONS Machine Base 1 2 Case Front 3 Output Power Board Assembly 4 Case Wraparound 5 Control Board 6 Case Back 7 Primary Power Board 8 Auxiliary Transformer 9 Main Transformer AWA EXE LINCOLN E Section E 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory of Operation Sie tees enced steeds esee apex EN Seed eege Section E Gerleral DescriptiOn udcoscu tentur S ERR R
27. 2531 or 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 55 LINCOLN P F 12 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 1 Remove main input power to the machine 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 this section Diagram 3 Locate the input rectifier D1 and lead loca tions See Figure F 2 FIGURE F 2 INPUT RECTIFIER AND LEADS 207 207A _ zz LC 0 Z Je BN A amp EE s m 1 O YIL C QS 0 Te O 209 PRO CUT 55 LINCOLN P F 14 F 14 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST continued TABLE F 1 INPUT RECTIFIER TEST POINTS TEST POINT TERMINALS ANALOG METER X10 RANGE 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 t
28. 5 VDC on the control board a LED2 should be lit when 5 VDC is pre sent See Figure F 14 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 15 VDC should be present at leads 216 to 219 See Figure EIS 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 LINCOLN P F 37 F 38 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST continued FIGURE F 13 OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs G3326 PRO CUT 55 OUTPUT PRO CUT 55 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 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 indi
29. 50V T12199 1 1N4004 1N5822 SCHOTTKY BARRIER DIODE D15 D16 D17 D18 D21 DZ1 DZ2 J1 7 4 1N4936 112702 19 1N4742A J2 J3 J4 J5 1824 HEADER 18248 10 HEADER 18248 16 HEADER 518248 6 HEADER 518248 8 HEADER LED1 LED2 LED3 Q1 02 08 Q4 119657 2 RED LED 112704 68 2N4401 Q5 Ri R2 R46 R132 R3 R30 R32 R33 R34 R36 R37 R38 R39 R4 R5 112704 80 HEXFET TRANS SS 112704 69 HEXFET TRANS SS 1 0 OHM 5W RESISTOR 19400 2671 19400 2430 19400 30R1 2 67K 1 4W 243 1 4W 30 1 1 4W 619 1 4W R6 R7 R8 19400 6190 19400 8251 19400 3921 8 25K 1 4W 3 92K 1 4W 2 0K 1 4W R9 R88 R103 R10 R42 R95 R96 R11 R12 R13 R14 R17 R26 R27 R49 R51 R59 R61 R62 R63 R68 R69 R81 R84 R93 R94 R104 R106 R108 R134 R138 R139 R152 R153 R154 R156 R158 R160 R164 R165 R166 R178 R179 R180 R181 R182 19400 2001 19400 1001 1K 1 4W 19400 5110 511 1 4W 19400 3320 332 1 4W 19400 1002 x R18 R19 R47 R53 R55 R57 R85 R149 R157 R20 R22 R110 R111 R124 R125 R126 R127 R128 R142 R143 R144 R145 R146 R147 R901 R21 R23 1 2W TRI 8 19400 5111 5 11K 1 4W 10 1 4W a ES SH m D 18 2K 1 4W R24 R35 2 R28 R112 R115 R116 R117 7 R118 R119 221 1 4W 3 32K 1 4W 1 e R29 R91 R102 3 3 R40 R73 R107 R43 R44 R45 R136 R137 R170 R171 R172 R48 R67 R70 R87 R101 R52 R54 R56 co 519400 768 9400 4751 19400 3321 1
30. ET0721 1 aii steer oet thea ne G 5 Display Board M18920 ite ette Eee teer tee u ee n rares s esee esr Febr EU ee peus G 6 Control Schematic G3327 esris anan aaa aaea eene eene a snnt nnns sinn aaiae G 7 Control P C Board Assembly G3328 1 sese G 8 Control P C Board Assembly 3328 2 essei ai gai G 9 Output P C Board Assembly G33226 1 E G 10 Output P C Board Assembly G3326 2 sse enne nennen nns G 11 Power P C Board Assembly G3172 1 sse enne G 12 Power P C Board Assembly GO 72 21 G 13 PRO CUT 55 LINCOLN G 2 ELECTRICAL DIAGRAMS Wiring Diagram 208V 230V 460V L10634 G 2 v690L1 386 671 quvoag 40 3GIS IN3NOdWOO WOH3 Q3M3IA 3ON3h03S SNIB3BIWDIN ALIAVO HO103NNOO MOTHA A NMO H9 N amg n ALIHM M WER EBI MOVIE 8 3000 40109 3NIHOVIW 40 INOS 2 S14 d3d S108AAS 1Vv9I819313 LAS Q3HO 1VIN V SHY SHOLIODVdYO Z9 ANY 19 NOILVHAdO Ak Dpp HOS SI NMOHS NOLLO3NNOO 39VL 10A LAdNI HOS NOLLO3NNOO 31VlBidOBddYV NO QV31 V 39v Td Y3EWNN 3009 NOWIAOO Y 9NIAVH AH LIInOHIO HO SLN3NOdINOO LOWX 3HL MOHS LON AVIA IWvHOVIG SIHL QuvO8 313 14WOO Y 20 ALTIIBV3ONVHOU3LNI JHL Q N ON gar r De 9 ooo oo Oo O0 O0 O 0 o o oo oo o o o Oo o o to et om 9 1 D I Ir oer LEI gr er er ont OION OS 99 M aw CE 196 Hom uri 908 3ufiSS3ud zZ E A Ie pezos oer XVN A even e LINOHIO 9NIQNOS 3ALLO31
31. Pro Cut System sessseeeeeeee B 8 PRO CUT 55 LINCOLN P B 2 OPERATION uiis OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS A 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 55 LINCOLN amp B 3 B 3 OPERATION GENERAL DESCRIPTION The Pro Cut 55 is an inverter based constant current continuous control plasma cutting power source It provides superior and reliable starting characteristics cutting visibility and arc stability When cutting expanded metal the Pro Cut 55 out performs the
32. See Figure F 18 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 8 When replacing the control board align the mounting holes with the eight mounting pins and gently slide the PC board onto the mounting pins until the board snaps onto the pins LINCOLN P 10 11 12 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 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 Departme
33. Test Procedures i F 10 Replacement Procedures EEN F 40 Electrical DIagrams orn tetra Pride ge EE EELER Section G LE ICRUETITE P309 Series A P210 K PRO CUT 55 LINCOLN amp Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION Installation Technical SpecifICations EE A 2 Safety Proca tiOnS P A 4 Select SUITADISO LOCAU E A 4 le lee EE A 4 Bnet mS A 4 RERO A 4 High Frequency Interference Protection ccsecccecesseeeceeeeseeeesenenseceseeseseeeeeeeseseeeseesenseeeeeeees A 4 Input Electrical Connectloris ein ore utn xv RR EFE H NER eaa ENEE cveseysincgseeexaiaeiiateres sess A 5 Ground COnneCtiOn seisein A 5 Input Power Cord Connector Installaton enne A 5 Input Wire and Fuse Glze ee A 5 Reconnect Proceduro iseni ne A 6 Gas INPUT Corinectioris iciiie oe ideni aang adien recen dea ves Diada ia ER nk sweat ANAE Ce ven A 7 OUTPUT COMMECTIOINS ce rm A 8 Eeee EE EE E A E AT A 8 PRO CUT 55 LINCOLN P A 2 A 2 INSTALLATION TECHNICAL SPECIFICATIONS PRO CUT 55 INPUT RATINGS Single Phase Input Input Currents Rated Output Amps Voltage and Hertz 208 1 60 60 55 230 1 60 55 55 460 1 60 30 55 208 1 60 44 40 230 1 60 40 40 460 1 60 23 40 Three Phase Input Input Currents Rated Output Amps Voltage and Hertz 208 3 60 31 55 230 3 60 28 55 460 3 60 17 55 208 3 60 23 40 230 3 60 21 40 46
34. 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 each of the secondary windings 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 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 electrical 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 1 DISPLAY BOARD Ld sor gt Z mt GE TRIGGER amp SAFETY ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE ELECTRODE SO
35. and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 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 55 LINCOLN amp 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
36. areas of Block Logic Diagram are the subject of discussion LINCOLN P E 3 WORK ELECTRODE NOZZLE TORCH CONNECTOR C O ozmroo mooz omrm TRIGGER amp SAFETY AIR SOLENOID POWER BOARD MAIN EM TRANSFORMER OUTPUT BOARD Ieren I INPUT SWITCH RECTIFIER CAPACITOR R R ZN gd C7 E rot IN CURRENT 3 TRANSFORMER r CAPACITOR Cc H AIR B PRESSURE 9 SWITCH i i j ELECTRODE amp TRANSFER 9 CURRENT FEEDBACK PILOT ENABLE CONTRO BORED ELECTRODE SOLENOID ENABLE 18 36VAC AIR SOLENOID ENABLE 3 TIERS G BZ THERMOSTATS DA EB E 1 af xf w t Y FAN r om 1 DISPLAY BOARD ig c UXILIARY A 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 input relay 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 transformer primary winding with DC current flow See IGBT Operation discussion and diagrams in this section
37. 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 Point G3326 PRO CUT 55 OUTPIUT po ME est 9 T d d dv PRO CUT 55 LINCOLN P 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 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The test will 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
38. 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 55 comes standard with an air regulator coarse air filter and pressure gauge The machine also comes with an 11 foot 3 35m input power cord There are four different torch and cable systems to choose from hand held torch with 25 foot 7 62m or 50 foot 15 24m cable machine and robotic torch both with 25 foot 7 62m and 50 foot 15 24m cable Consumables are included with each Pro Cut pur chase so that cutting can begin right out of the box Consumables can also be ordered as individual pack ages An undercarriage kit can be ordered separately The Pro Cut 55 initiates the plasma arc with a simple yet reliable touch start mechanism This system elim inates many of the failure problems associated with hi frequency start systems The Pro Cut 55 is capable of cutting with nitrogen or air The Pro Cut 55 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 55 is capable of all cutting and go
39. 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 F 34 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 11 CONTROL BOARD LEDs PRO CUT 55 CONTROL G3328 p 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 LINCOLN P F 34 F 35 F 35 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST A WARNING Service and repair should be performed by only Lincoln Ele
40. i e e R46 ER VR pe x 10 0 ma 27 5W 1K 1K 2 P y 5W 5W 10K 1 0K 100K wx H Pp x TEST E 2 E g T 8v Bg d In 5 e c 5w s 47 5K i D6 L hd e e NOTE 202 208 206 8207 BOLT ON WITH FILTER CAPS ee NE Sas s Wee dF 9 5136 dV re i agit ae m g L10616 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 5 29 98H LINCOLN amp available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result PRO CUT 55 L ELECTRIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 5 ELECTRICAL DIAGRAMS Display P C Board Assembly L10721 1 ITEM PART No IDENTIFICATION DOLOROSO 516668 4 2700pF 50 13490 26 4 7136 112702 27 1N4740 8875 1 8875 5 8875 2 8875 6 8875 3 8875 7 8875 4 2104 68 GHT BAR GHT B
41. inside one of the enclosure panels of your machine NOTE G 3 ELECTRICAL DIAGRAMS Plasma Output Board Schematic L10722 G 3 N NO 5o e gi a4 ite PRO CUT 55 gine DR Op Je Lpd Ord Gru ve CO HUT Le Org 920 cer Zo Wl G gt 9 gt LOZZdH NOLLO3NNOO ONNOY H1Uv3 8ZQ vZQ 920 vo siojeubisep eoueueje1 pesnur E E eS a ang E n NOILOANNOO 3A vu4 C47 HALINO YWSYTd div SS T zo 100 NOLLO3NNOO NOWWOD AN X 3000 NORWOO Y ONIAVH S TOHINOO 40 AHLIOHIO HO SLN3NOdIWOO LOVX3 3HL MOHS LON INIOd SOUNOS ATddNS YIMOd O 986 29401 SWN 31 AVI WYHOVIG SIHL IHvO8 31314WOO V JO ALITIBVJONVHOW3INI JHL 9NLLO333V LNOHLIM n 3ONYHO AYN GHVOE LINOHIO Q31NIHd V NO AWLINOKIO HO SININOdIOO 3ONIS YN JN39vLON Vins wr 34S 3SIMH3HLO me 000 SALON Spo l HLO SST AE xov A i 7 E S zam Xnv xn k ed 0001 E mos d SIS Di m SO yega Ta Iks vus oid Hal L I 1 Fa M e ae Fo my lp ee gt Es e l ver A O EE Mae hi ia is ino men va A Alt M09 Lg yon WES cm nS AM m 4 i ace PRETA x nag 1 i oi pnm VA Tz T gt P uf gt ve DAT ES m vA 30081933 tou uiv Im Pj ZENZ CIONTOS ENSIS QI0N3108
42. overcurrent protection e Works with pure nitrogen for cutting nonferrous materials e Reconnectable for 230 VAC or 460 VAC inputs Quick disconnect torch e Display indicators for machine status e Unique electrode and Vortech nozzle design for optimum cooling and long life e Swirl texture inside Vortech nozzle for better start ing reliability and higher quality cuts e Unique drag cup design for durability and elimina tion of double arcing LINCOLN P OPERATION CUTTING CAPABILITY The Pro Cut 55 is rated at 55 amps at 50 duty cycle on a 10 minute basis or 40 amps at 100 duty cycle If the duty cycle is exceeded a thermal protector 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 55 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 25 material Amps Speed IPM 35 38 45 57 55 62 FIGURE B 1 LINCOLN S PRO CUT 55 MILD STEEL CUT CAPACITY CHART 100 80 f x m eo 0 0 000 0 125 0 250 Recommended Torch Travel Speed IPM 8096 of Maximum Speed RB o CH CH 0 375 Material Thickness CONSUMABLE LIFE The expected life for the Pro Cut 55 s electrode under normal operating conditions is approximately 320 starts cuts An erosion of 060 in 1 5mm is typical for end of e
43. 0 3 60 15 40 IDLE CURRENT AND WATTS 230 1 60 0 42 Amps 98 Watts RATED OUTPUT Rated Output Amps 55 40 OUTPUT Current Range Open Circuit Voltage Pilot Current 25 55 Amps 335VDC Maximum 18 Amps 100 Duty Cycle PRO CUT 55 LINCOLN amp INSTALLATION TECHNICAL SPECIFICATIONS Cont d PRO CUT 55 GAS REQUIREMENTS Required Gas Flow Rate Required Gas Inlet Pressure 70 PSI 360 SCHF 80 to 150 PSI 4 8 Bar 10160 LHR 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 2 Input Supply Wires 1 Ground Wire 230VAC Single Phase 8 8 4mm 10 5 3mm 460VAC Single Phase 8 8 4mm 10 3mm 230VAC Single Phase 10 5 3mm 10 b 3mm 460VAC Single Phase 10 5 3mm 10 b 3mm PHYSICAL DIMENSIONS Height Width Depth Weight with Torch Cable 12 6 Inches 11 0 Inches 26 0 Inches 70 Ibs 32 kg 320 mm 280 mm 660 mm 25 ft cable 85 Ibs 39 kg 50 ft cable PRO CUT 55 LINCOLN amp A 3 A 4 A 4 INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS A WARNING e ELECTRIC SHOCK can kill e Turn the input power OFF at the disconnect switch or fuse bo
44. 001 174W R23 R24 R42 R43 R44 R45 R60 R63 R64 R65 R66 R73 R99 R100 R7 R8 R26 R27 R47 R48 R68 8 114648 21 2 7 GW R69 R10 R11 R12 3 B24378 3 1007 10W R13 R14 R15 R16 R34 R35 10 S 19400 1503 150K 1 4M R50 R5 1 R83 RBC R17 R19 R29 R30 R3 1 R40 9g 19400 22123 221K 1 4W R49 R61 R74 R28 T10812 4 IOK 1 2W TRIMMER R32 R7 1 R98 3 19400 22 12 22 IK 1 4W R33 R38 2 19400 332 3 32K 1 4W R36 R52 R89 RIO 4 S 19400 619 6 19K 1 4V R37 R55 R93 3 19400 768 7 68K 1 4W R39 R53 R57 R70 RBS 5 519400 1002 IOK 174W R54 519400 1372 13 7K 74W R56 S 19400 294 2 94K 174W R72 519400 1000 100 1 4W R75 S 19400 5620 562 1 4W R76 S 19400 280 2 8K 1 4W H77 19400 475 4 75K R78 519400 1822 8 2K 1 4W R84 R87 E S 19400 3323 332K 1 4M R88 S 19400 1652 6 5K 1 4W R91 R92 E S198400 1502 5K 1 4W R94 19400 4752 47 BK 1 4W R95 R96 2 19400 2211 2 21K 1 4W R97 112300 79 WATT 1 OHM 1X RESISTOR R101 R102 R103 R104 R105 E T14648 19 K 5W R106 R107 R108 R 109 R110 R111 R112 R113 1 19400 1821 82K 1 4W R114 R1IS RT IG RTIT 4 S 19400 1004 M 74W T1 1 13000 46 TRANSFORMER X1 1 15 128 10 1C 431 VOLTAGE REF X2 X3 2 15128 4 TC LM224 OP AMP G3172 2 5 29 98H PRO CUT 55 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 availab
45. 0Hd gt ayog Od 1NOH3 3SY9 1fid1no asva ANIHOWW 40 301S 1497 OVA0ES 00c ong L Los 208 08 VEDZ 202 IE 06 02 a OS 20 906 106 W200 LOANNOOSY AuvWIBd 7S SNILO333V LNOHLIM 39NYHO AVIN QHVOB LINDYIO G31NIBd V JO AYLINOHID HO SLN3NOdIWOO 3ONIS LINOHID ATddNS OL M A n SVNIAUSI LO3NNOO 3009 1v01810313 101 ONY VNOLLVN 43d 3NIHOYIN GNNOSS NIT 3SVHd 33HH L HOS LINDYID Add AS OL M 0 SIVNIWYAL LO3NNOO 3000 ROL 1V001 ANY TYNOLLWN H3d 3NIHOVIN ANNOYS LAGNI ISVHd 3 TONIS 803 318VO LNANI HLIM G3riddn s LON SINIHOYW HOS LINDHIO Add OL SAYIT ILHM 2 Q3u i0v18 LO3NNOO 3009 91810313 1VNOILVN Yad GNNOYD OL Qv31N3389 193NNOO INdNI ISYHd 33HH1 HO NOLLWINSNI A009 3dIAOHd OL Sd WL HLIM AY371034 dvHM LINDYIO Add AS OL SO 2 UU 9 39V 18 LO3NNOO 3000 91419973 TWNOILVN Yad ONNOY9 OL QY31 N33H9 193NNOO NANI 3SYHd 3TONIS HOS 318VO INANI HLIM GaliddNS S3NIHOVIN DC 195v zr D 9 zomp a 7996 gt 0 4 AY te xz MG EH EE BESCH KR foe q 602 aama INNI l ta INIH VN 40 301S 1HOlH YSWHOSSNVYL LNAYYENO El DEIER SE we OU 02 OI Y Iw 602 n AE ZH 902 war a N VN 310N SYOLOW Nv4 VN H3d LMdNI 3NIHOVI 40 HCH L10634 8 7 98A This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to LINCOLN je your code is pasted
46. 165 R 166 I anak eg f l R178 R179 R180 R18 1 R182 l iM R18 1 524073 1 10K 1 2W TRIMMER l E R12 e SIS 2 fa ao l R19 R53 R55 R57 R85 R149 7 S19400 5111 5 11K 1 4W m ic Ria ays ii l R157 T R144 j T T Jq z l R20 R22 R110 R111 R124 16 19400 10RO 10 1 4W l x R125 R 126 R127 R128 R142 a ELE TWH l R143 R 144 R 145 R146 R 147 gl SERERE E BleT 1 eR ne l E B Es I G T50 l qd R21 R23 2 S19400 1822 18 2K_1 4W Lem ET a I H R24 R35 2 19400 2210 221 174W l Si R28 R112 R115 R116 R117 amp 819400 3321 3 32K 174W l l l l LTES Re l R118 W MISI b i lo m a l R29 R91 R102 3 818400 8250 825 174W BS eges ke 2i e E a e amp m E I l R31 1 S19400 1004 1M 174W Crit dk IT L pp I R40 R73 R107 3 19400 7681 7 68K 1 4W LI D II i R43 R44 R45 R136 R137 R170 8 819400 4751 4 76K als GOH HR R171 R172 a p nt L I R47 R49 R80 ROG R 183 5 519400 1003 100K 1 4W SI o l R48 R67 R70 R87 R101 5 519400 4752 47 5K 1 4W Es Fi T I R52 R54 R56 3 S19400 1000 100 1 4W r 7 R58 R76 R99 R 100 4 819400 3741 3 74K 1 4W I r7 F l R72 R187 R195 3 519400 1501 1 5K 174W I I I R77 R82 R175 R 177 4 S19400 1301 1 3K 1 4W I I I R78 R113 R114 R159 4 19400 1211 1 21K 1 4W I I R79 R83 R155 R 167 4 19400 2213 221K 1 4W l l l R97 1 818400 8252 B2 5k 1 4W I l R98 1 919400 2431 2 43K 1 4W ETE SC E MEE ER NETTEN RR E E E E RN RET
47. 2 MODB IRQ 38 xira 5 AIR SOLENOID 5 XTAL RESET EGAL X5 PAL 7 TRIGGER m per V 10 0K nor EEN THERMOSTAT OK u pos CONTROL POT a7 pez PURGE ngs SAFETY RESET AFETYRESET al cq PSLOK PSLOK i aca eR PRIMARY VOLTAGE leen ay ai Paa COM ELECTRODE AMPS e Tha RETRACT_ARC ap Fa TACH INPUT wo LEE xl wh SET 3 y X18 RE 3 no S Pa 4 IBIAS TACH INPUT 7 9 s n COM COM s r 5 IBIAS n e 51 3 as Ne SINK e ID SENSE AUX VJ M LM2907 V im w n COM SENSE AMPS E Ee Sov o OUTPUT g 10 0K Sch SENSE_AMPS RETRACT ARC m d T B o A S R THERMAL 3 D a8 POWER SUPPLY g 3 rc ke XFMR MACHINE OVERVIEW 3 AUD V PWM 55V DE 4 x3 e d o x16 x10 3 LM224 TCF6000 68HC711E9 LABELS A sin vor COM COM FILENAME G3327_2C1 W n FT FRAME TZ EARTH peperere pen ferre S i Men E oeo G3327 Am S 4 b A NUMBER 9 4 98D 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 LELECTRIC available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result PRO CUT 55 in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 8
48. 4 1 R45 R46 4 19400 1503 150K 1 4W R43 R48 2 519400 1652 16 5K 1 4W R44 R49 2 19400 1500 150 1 4w R50 R5 1 R52 R53 4 T14650 1 1500 OHMS 15 W RESISTOR TP 1 TP2 TPS 3 T13640 20 480V 180J MOV TP4 1 T13640 9 20J TP5 1 T13640 15 15J xt 1 15018 19 IC DRI VER FET 6 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 provided 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 LINCOLN je G3326 1 10 31 97E G 11 ELECTRICAL DIAGRAMS SH Output P C Board Assembly G3326 2 NOTE Soe Be TZ TP D qd 4 8 L z cer vo 4 S 2 Q E23 ow PRO CUT 55 OUTPUT
49. 4J21 White 5J21 18VAC 7 If the correct test voltages are present the 9 If the auxiliary transformer tests good but it auxiliary transformer is good does not function when connected to the Pro Cut 55 check the harness wiring to the auxiliary transformer See the Wiring Diagram 8 If any of the voltages are missing or very low with the proper primary voltage applied the auxiliary transformer may be faulty 10 When finished with the test replace plugs 21 and 22 and the case wraparound LINCOLN P 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 216 383 2531 or 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 C
50. 5 15 leading angle in the direction of the cut e Use the drag cup to maintain constant standoff for better cut quality and to protect the nozzle from spatter e Use the drag cup with a metal template to prevent nozzle double arcing 5 15 Leading Angle gt Direction of Travel j n 10 Jo Arc Lag e Finish the cut to be made and release the trigger e 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 e f the dross is difficult to remove reduce the cutting speed High speed dross is more difficult to remove than low speed dross The right side of the cut is more square than the left as viewed along the direction of travel Clean spatter and scale from the nozzle and drag cup frequently For gouging tilt the torch about 45 from the work piece and hold the nozzle 1 8 in 8 2mm to 3 16 4 7mm above the workpiece ANGLE OF APPROACH TORCH HELD AT y 45 ANGLE THROUGHOUT GOUGE I MAINTAINED THROUGHOUT SAFETY STATUS INDICATOR e f 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 overtigh
51. 705 23 IN5818 I b Q DZ1 072 2 112702 18 1N47428 I sa DZ4 1 T12702 52 1N4733 CDN 9ox Ji 1 518248 4 HEADER n N oy J2 1 818248 10 HEADER r5 J3 1 S18248 16 HEADER R173 R eooo Yi 1 J4 1 518248 6 HEADER 1 cs GEB bes J5 1 518248 8 HEADER I CO LEDI LED2 LEDS 3 T13657 2 RED LED I ee ee eo V Y 81 02 03 3 1T12704 68 2N4401 I 2 aos St R136 NEE 04 i T12704 80 HEXFET TRANS 55 G T wo Rr T KS 1 T12704 68 2N4403 1 E amp x10 X5 ex Ra H V RI 1 T13165 16 1 0 OHM 5W RESISTOR I T 3 amp dM R62 ag Y R2 R46 R 133 3 1519400 2671 2 67K 1 4W I TR 628 Y R3 R30 R32 R33 R34 R36 R37 9 1819400 2130 243 174W 1 LA FA p WW o Ge Ge 1 819400 30RT 30 1 174W H e ale amp 054 hdl l R5 T___ S19400 6190 819 174W I e EE LLLI E LL c A R6 1 819400 8251 8 25K 1 4W I RESgSE S mE ESER x12 Y R7 R190 R191 R193 R194 5 19400 3921 3 92K 174W Ki f j E E Gl ck Te l R8 I 19400 2001 2 0K 174W LI ITET T T TTT RG R88 R 103 3 8189400 1001 IK 174W I DST Lj R10 R42 R95 R96 4 S19400 5110 511 1 4W I ERE LILLLI amp kl LY Ril RIZ R13 R14 4__ S19400 3320 332 174W I 5 re EF k a la Eles E ES i R17 R26 R27 R6 1 R62 R63 32 519400 1002 TOK 174W 1 2l el for Ec fae lee y Ed R68 R69 RB 1 R84 R93 R94 l T E oO d D I TT R104 R106 R 108 R134 R138 I 658 amp R 139 R 152 R153 R154 R156 I x2 S Joe 71 R158 R 160 R 164 R
52. 9400 8250 1 19400 1004 1 519400 4752 19400 1000 825 1 4W 1M 1 2W 7 68K 1 4W 4 75K 47 5K 1 4W 00 1 4W R58 R76 R99 R100 R72 R900 R77 R82 R175 R177 R78 R113 R114 R159 R79 R83 R155 R167 R80 R89 19400 3741 19400 150 19400 221 19400 130 19400 121 19400 221 19400 1003 3 74K 1 4W 5K 1 4W 2 21K 1 4W SK 1 4W 1 21K 1 4W 221K 1 4W 100K 1 4W EIS R98 R97 R109 431 19400 8252 2 43K 1 4W 82 5K 1 4W 6 81K 1 4W R120 R121 R122 R123 d R130 R131 R174 R133 R173 R140 R141 R135 R183 19400 6811 519400 26R7 19400 221 19400 681 19400 267 ee 19400 2670 D 26 7 1 4W 22 1K 1 4W 68 1K 1 4W 26 7K 1 4W 267 1 4W 5K 1 4W nr R176 R129 R184 TP1 TP2 19400 1502 19400 4750 19400 5621 475 1 4W 5 62K 1 4W 15J X1 X2 X4 X6 X5 x lt gt x lt x lt oS 3 en en en m Io no n z i Ei 15128 16 LINEAR INTEGRATED CIRCUIT LM224 OP AMP PRECISION OP AMP IC ROM ASSEMBLY EGULATOR ASBLY 5V REG ASBLY VOLTAGE REGULATOR X10 X16 ro Es 1 X12 M15102 3 15128 12 15018 18 IC ARRAY CLAMPING ESET LC UNDERVOLT SENSING CIR SS PWM CONTROLLER I C SS re En X18 X14 X15 X18 15018 19 816665 5 IC DRIVER FET 6A CMOS CONVERTER D A SERIAL 10 BIT SS FREQ TO VOLTAGE CONVERTER 8 0 MHZ NOTE Lincoln Electric assumes no responsibility for liablilit
53. AR LIGHT BAR GHT BAR T BAR T BAR LIGHT BAR 2N4401 LE LE LE LE LE LE LE D YELLOW D RED D RED D YELLOW D YELLOW D GREEN D GREEN LE LE D2 LED D3 LED6 ITI 2 r m el E Q1 Q2 Q3 Q4 R1 R5 R9 R13 R2 R6 R10 R14 R3 R4 R7 R8 R11 R1 R15 R16 R17 R18 R19 2 9400 3321 9400 6811 9400 1000 9400 75R0 9400 8250 9400 2671 3 32K 1 4W 6 81K 1 4W 100 1 4W 75 1 4W 825 1 4W 2 67K 1 4W r olofo CT r r r My mitt OCH co oo o1 R20 9400 2430 243 1 4W 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 provided 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 LINCOLN L10721 1 1 9 98M G 6 ELECTRICAL DIAGRAMS Display Board M18920 G 6
54. AUTION 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 two screws from the lower left and right to the equipment 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 LINCOLN P 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 two phillips head screws previ ously removed Replace leads X20 and X40 Replace plugs J30 J31 J32 and J33 Replace leads X4 and X2 Replace lead B21 and torque it to 70 inch pounds oN DO OC 9 Clear and secure all leads and replace the wraparound cover LINCOLN P
55. 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 55 LINCOLN P F 2 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 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
56. CUIT TEST continued FIGURE F 10 OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS G3326 PRO CUT 55 OUTPUT LED3 v LED5 W D25 i vy LED4 PRO CUT 55 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 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 LINCOLN amp LEAD 2 LEAD 4 J32 LEAD 312 LEAD 344 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 LEDS 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
57. 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 55 LINCOLN P 4 The following tests will be performed with the input power applied to the Pro Cut 55 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 55 T NOTE This test should only be conducted with the Pro Cut 55 reconnect switch and A jumper configured for 400 VAC and above F 19 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST continued Check for the appropriate voltages outlined 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 This will prevent output 7 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 NO
58. Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source 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
59. E 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 Refer to 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 screws 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 elemen
60. E R RER REN ENEERRE aeaa KE AAA RE FERRE ERA ENEE E 2 Input Line Voltage Contactor and Main Transtormer E 2 NC ele E ne Me e E 3 Main Iranstortrier eise aluo LuME LI IM DL IMEEM E 4 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 si oe eege wed edie er bel eae lee tay ewes deed eetecanidetes eua Ces rares ea de E 7 Insulated Gate Bipolar Transistor IGBT Operation cccccesscceessneeeeeseseneeeeeessneeeeeeseeeeeeeene E 8 Pulse le lie UE Le E GA EE E 9 Minimum OUT e EE E 9 Maximum Outputs cep E 9 FIGURE E 1 PRO CUT 55 BLOCK LOGIC DIAGRAM ELECTRODE POWER BOARD MAIN TRANSFORMER OUTPUT BOARD CURRENT TRANSFORMER Tom omzzoomx AIR PRESSURE SWITCH zo domdonrv ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE CONTROL BOARD ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE D DISPLAY BOARD 18 36VAC THERMOSTATS g s sor D gt Em m OUTPUT FAN MOTORS CONTROL AUXILIARY TRANSFORMER PRO CUT 55 LINCOLN amp E 2 E 2 THEORY OF OPERATION FIGURE E 2 INPUT LINE VOLTAGE POWER BOARD INPUT RECTIFIER ro4 s0 omzzoom AIR PRESSURE SWITCH zo JomJomv 18 36VAC THERMOSTATS
61. E lie un ua emer al R109 1 519400 6811 6 81K_1 4W R120 R121 R122 R123 4 S519400 26R7 26 7 174W R129 1 519400 5621 5 62K_1 4W R130 1 519400 2212 22 IK 174W R131 1 S19400 6812 68 IK 1 4W R132 1 516296 5 10K TRIMMER R135 R 184 2 819400 1502 15K 1 4W R140 R141 2 19400 2670 267 174W R173 1 T10812 39 50K 1 2W TRIMMER R174 1 519400 5622 56 2 174W R176 1 19400 4750 478 1 4W R188 1 S 19400 3922 39 2K 1 4W R 189 R192 2 T10812 68 IK 1 2W TRIMMER TPT TP2 2 T13640 15 15J xi 1 S 15128 16 IC LT1O14 LINEAR INTEGRATED CIRCUIT X2 1 915128 18 IC 330748 OP AMP QUAD HI GH PERF x3 1 515128 4 IC LM224 OP AMP X4 X6 2 915128 13 TC OP27GZ PRECISION OP AMP x5 1 524085 3 ROM ASBLY SS x7 1 818647 TC LM360 VOLT REG WITH H S ASSEMBLY x8 1 S 16395 13 IC 7805 5V VOLTAGE REGULATOR ASBLY xS 1 815128 12 IC 7805 VOLTAGE REGULATOR X10 X16 2 S15018 16 TC TCF6000 ARRAY CLAMPING HEX Xil 1 Mi5102 3 TC S8054HN CMOS UNDERVOT SENSING 55 X12 1 M15458 2 IC 3846 PWM CONTROLLER SS X13 X14 z2 160 16 19 TC DRIVER FET 6A X15 1 MI5105 8 TC 40733 CMOS CONV D A SERIAL 10B SS X18 1 MI3552 2 1C LM2307 CONVERTER F V Y 1 S16665 5 8 0 MHZ G3328 2 9 4 98D 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 L ELECTRIC avail
62. GAUGE Provides gas pressure 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 fol lowing 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 intermittently 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 work piece 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 ope
63. ITOR REMOVAL 1 Using the 3 8 wrench remove the four screws holding the heat sink assembly to the upper and bottom sections of the machine See Figure F 24 Remove the gas hose restraints from the bot tom of the heat sink assembly Remove the two thermostat leads from the thermostat which is located next to the upper capacitor Carefully remove the heat sink and capacitor assembly Clear any necessary leads Remove the faulty capacitors by using the slot head screw driver to loosen the clamps Take note of capacitor position in the clamp Observe polarity markings and terminal position CAPACITOR REPLACEMENT AND P C BOARD REPLACEMENT 1 Replace the capacitors by positioning them in the clamps Do not tighten the clamps They must be loose when the P C board is assembled to 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 the correct capacitor polari ties LINCOLN amp Assemble the four socket head screws and pre torque them to 25 inch pounds Make certain the capacitors are lined up correctly so that when the capacitor bolts are assembled through the P C board there will NOT be any distortion to the P C
64. LENOID ENABLE AIR SOLENOID ENABLE A copper nozzle with a patented internal swirl is used to focus the arc Asmall 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 solenoid valve allows enough forward force on the piston to maintain continu ity between the consumables After this continuity has been verified by the Pro Cut s 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 LI
65. LESHOOTING amp REPAIR OUTPUT POWER BOARD RESISTANCE TEST continued FIGURE F 4 OUTPUT POWER BOARD LEAD LOCATIONS G3326 PRO CUT 55 OUTPIUT O WA B2 P eT est Point b d TEST PROCEDURE 1 Remove input power to the Pro Cut 55 4 Remove leads X4 X2 B21 X20 X40 and machine plugs J33 and J32 from the output power 2 Perform the Input Filter Capacitor Doard See Figuie Ea Discharge Procedure detailed earlier in this Using the analog ohmmeter perform the section resistance checks Ger Table EA 3 Remove the torch assembly from the machine PRO CUT 55 LINCOLN P TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD RESISTANCE TEST continued TABLE F 4 OUTPUT POWER BOARD RESISTANCE TEST POINTS Probe J33 Pin4 to Probe Terminal B11 Probe Terminal B11 to Probe J33 Pin4 Probe J33 Pin4 to Probe Terminal B12 Probe Terminal B12 to Probe J33 Pin4 Probe R5 Test Point to Probe Terminal B1 Probe Terminal B1 to Probe R5 Test Point Probe R5 Test Point to Probe Terminal B2 Probe Terminal B2 Probe R5 Test Point Probe R5 Test Point Probe J32 Pint4 Probe J32 Pin14 to Probe R5 Test Point CIRCUIT OR COMPONENT S BEING TESTED
66. MENT continued 7 Carefully remove the input rectifier 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 Essex DC 4 8 Insulating Com pound to all six screw heads and termi nals The heavy input lead terminals should be against the rectifier terminals LINCOLN P 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 25 55 Amps Maximum Open Circuit Voltage 335 Volts PRO CUT 55 LINCOLN amp F 58 NOTES LINCOLN P F 58 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section c ccccccesseeseeeeeeseeeeseneeeeeeesesneeeenseeeesneaeseseeeeeseaesesseeeeneanes Section G Wiring Diagram 208V 230V 460V 10624 G 2 Plasma Output Board Schematic L10722 sss eene G 3 Power P C Board Schematic L10616 ssssssssssssssseeeeeee enne G 4 Display P C Board Assembly
67. NCOLN amp E 6 THEORY OF OPERATION FIGURE E 6 CONTROL AND DISPLAY BOARDS POWER BOARD CR1 RELAY INPUT LINE SWITCH IGBT CAPACITOR IGBT IGBT CAPACITOR INPUT RECTIFIER est gt F ro4 z6 somzzooma AIR E PRESSURE s SWITCH i Cc T l o N SIGNAL CONTROL BOARD 18 36VAC THERMOSTATS R t o Wi FAN EE OUTPUT CONTROL AUXILIARY TRANSFORMER 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 L CURRENT TRANSFORMER gt Z Dmx WORK il NOZZLE ELECTRODE MAIN TORCH TRANSFORMER OUTPUT BOARD ZI CONNECTOR crc a O ozmroo moom omrm TRIGGER amp SAFETY AIR SOLENOID In TRIGGER amp SAFETY ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE lt mo regulates the output of the machine by controlling the IGBT switching times through pulse width modulation circuitry See Pulse Width Modulation in this section The display board receives commands from the con trol board and via indicator lights communicates Pro Cut 55 status and operating conditions to the u
68. STALLATION INPUT CONNECTIONS A WARNING ELECTRIC SHOCK can kill 9 Have a qualified electrician install and service this equipment e 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 s voltage phase and frequency as specified on the machine s 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 55 should be connected only by a quali fied 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 55 must be properly ground ed A ground terminal marked with the symbol 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 55 is supplied with one 11 foot 3 35m 8 AWG 3 lead input power cord already connected to the machine A cord connector provides a strain reli
69. SVM140 A November 1998 PRO CUT 55 For use with machine code numbers 10473 10474 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 amp World s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors 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 are known to the State of California to cause can cer birth defects and other reproductive harm The Above For Diesel 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 The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The Above For Gasoline Engines
70. T 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 460VAC 440VAC 415VAC 380VAC TERMINALS 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 55 LINCOLN P F 20 F 20 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD RESISTANCE 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 216 383 2531 or 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 55 LINCOLN P F 21 F 21 TROUB
71. TION 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 55 LINCOLN amp 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 TEST PROCEDURE 1 Remove main input power to the Pro Cut 4 55 2 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in 5 this section 3 Locate the primary power board and asso ciated lead locations See Figure F 3 PRO CUT 55 LINCOLN amp CAPACITOR C2 TERMINALS Qo 207 202 6 N S N e PRO CUT POWER G3172 CAPACITOR C1 TERMINALS Carefully remove the main transformer pri mary leads 201 204 205 and 208 from the power board Use the analog ohmmeter to perform the test outlined in Table F2 F 17 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
72. 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 input relay The machine output will also be disabled NOTE Unshaded areas of Block Logic Diagram are the subject of discussion LINCOLN P E 4 THEORY OF OPERATION FIGURE E 4 MAIN TRANSFORMER POWER BOARD INPUT n RECTIFIER CAPACITOR d T IGBT CAPACITOR rod s06 Jomzzoom CR 1 RELAY DRIVE SIGNAI AIR PRESSURE SWITCH zo AomJomv THERMOSTATS OUTPUT FAN MOTORS CONTROL AUXILIARY TRANSFORMER 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 primary 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 ga
73. able from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result PRO CUT 55 in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 10 ELECTRICAL DIAGRAMS SR Output P C Board Assembly G3326 1 NOTE sono once io90900000 31 3000000000 xx 103 4 3 amp 4 z e WI 4 g D 4 5 NS p 5 e o B H ics o E d 2 Es gt Es o x SC o o oa EA o K B amp q m g E 4 L 4 E m o pn mom om m m mm pd EI ITEM REQ D PART NO IDENTIFICATION B1 B2 2 T13157 14 TAB TERMI NAL C1 C3 C4 C11 C I5 C26 6 520500 5 00 15 2000V cS C6 C7 C25 4 520500 7 0477 1600 C8 C12 C17 3 16668 7 820pF 50 E9 C10 C21 3 T11577 52 0047 or 005 1400 C13 1
74. and the auxiliary transformer T2 for loose or faulty connections See the Wiring Diagram Perform the Auxiliary Trans Machine is dead not output no status indicator lights fans run All status indicators remain imme diately after power up Check the input voltage at the machine Input voltage must match the rating plate and the reconnect panel 1 The microprocessor has experi enced a memory fault Contact your Local Lincoln Authorized Field Service Facility Perform the Transformer Test Perform the Low Voltage Circuit Test Perform the Input Rectifier Test 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 Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 PRO CUT 55 LINCOLN P 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 55 is reconnected correctly for the input voltage being applied Be sure to re
75. and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine NCOLN je G3326 2 5 29 98D G 12 ELECTRICAL DIAGRAMS G 12 Power P C Board Assembly G3172 1 LINCOLN P E N N q d e N e mov uo a ozy za Es E E ER e BE E g te a NS EZE Leza OOo y O C1 05 08 C11 ITEM REQ D PART NO 4 l 16668 6 IDENTIFICATION O O 4700pF 50 0047 1000V 022 50 C3 04 014 3 516668 5 C7 1 13490 93 13 fe D1 D2 D3 D4 D5 D6 D7 D12 D13 D14 Z1 DZ5 D8 D9 D10 D11 4 112705 44 D DZ9 DZ12 i i ase a T12199 1 E N o RS B eo 4 27 35 150pF 100 3490 130 271 50 1 4293 18 DPST RELAY 1N4004 DIODE 1000V 1A DZ2 DZ3 DZ6 DZ7 DZ8 DZ10 11 DZ18 DZ14 T12702 29 pO pO 112702 19 1 20351 6 Hi OCI1 0CI2 2 15000 22 l 12704 75 T12704 73 1 HEADER pT OPTO ISOLATOR ee FET SS IC PKG MOSFET SS R1 R6 R2 R67 R79 0 R25 R41 R46 R62 R80 R81 R82 19400 10R0 R2 R3 R4 R24 R42 R7 R8 R2 R69 R10 R11 R13 R14 R50 R51 R5 R21 R22 R23 R43 R44 R45 R60 R63 R64 R65 R66 6 R27 R47 R48 R68 R12 R15 R16 R34 R35 R83 R86 19400 1001 T14648 21 114649 4 19400 1503 T Lese d 9400 000 10 1 4W 1K 1 4W 2 7 OHM SW
76. aparound and perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section Locate the primary power board and associ ated lead and plug connections See Figure E23 LINCOLN P PRIMARY POWER BOARD WITH INPUT FILTER CAPACITORS 4 Label the leads for reassembly 5 Remove Plug J10 6 Using the 7 16 wrench remove leads 201 202A 203A 204 205 206 207A 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 PRIMARY POWER P C BOARD 7 16 CAPACITOR BOLT 4 3 8 MOUNTING INSULATOR 2 d MOUNTING HEAD SCREW 2 SCREW 4 7 Using the slot head screw driver remove the 9 Carefully remove the primary power board two mounting screws from the left side of the from the heat sink primary power board See Figure F 24 Take note of insulator placement for reassembly A CAUTION 8 Using the 3 16 allen type wrench remove the four socket head screws and lock wash Be sure to follow the recommended static free ers mounting the primary power board to the methods for handling printed circuit boards heat sink Failure to do so can result in permanent damage to the equipment LINCOLN P F 53 F 53 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued CAPAC
77. ard may be faulty Replace If the machine operates normal ly with the Thermal LED lit the display board may be faulty Either the duty cycle has been exceeded the fans are not functioning or the louvers are 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 216 383 2531 or 1 800 833 9353 PRO CUT 55 LINCOLN P TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE A 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 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 216 383 2531 or 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 b
78. as c19 3 XM H lem C55 R133 B 8 i KHH le foc Gy C Tn Y d H BEBE TT d LI QUEM I ko gt Lm B e nm x12 x4 Y e OL EEND Uu ERES L7 Biel d Ko EC A TT Sep DS P en I NNSS 7 2 E SEE BER 1 all l LEDS R24 Gg E fe SEST Ye S Eil I E E Ce E i e 3 i OQ E eer sl 18 pz SR I T R73 JAIL S ui L 7 I me RS i peu MM mec PES RO I T SERTE LILILI emp hist E ex l CO merj P BEEF EEE e l B TTT I I I I I I in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ITEM C1 PART NO 13490 92 DESCRIPTION 3300 50 2 C8 C10 013 014 017 C20 C23 C24 029 031 034 035 C36 C37 039 040 C41 047 C53 C55 C58 C63 C64 C65 C66 C68 C69 C73 C74 C075 C3 C4 C18 16668 5 13490 121 022 50 1000 85 47 50 o a alr C7 C9 13490 63 513490 71 100 50 T11577 52 0047 or 005 1400 C15 C16 032 033 C42 C19 025 C50 C21 026 028 30 054 057 C62 C71 C22 043 044 3 C45 1 e eo co e r 13490 93 27 35 516668 11 1 50 13490 25 4 71 35 13490 42 1 0 35 816668 4 516668 9 fT 50pF 100 2700pF 50 C46 C52 C48 C56 me 16668 13 10pF 100 516668 8 330pF 100 15 100 C59 C60 C61 C72 D1 D2 D3 D4 D5 D6 D7 D8 D9 D14 D20 D22 D23 D25 D26 D27 D10 D11 D12 D13 d 13490 108 1 816668 3 100pF 100 13490 126 13490 19 1 8 20 16668 10 4700pF 50 018
79. ause 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 A lead to the appropriate terminal LINCOLN P FIGURE A 2 RECONNECTION DIAGRAM RECONNECT PROCEDURE CH e Disconnect input power before inspecting or servicing machine Do not operate with wraparound removed ELECTRIC Do not touch electrically live parts SHOCK 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 f VOLTAGE 380 460V 9 9 pug 1 VOLTAGE 200 230V INSTALLATION GAS INPUT CONNECTIONS Supply the Pro Cut 55 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 55 can cause severe problems Use only a clean air supply Connect the gas supply to the Pro Cut 55 s pneumatic nipple at the air filter See Figure A 3 e Compressed gas should be supplied to the fitting
80. board Finish tightening the four screws to 40 48 inch pounds Assemble the two slot head screws with their appropriate insulators 8 Tighten the capacitor clamps 9 Place the assembly into the machine and 10 11 12 18 14 15 16 connect the two thermostat leads previous ly removed Secure the assembly to the upper and bot tom sections of the unit using the 3 8 wrench and the four screws previously removed Connect the J10 plug Connect leads 201 204 205 208 and 209 previously removed Connect leads 202A 207A 206 and 203A to the capacitor terminals Torque to 50 60 inch pounds Replace the gas hose restraints previously removed Clear and reposition any leads that may be disturbed Replace the case wraparound cover F 54 F 54 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER BRIDGE 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 perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting as
81. cates that the air solenoid driver circuit is functioning When this LED is lit the air solenoid should be activated PRO CUT 55 LINCOLN P 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 F 39 F 39 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST continued FIGURE F 14 CONTROL BOARD LEDs PRO CUT 55 CONTROL G3328 J CONTROL BOARD LED DEFINITIONS LED1 Red This light indicates that 18 VAC is LED2 Red This light indicates that the 5 5 being supplied to the control board from the VDC is present This voltage is derived from the auxiliary transformer It also shows that the 18 15 VDC supply The 5 5 VDC supply
82. 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 A 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 cylinder 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 55 regulator should never exceed 150 psi e Install a hose between the nitrogen gas cylinder reg ulator and the Pro Cut 55 gas inlet PRO CUT 55 LINCOLN amp INSTALLATION OUTPUT CONNECTIONS FIGURE A 4 TORCH CONNECTION AT CASE FRONT TORCH CONNECTION The Pro Cut 55 is supplied from the factory with a PCT 80 cutting torch Additional cutting torches can be mu ordered from the K1571 series Hand held and mech O anized torches come with 25 or 50 foot cables Q Q All torches are connected to the Pro Cut with a quick connect at the case front for easy change over See Figure A 4 For m
83. contact a hot surface SUGGESTIONS FOR EXTRA UTILITY FROM THE PRO CUT SYSTEM A WARNING ELECTRIC SHOCK can kill Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replac ing consumables e LINCOLN P 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 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 the mid range setting 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 star
84. ctric 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 216 383 2531 or 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 55 LINCOLN amp 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 RECTIFIER 12VAC Brown 56 6J30 PLASMA OUTPUT Zz nen DER 51 4430 BOARD D 24VAC pep M ig 11 415VDC 6J2 SCH at CONTROL BOARD 415VDC 15VDC 9J2 219 4J1 PROCEDURE 1 Remove inpu
85. e bien s isoler de la masse quand on soude 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 rox
86. e decane oL eerie beads Enn esa Deets e da sages Pa p ERR bea kx bias te deen Gee E RI esa A 8 cun me end Section 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 Consumable NTC eem B 4 Bild Lee cle B 4 GontrolS and Sallins esris RE B 5 Ee r B 5 Cutting Operations E B 5 UseriResporisiDIlILy iiio itor Etiket rin EE eid vi psi ets B 7 Preheat Temperature for Plasma Cutting rssicon aE EES B 7 Procedure RecommendatioOrs niat rhet tug Ere nx lx ua ana aa aN NEEN REESE EE Edge 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 iiec e titre EE on denk drca Lade eh bove Seb eege Rb ERR X ERE F 2 How to Use Troubleshooting G ldoe rrt ner einn nora d Rura cux oe ER Eo SEEEEn F 2 TROUDIESNOOTING GUIDE e F 4
87. ease 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 216 383 2531 or 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 5 16 Nut driver Volt ohmmeter 12 VDC 1 Amp Power Supply This procedure takes approximately 15 minutes to perform PRO CUT 55 LINCOLN P 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 55 machine NOTE Take the 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 i
88. ef 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 delay type circuit breakers recommended on the Technical Specifications page Choose an input and grounding wire size according to local or national codes also see the Technical Specifications page Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from inrush currents even if you are not cutting at high currents LINCOLN P A 6 INSTALLATION RECONNECT PROCEDURE When received directly from the factory the machines are internally connected for 230 VAC Reconnection 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 procedure ONLY while the Pro Cut is dis connected from the input power A CAUTION Failure to follow these instructions can c
89. efore 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 55 LINCOLN P F 10 F 11 TROUBLESHOOTING amp REPAIR A WARNING ELECTRIC SHOCK can kill e Have an electrician install and service this equipment Scan 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 terminals located in the top and 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 One pair is at the top and one pair is at the bottom of the Power Board Use elect
90. es and gases When welding keep your head 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 7 WELDING SPARKS can cause fire or ex
91. etween 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 216 383 2531 or 1 800 833 9353 PRO CUT 55 LINCOLN amp 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 Air Low LED is lit 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 55 Press the purge button and set the regulator to 70 psi 448 kPa Do not reset the air pres sure while the air is off not flow ing 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 55 Make sure the torch consum ables are in place and in g
92. gned to support the full weight of the machine Using it to lift the machine could cause per sonal injury or damage to the machine e Either the front or rear handles or both may be used to lift or move the machine TILTING The Pro Cut 55 must be placed on a stable level sur face so it will not topple over HIGH FREQUENCY INTERFERENCE PROTECTION The Pro Cut 55 employs a touch start mechanism for arc initiation This eliminates high frequency emissions 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 Keep the work ground clamp isolated from other work clamps that have high frequency e If 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 procedures may cause improper function of the Pro Cut or possibly even damage the control system or power supply components LINCOLN P IN
93. good electrical connection 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 55 LINCOLN amp 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 fum
94. han 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 a coating of Essex D 4 8 insulating com NOTE Before replacing the input rectifier D1 Bud check the input power switch S1 and P j perform the 8 If the input rectifier is faulty see the Input Also check for leaky or faulty filter capacitors procedure See the Wiring Diagram and PRO CUT 55 LINCOLN P F 15 F 15 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE 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 216 383 2531 or 1 800 833 9353 WELD DESCRIP
95. ies 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 provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result G 8 G3328 1 11 21 97L PRO CUT 55 G 9 ELECTRICAL DIAGRAMS G 9 Control P C Board Assembly G3328 2
96. ique ou autres produits irritants defonctionnement 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
97. ircuit Diagram This procedure takes approximately 19 minutes to perform PRO CUT 55 LINCOLN P F 31 TRIGGER SWITCH IN TORCH HANDLE F 31 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 9 SIMPLIFIED TRIGGER CIRCUIT DIAGRAM OUTPUT BOARD TORCH RECEPTACLE PROCEDURE 1 2 Remove input power to the Pro Cut 55 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 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 and related figures Apply the correct input power to the Pro Cut 55 Carefully check for approximately 17 VDC from plug J31 pin 1 lead 4 positive to plug J31 pin 2 lead 2 negative See Figure F 10 If the correct voltage is not pre sent perform the Low Voltage Circuit Test Also see Output Board LED Definitions jand related figures
98. irt cuffless trousers high shoes 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 55 LINCOLN amp xal 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 c
99. is used VAC is being rectified and should be regulated to to power the circuitry on the control board 15 VDC This 15 VDC supply is used to power Ep3 Red This light indicates that 18 VAC is the circuitry on the control board 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 L10721 DISPLAY BOARD REAR VIEW PRO CUT 55 LINCOLN P 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 perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 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 dri
100. le from Lincoln Electric This information is provided 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
101. lectrode life However the electrode 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 55 sys tem 35 A 45 A 55 A 0 500 0 625 0 750 LIMITATIONS Do not exceed output current and duty cycle rating of machine Do not use the Pro Cut 55 for pipe thawing LINCOLN E ELECTRIC B 5 B 5 OPERATION CONTROLS AND SETTINGS FIGURE B 2 CASE FRONT CONTROLS OMNOARWNS OUTPUT CURRENT CONTROL KNOB TORCH CONNECTOR WORK CABLE INPUT POWER SWITCH GAS REGULATOR KNOB GAS REGULATOR GAUGE GAS PURGE BUTTON RESET BUTTON STATUS DISPLAY BOARD INDICATORS OUTPUT CURRENT CONTROL KNOB Adjusts the amount of cutting current applied Affects cut ting speed dross formation cut width heat zone and travel speed TORCH CONNECTOR Quick connect type cou pling for the PCT 80 cutting torch WORK CABLE Provides clamp and cable con nection to workpiece ON OFF POWER SWITCH Turns machine on or off 5 GAS REGULATOR KNOB Adjusts compressed gas pressure delivered to the torch Length of torch hose is an adjustment factor Optimum set ting is 70 75 psi The gas purge button must be pressed in to set pressure GAS REGULATOR
102. lem 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 LINCOLN P 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 216 383 or 1 800 833 9353 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
103. move 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 Test 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 55 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 Perform the Trigger Circuit Perform the Gas Solenoid Test Perform the Torch Continuity and Solenoid Test The control board may be faulty Replace The output 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
104. n 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 55 LINCOLN P F 25 F 25 TROUBLESHOOTING amp REPAIR AIR GAS 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
105. nt for electrical trou bleshooting assistance before you proceed Call 216 383 2531 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 55 LINCOLN P 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 55 4 Carefully slide do not force the front away machine from the rest of the machine about one inch This will allow more working room to 2 Remove the wraparound cover and perform 9 the Input Filter Capacitor Discharge remove the display board 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 55 LINCOLN P F 45 F 45 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL amp REPLACEMENT 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
106. occur within a 15 minute period If the fan or fans are not turning or the air intake lou vers are obstructed the input power must be removed and the fan problem or air obstruction must be cor rected LINCOLN D 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 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 CONTROL AND DISPLAY BOARDS GATE SOURCE O lt BODY REGION n lt DRAIN DRIFT REGION n
107. odes for cut ting 22150 Shield Cup This shields the torch tip and provides more visibility to the workpiece than the drag cup 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 Only Genuine Lincoln Electric consumables yield the best cutting performance for the Pro Cut 55 e The patent pending VORTECH nozzle provides an extra kick of swirl as the arc exits the nozzle which improves cutting performance No other noz zle has this capability or can match its performance LINCOLN P Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE Maintenance LIE Section D I A D 2 Input Filter Capacitor Discharge Procedure ENEE D 2 elle En E Le D 3 Pernodie E age D 3 PRO CUT 55 LINCOLN P D 2 MAINTENANCE D 2 A WARNING ELECTRIC SHOCK can kill 9 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 Prior to performing preventative maintenance per form the following capacitor discharge procedure to avoid electric shock INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 1
108. ood condition Perform Tel Torch Continuity and Solenoid Test Check leads N E 364 and 369 between the torch receptacle and the output board See the Wiring Diagram The output board may be faulty Replace The Safety LED is lit and ready Press the reset button f the torch and consumables are properly installed the Safety LED should turn off 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 216 383 2531 or 1 800 833 9353 PRO CUT 55 LINCOLN amp 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 LED FUNCTION PROBLEMS The Thermal LED is lit 1 One of the machine s ther 1 The thermostat may be faulty mostats has tripped Do not Replace turn the Pro Cut 55 off Allow the machine to cool The ther mostat s will reset themselves The control bo
109. ore information on the torch and its components refer to the PCT 80 Operator s Manual IM588 PRO CUT55 i o Iu NS W 1 TORCH CONNECTION LINCOLN amp Section B 1 Section B 1 TABLE OF CONTENTS OPERATION SECTION ell M t Section B DalSty INSIUCH OMS M 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 aetci tenis a R disease B 4 Blogia c dietens B 4 Gontrols and SONOS os otn e fortia rep evi iie ibo ester Eie Feet peres Ve Hee do De oe ve eo EE De as d eure ce B 5 Pilot Arc COnSiQGrations EEUU B 5 CURNA OPAO E X B 5 User ReSponsiblllity EE B 7 Preheat Temperature for Plasma Cutting 2 ccccsecceeceeseeeeeeeeeseeeeeseesseceeeesseeeeeesesseeeeeseeeseeees B 7 Procedure Recommendations 2 cccsecccecesseeeceeeeeseeeeeeeeenneceesesaeeeeeeeeaaeeeesensneeceesessseeeeesensnnees B 7 GSTS e sesh ccc B 7 Thin Gauge Sheet OI B 7 Thick Sections of E E B 8 Suggestions for Extra Utility From the
110. plosion 6 a Remove fire hazards 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 sh
111. pment 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 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 prob
112. procedure takes approximately 18 minutes to perform PRO CUT 55 LINCOLN P F 28 F 28 TROUBLESHOOTING amp REPAIR T2 AUXILIARY TRANSFORMER TEST continued FIGURE F 8 T2 AUXILIARY TRANSFORMER PLUG J22 PROCEDURE 1 2 Remove main input power to the Pro Cut 55 machine Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section Locate the auxiliary transformer just behind the input line switch on the lower right side of the machine Locate and disconnect plugs J21 and J22 from the wiring harness Cut any necessary cable ties See Figure F 8 PRO CUT 55 LINCOLN amp T2 AUXILIARY TRANSFORMER 5 9 4 8 2 6 PLUG J21 6 3 4 1 PLUG J22 Carefully apply the 230 VAC isolated supply to leads H1 1J22 and H3 222 of the aux iliary transformer These leads are located in plug J22 Carefully check for the presence of the fol lowing primary and secondary voltages at the appropriate leads at plugs J21 and J22 See Figure F 8 and Table F 6 F 29 F 29 TROUBLESHOOTING amp REPAIR T2 AUXILIARY TRANSFORMER TEST continued TABLE F 6 J21 AND J22 VOLTAGES TEST POINT EXPECTED VOLTAGE H1 1J22 200 208VAC H1 1J22 380 415VAC H1 1J22 440 460VAC Brown 8J21 Brown 3J21 12VAC Red 2J21 Red 6J21 24VAC Blue 9J21 White 5J21 18VAC Blue
113. proceed Call 216 383 2531 or 1 800 833 9353 PRO CUT 55 LINCOLN P F 2 F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES A 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 warning 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 equi
114. rating steps each 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 55 LINCOLN amp B 6 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 pressure while the air is NOT flowing e When ready to cut place the torch near the work make certain all safety precaution
115. 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 tobe 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 55 LINCOLN P 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 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 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION
116. rically 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 EI LOCATION OF INPUT FILTER CAPACITOR TERMINALS INPUT POWER BOARD UPPER CAPACITOR TERMINALS LOWER CAPACITOR TERMINALS POWER GLOVES PRO CUT 55 LINCOLN P TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST A 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 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 216 383
117. s have been taken and pull 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 e 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 Hold the nozzle standoff 1 8 in 8 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 10 to 20 behind the travel direction e Use a
118. ser LINCOLN P E 7 E 7 THEORY OF OPERATION PROTECTION CIRCUITS Protection circuits are designed into the Pro Cut 55 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 55 is electrically protected from produc ing higher than normal output currents If the output current exceeds 50 60 amps an electronic protection circuit limits the current to within the capabilities 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 power 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 fans are operating normally the power switch may be left on and the reset should
119. sistance before you proceed Call 216 383 2531 or 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 Essex DC 4 8 Lincoln E3539 Electrical Insulating Compound This procedure takes approximately 16 minutes to perform LINCOLN P F 55 F 55 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued PROCEDURE 1 2 Perform the Input Filter Capacitor e Discharge Procedure detailed earlier in this 3 Remove input power to the Pro Cut 55 section Locate the input rectifier and the leads con nected to it See Figure F 25 Identify and mark the leads connected to the rectifier terminals CAP HEAD MOUNTING SCREW 5 With the phillips head screw driver remove the lead terminals connected to the rectifier terminals Using the 3 16 allen wrench remove the two cap head screws and washers mounting the input rectifier bridge to the center panel assembly 20 207A 209 FIGURE F 25 INPUT RECTIFIER LEAD LOCATIONS LINCOLN P F 56 TROUBLESHOOTING amp REPAIR F 56 INPUT RECTIFIER BRIDGE REMOVAL AND REPLACE
120. t 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 e 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 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
121. t power to the Pro Cut 55 machine 2 Using the 5 16 nutdriver remove the case wraparound cover A WARNING ELECTRIC SHOCK can kill Do not touch electrically hot parts Scan 09 3 Apply the correct input power to the machine and carefully check for the following voltages 4 Check for the presence of approximately 28 VDC on the output board a LED1 should be lit when 28 VDC is present See Figure F 13 and b To verify the presence of 28 VDC check across capacitor C13 Make certain the voltmeter probes make good contact with the capacitor leads See Figure F 13 PRO CUT 55 LINCOLN P D S P I A Y Check for the presence of 17 VDC on the out put board a LED2 should be lit when 17 VDC is present See See Definitions and Figure F 12 Low Voltage Circuit Diagram b To verify the presence of 17 VDC check from plug J31 Pin 6 to diode D25 anode See Figure F 13 Make certain the volt meter probes make good contact with pin 6 and the diode anode lead Check for the presence of 15 VDC on the control board a LED1 should be lit when 15 VDC is pre sent See See Board LED Definitions and Check for the presence of 15 VDC on the con trol board a LEDS should be lit when 15 VDC is pre sent See Figure F 13 See Control Board LED Definitions and F 37 10 11 TROUBLESHOOTING amp REPAIR Check for the presence of
122. te signals CURRENT TRANSFORMER SIGNAL CONTROL BOARD ELECTRODE SOLENOID ENABLE 18 36VAC AIR SOLENOID ENABLE g DISPLAY BOARD ec Sor 0 5 E CES MAIN TRANSFORMER renin ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE 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 LINCOLN amp E 5 E 5 THEORY OF OPERATION FIGURE E 5 PLASMA OUTPUT BOARD AND TORCH POWER BOARD INPUT RECTIFIER CURRENT TRANSFORMER em Jomzzoom AIR PRESSURE SWITCH zo JAomJo v 18 36VAC THERMOSTATS OUTPUT CONTROL FAN MOTORS AUXILIARY TRANSFORMER OUTPUT BOARD AND TORCH The output board contains an Insulated Gate Bipolar Transistor IGBT which upon receiving
123. ten LINCOLN amp B 7 OPERATION A WARNING S e ELECTRIC SHOCK can kill e Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replac ing consumables 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 Suggestions for Extra Utility from the Pro Cut Check the 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 Replace the nozzle when the orifice exit is eroded away or oval shaped 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 e f the machine does not reset or continues to trip consult the Troubleshooting Section Use the proper cutting or gouging procedures referred to in Procedure Recommendations 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
124. 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 G3172 1 10 31 97E PRO CUT 55 G 13 ELECTRICAL DIAGRAMS G 13 Power P C Board Assembly G3172 2 LINCOLN P PRO CUT POWER ITEM REQ D PART NO IDENTIFICATION C1 C5 ER EI 4 S18668 8 4700pF 80 ES be C9 C12 4 520500 4 0047 7 1000V C3 C14 2 Si6668 5 022 50 C4 C10 C17 3 516668 9 150pF 100 C7 C20 2 13490 93 27 38 C13 1 513490 130 27 50 C15 1 13490 83 50 25V C16 C 19 2 51349042 0 38 C 18 1 13490 39 8 15 CRI 1 14293 18 DPST RELAY D 1 D2 D3 D4 D5 D6 D7 D 12 13 T12199 1 4004 D 13 014 D15 D16 D17 D8 D9 D10 D11 4 T12705 44 DIODE 1000V 1A DZ1 DZ5 DZ9 DZ 12 4 T12702 40 4738 DZ2 023 026 DZ7 D28 DZ 10 S T12702 29 47440 DZ 11 DZ 13 DZ 14 DZ4 DZ 15 2 12702 19 47420 DZ 16 12702 52 4733A J10 2035 1 6 HEADER OCT 1 OCI 2 OCI3 3 15000 22 OPTO ISOLATOR 1 T12704 78 FET 55 02 03 04 05 7 T12704 73 IC PKG MOSFET SS R1 R6 R20 R25 R4 L R46 R62 I2 519400 10RO 0 1 4W R67 R79 R80 R8 1 R82 RZ R3 R4 RS R18 R2 1 R22 2 519400 1
125. 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 TYPICAL IGBT OUTPUTS lusec KR 48 S l usec 50 u sec MINIMUM OUTPUT 22usec 3usec D A Se c 22u sec MAXIMUM OUTPUT LINCOLN amp E 10 NOTES LINCOLN P E 10 Section F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION Troubleshooting amp Repair Section qo cece cece eee e eee e ee eeeeeeeaaaaeeeeeeeeeeeteeeeeeeaaae Section F How to Use Troubleshooting Guide EEN F 2 PC Board Troubleshooting Procedures and Replacement AA F 3 TroubleshiGotinig RET eise PUE Hd Gp Gem d uie F 4 Test Procedures Input Filter Capacitor Discharge Procecdure F 10 Input Rectifier Test ee F 12 Primary Power Board Resistance Test and Capacitor Voltage Test F 15 Output Power Board Resistance Test F 20 Torch Continuity and Solenoid Test ccecceeseeceeeeeeeeeeeeeeseeeeeeeeeseeeeeesesseeeeensesseeeeens F 23 Air Gas Solenoid Test F 25 T2 Auxiliary Transformer Test eeseeessesseeeeessisseeeeseeee nemen nennen nennen F 27 lge eeler Oe F 30 Low Voltage Circuit Test iecit oci eel ecran rer ash idles o den EE Eege F 35 Replacement Procedures Control
126. thru Mid Range Output set below mid range e 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 LINCOLN amp B 8 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 mid range 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 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 body to
127. ting the cut from the edge of the plate when possible e Pierce cutting should be done only when nec essary If piercing angle the torch about 30 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 Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES Accessories oen tet hi ian E I ec A a eee Section C Optlons Accessorles tett t tt tnt ttn EA ett AEANEEEEEEEEEEEENEEEEAESEEEEEENEEE EENES EAEAN EEEE EEEn C 2 PRO CUT 55 LINCOLN P ACCESSORIES GENERAL OPTIONS ACCESSORIES The following options accessories are available for your Pro Cut 55 from your local Lincoln Distributor K1600 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 22147 068 Vortech nozzle with an 068 1 7 mm Orifice 22149 Electrode replacement electr
128. 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 216 383 2531 or 1 800 833 9353 PRO CUT 55 LINCOLN amp 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 section 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 b
129. uging applications within its output capacity of 25 to 55 amps These applications include thin gage sheet metal and expanded metal OPERATIONAL FEATURES AND CONTROLS The Pro Cut 55 comes 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 55 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 e Light weight and portable design for industrial use e Continuous control 25 55 amps e Reliable touch start mechanism for plasma arc initi ation e Unique microprocessor controlled sequence for safe and consistent starting starting e Rapid arc transfer for fast cutting of expanded metal e High transfer distance for ease of use e nput overvoltage protection e 3 0 second pilot arc e Purge momentary push button e Air regulator and pressure gauge located on the front of machine for convenience e Parts in Place mechanism to detect proper instal lation of consumables and torch e Automatic detection of faulty output control n line coarse air filter Preflow Postflow timing Preflow is eliminated if arc is re initiated in Postflow e Thermostatic Protection e Solid state
130. ver Needle nose pliers This procedure takes approximately 15 minutes to perform PRO CUT 55 LINCOLN P 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 55 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 ase df ine Machin 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 PRO CUT 55 LINCOLN P F 42 F 42 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued 5 Locate the control board and the five molex type plugs connected to it See Figure F 17 6 Carefully remove the five molex type plugs by depressing the locking tabs and gently 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 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
131. x 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 55 grounding terminal located on the side of the Case Back Assembly to a good electrical earth ground Always wear dry insulating gloves Turn the 55 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 55 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 55 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 min Failure to observe these pre cautions could result in excessive operating tempera tures or damage to the torch STACKING The Pro Cut 55 cannot be stacked LIFTING AND MOVING A WARNING FALLING EQUIPMENT can cause injury e Do not use the pull handle on the optional undercarriage if installed to lift the machine This handle is not desi
132. ylinder valve Valve protection caps should always 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 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 d

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